SAUDI ARAMCO CONSTRUCTION SAFETY MANUAL

PREFACE
Dhahran, Saudi Arabia
February, 1993

The purposeof the SaudiAramco ConstructionSafety Manual (CSM) is to prevent

injury, loss of life, and damageto assets. This is the fourth revision of the CSM.
Since its 1974 introduction, the Construction Safety Manual has provided safety
criteria for all constructionwork performedby SaudiAramco and its contractors.

Many of the requirementsin this manualdetail the needfor SaudiAramco servicesor

equipment. Where referencesindicate that certain equipment(fall protection, safety
shoes,etc.) shouldbe providedor servicesrendered@o-monitoring, etc.), the intent
is that contractors must provide equivalentequipment or services(as approvedby
SaudiAramco) from their own resources.

The constructionindustry functions in a dynamicallychangingwork environmentin

which updating of equipmentand standardsis a continuousprocessresulting from
changes in operating variables, regulatory requirements, and safety practices.
Although this manual has been updated to reflect the latest Saudi Aramco and
constructionindustry practices,as time goeson there may be a needto considernew
procedures,standards,or operating conditions. Such new developments,including
potentialconflicts with existing provisions, shouldbe referred to the Loss Prevention
Department for resolution. The Loss Prevention Department will issue interim
revisionsor updateswhereappropriate.

Good loss prevention is an integral part of good project management. For our
projects and maintenanceprograms to proceed safely, all Saudi Aramco and
contractor personnelinvolved in constructionactivities, whether managementor line
employees,needto understandand follow the provisionsin this Manual. Only with
the active commitment of everyonecan we ensurethat Saudi Aramco maintainsthe
safestpossiblework environment.

A. G. AL-GHANIM,
SeniorVice President,
Engineeringand Project Management
a I. Administration .................................................................. 1
1.0 SAUDI ARAMCO LOSS PREVENTION POLICY AND PROGRAM ................ .Z
1.1 Law Prevention Policy Implement!&ln ........................................ 2
1.1.1 Compliaoce With Construction Requirements ....................... .2
1.1.2 OperatingStandardsandInstluctions.. ................................ .2
1.1.3 Personal Protection.. ..................................................... .2
1.1.4 Inspection ................................................................. .2
1.1.5 EducationandTraining.. ................................................ .3
1.1.6 Motivation and Recognition ............................................ .3
1.1.7 JobPlacement.. ........................................................... .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 TrafficSafety.. ............................................................ .3
1.1.12 Accountability.. ........................................................... .4
1.1.13 Compliance Reviews ..................................................... .4
1.2 Saudi Aramco Loss Prevention Requirements For Contractors .......... .
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

2.0 SAUDI ARAMCO LOSS PREVENTION DEPARTMENT SERVICES.. ............. .7

2.1 Loss Prevention Program.. ....................................................... .7
2.2 Program Management Scrvic~ .................................................. I3
2.3 Program Maintenance Service ................................................. .9

3.0 ACCIDENT INVESTIGATION, ANALYSIS AND REPORTING ...................... 10

3.1 Reports Required by Saudi Aramco ........................................... .10
3.2 Accident Investigation.. ........................................................... .I1
3.2.1 Responsibilities for Investigation ....................................... 11
3.2. I I Supervisor/Safety Representative .................................... 11
3.2.1.2 Project Manager.. ............................................................ II
3.3 Cases to be Investigated.. .......................................................... 12
3.4 Accident Investigation Guidelines .............................................. .12
3.5 Accident Analysis ................................................................. .12
3.5.1 Classification ............................................................... 12

4.0 RESPONSIBILITIES FOR SAFETY.. ........................................................ .I6

4.1 Contractor Senior Management.. ............................................... .I6
4.2 Design Engineer .................................................................... .16
4.3 Contractor’s Safety Offker ...................................................... .16
4.4 Construction Manager/Superintendent.. ...................................... .17
4.5 Site Safety SupeDlisor .............................................................. 18
4.6 Equipment Manager/Supervisor.. .............................................. .I8
4.7 Engineer/Supervisor.. ............................................................. .18

Fcbnuy 1993 -Table Of Contenta Page ii

 4.8 FOreImlll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.9 Worker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5.0 EMERGENCY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5.1 Action to he Taken . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.2 Contact After OffKe Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3 Help in an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

6.0 SAFETY 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

7.0 SITE PLANNING AND HOUSEKEEPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

7.1 Initial Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.1.1 Hazard Identification Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.1.2 Los.5 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 SafeMeansofAccessandEgress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Ares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.4 Welfare Facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.5 Good Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.6 Construction Sites and Materials Storage Yards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

8.0 FIRST AID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

8.1 Provision of First Aid Facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.2 First Aid Attendants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
a.3 First Aid Facilities At Work Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8.4 Labor And Workmen Law . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.0 PERSONAL 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 FaceProtection.. .......................................................... .44
9.3 Hand Protection.. .................................................................. .44
9.4 Foot Protection ...................................................................... 44
9.5 Hearing Protection.. ............................................................... .45
9.5.1 EarPlugs.. ................................................................. .45
9.5.2 Ear Muffs.. ................................................................. 45
9.6 Fall R&raining/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 GasMasks ....................................................................... 54
10.2.1.2 Chemical Gutridge 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 Precaution ................................................................. .57
10.4.1 Aircompressors.. ........................................................ .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 CarbonDioxideTypeExtinguisher.. .................................. .64
11.8.3 Dry Chemical Typo 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 ................................................................ 61
12.1 Equipment ............................................................................ 68
12.1.1 RemoteControlUnit ...................................................... 68
12.2 Safe Operation ....................................................................... 68
12.3 Radio Phrasfs ........................................................................ 68
12.4 Phonetic Alphabet.. ................................................................ .69
12.5 International Communications Union Agreement ........................... 70
125.1 Monitoring of Circuits.. .................................................. 71
12.52 Secrecy Act.. ............................................................... 71
12.5.3 Penalties.. .................................................................. .71
12.6 Message Priorities for Company Operations.. ............................... .71
12.7 Distrw 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
Ammo ................................................................................ 18
13.4 VehicIe Condition ................................................................... 78
13.5 Driver Training ...................................................................... 80
13.6 Enforcement of Safe Driving Practic@ ......................................... 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 S&Belts .................................................................... 83
13.11.2 Traffic Regulations.. ...................................................... 83

14.0 AIRCRAFf OPERATION ...................................................................... 84

14.1 General Operating Responsibilities .............................................. 84
14.1.1 Captain/Pilot ............................................................... 84
14.1.2 Camp Supervisors ........................................................ .84
14.2 Passenger Briefing/Instruction, 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 FYecautions for Helicopters ........................................... .86
14.5.1 LifeVests.. ................................................................ .86
II. General And Civil ............................................................ 87
1.0 WORK PERMIT SYSTEM.. ..................................................................... 88
1.1 IMinitiols ............................................................................ 88
1.1.1 RestrictedAreas.. ......................................................... .88
1.1.2 Issuer (Operation Supervisors). ......................................... .89
1.1.3 Receiver (Authorized CmRsmen) ...................................... .89
1.1.4 WorkPermit.. ............................................................. .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 ClearArea.. ............................................................... .90
1.3.3 Work Stoppage.. .......................................................... .90
1.4 Handling of Issued Work Permit ................................................ 90
1.5 Closing Out and Filing the Pwmit .............................................. 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 thu.?raI hutions ................................................................ 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 Walknays.. ................................................................. 101
2.5 Access and Egress.. ................................................................ .101
2.6 Hazardous Atmospheres and Materials ........................................ 101
2.6.1 Ventilation.. ................................................................ 101
2.6. I I Hazardous Atmospheres .................................................. IO2
2.6. I .2 Emergency Rescue Equipment ........................................ 102
2.6.2 Exhaust Gases.. ............................................................ 103
2.6.3 Organic Lead.. ............................................................. 103
2.7 Ed&e Protection, Markers and Fiied 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 EarricadeslSigns ........................................................... 12.5
 3.2 Method of Demolition .............................................................. 125
3.2.1 Demolition of Equipment Containing PCB:
Polychlorinated Biphenyl (ASKAREL) ................................ 126
3.2.2 Demolition Of Buildings With Asbestos / Insulation
Materials .................................................................... 126
3.3 Stability During Demolition ...................................................... 126
3.4 Working Place Clearance .......................................................... 126
3.4.1 Access ....................................................................... 126
3.4.2 Glass Removal ............................................................. 126
3.5 Structural Steel Removal .......................................................... 127
3.6 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
3.7 Rotective Clothing and Equipment.. .......................................... .127
3.8 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: &y-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

Fdmmy Is?33 - T.t.k Of CO”te”ta Paae vii

 5.2 Electric Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.2.1 Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
5.2.2 Welding Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
5.3 F’mtectise Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...142
5.4 Welding and Cutting: Tanks, Ves4.s and Drums . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
5.5 conthed Spaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
5.6 Personnel Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5.7 Health Ibar& . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.. . . . . . . . . . . . . . 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 Suppat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
TraFFc Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

9.0 WORKING PLACES, LADDERS, AND SCAFFOLDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

9.1 Working Places, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
9.1.1 Falls . . . . . . . . . . . . . . . .. ... . . . . .. . . .. 156
9.1.2 AccessandEgress .. .. ... . . . ... . .. 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 Stt-uctares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
9.1.11 WorkOverWater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 ScafTolding Componen& ........................................................... 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 BoardBearers.. ............................................................ 169
9.4.6 Bracing.. .................................................................... 170
9.4.7 Ties .......................................................................... 170
9.4.8 PlatformUnits.. ............................................................ 171
9.4.9 Guardrail Systems and Toeboards ....................................... 172
9.4.10 Access.. ..................................................................... 172
9.4.11 ScaffoldLadders.. ......................................................... 172
9.4.1 1.1 Portable Straight and Extension Ladders ......................... 173
9.4.11.2 Vertical Ladder ............................................................... 173
9.4.12 Workmanship.. ............................................................. 174
9.4.13 Inspections .................................................................. 174
9.5 Fabricated Tubular Frame and System Scaffolding.. ...................... .174
9.6 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. I Design, Loading and Dimensions .................................... 176
9.6.2.2 Platform .......................................................................... 177
9.6.2.3 Limitations ...................................................................... 177
9.6.3. Medium Duty To be. 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
9.1 Free-Standing Tower ScafTolds ................................................... 179
9.7.1 General Requirements ..................................................... 179
9.7.2 Design, Loading and Dimensions.. ..................................... 179
9.7.3 RumersaodBearcrs.. ..................................................... 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
9.8 Mobile Tower Scaffolds.. .......................................................... 180
9.8.1 Foundations.. ............................................................... 180
9.8.2 Operation.. .................................................................. 181
9.8.3 Limitations.. ............................................................... .181
9.9 Scaffolds for Tanks and VeseIs .................................................. 181
9.9.1 Bracket Scaffolds .......................................................... 181
9.10 SpeciaI ScatTolds.. ................................................................... 182
9.11 SadTold Temainology ............................................................. .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 RepairandStorage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
10.1.4 Seltition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
10.2.9 Hacksaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
10.2.10 Hand saws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
10.3 Power Tools, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I . . . . . . . . . . . . . . . . 196
10.3.1 Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
10.3.2 Repair and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
10.4 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
10.5 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 Persooal 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
10.6 Ele&icaIly 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 Indwldual 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 FirePrecautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
 11.2 Health Hazards Associated With Paints ........................................ 221
11.2.1 Tonic Materials.. .......................................................... 221
11.2.2 Dermatitic Materials ...................................................... 222
11.2.3 PreventionofHealthHazards.. ......................................... ,222
11.3 Ventilation in Confined Spaces.. ................................................ .222
11.4 Surface Reparation ............................................................... .223
11.4.1 Abrasive Blast Cleaning ................................................. ,224
11.4.2 Hydroblast and Steam Cleaning ........................................ .224
11.4.3 HandandPowerToolCleaning.. ...................................... ,224
11.4.4 Chemical Cleaning.. ...................................................... ,225
11.4.5 General Safety in Surf ace.Preparation ................................. ,225
11.5 Personal Protective Equipment ................................................... 226
11.6 Paint Application .................................................................... 22a
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

12.0 CONCRETE, CONCRETE FORMS, AND SHORING .................................. 232

12.1 GOWal ................................................................................ 232
12.2 Reinforcing Steel .................................................................... 232
12.3 Bulk Concrete Handling ........................................................... 232
12.4 Concrete Hacement ................................................................. 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. I 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
III. Mechanical Equipment And Materials .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . 237
1.0 CRANES AND LIFUNG EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
1.1 Conlpetent Person . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
1.2 Saudi Aramm Crane Operations (General Requirements) . . . . . . . . . . . . . . . . . 239
1.3 Saudi Aramco Crane Operator Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
1.4 S@al Crane operating Procedurfs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.50
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 Compressoors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Cooveyor Belts and Monorails . . . . . . . . .._..... .._ .. .. 270
4.2.4 Concrete Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
4.3 Site Stores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
4.4 ManualHandling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
IV. Electrical And Radiation ................................................... 275
1.0 ELECTRICITY ..................................................................................... 276
1.1 v&age ............................................................................... .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 ............................................. 2SO
1.6 Overhead Power Trammission and Distribution.. .......................... .2Sl
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
I .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 Conshuction ............................................... 285
1.6.10.2 Stringing/Removing De-energized Conductors ................ 287
I .6.10.3 Stringing Adjacent to Energized Lines ............................ 288
1.6.11 Underground Lines.. ..................................................... ,289
I .6. I I, 1 Work in Manholes ........................................................... 290
1.6. I 1.2 Trenching and Excavating.. ............................................. 290
1.6.12 Construction in Energized Substations.. .............................. .291
1.6.12.1 BanicadesandBaniers ................................................... 291
1.6.12.2 Control Panels.. ............................................................... 291
1.6.12.3 Mechanized Equipment.. ................................................. 291
I .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 ExposureLimits .......................................................... .296
2.3 Responsibilities for Safe Handling.. ............................................ .297
2.3.1 Contractor.. ................................................................ ,297
2.3.2 Competent Person ........................................................ ,297
2.3.3. Radiographer .............................................................. .297
2.4 Shipping and Transportation.. .................................................. .298
2.5 Storage Ares ....................................................................... .298
V. Chemicals And Operations . . . . . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . 300
1.0 LIQUEFIED PETROLEUM GASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
1.1 GeneraI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
1.2 storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
1.3 Handling of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
1.4 Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
1.5 TI-allspotitiOa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Gene-al Instruction Manual . .. .. . .. . ... ,308
2.1.2 Producing Instruction Manual . . . . . . . . . . . . . . .,. .. . ,308
2.1.3 Refinery Instmction Manual . . . . . .__.., .._ . . . .._. 308
2.1.4 Saudi Ammo 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 .3 10

3.0 PRESSURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

3.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
3.1.1 SAES-A-004 (Pressure Testing) . . . . .._...........__..................... 312
3.1.2 Supports . ..t................................................................. 312
3.1.3 VenbandDrains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
3.1.4 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
3.1.5 PipingsAndJoints . . . . . . . . . .._............................................ 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
4.1 Work on Equipment Which Has Contained Tetraethyl Lead
(Organic Lead Compounds) ..................................................... .324
4.7.1 Intmduction.. .............................................................. .324
4.7.2 Precautions.. ............................................................... .325

February 1993 -Table Of Coaem Page xvii

VI. Marine .......................................................................... 329
1.0 COFFERDAMS .................................................................................... .330
1.1 Design .................................................................................. 330
1.2 Before Work Starts ................................................................. 330
1.3 COtlStIUCtiOll.......................................................................... 330
1.4 Potential Hanwds ................................................................... 331
1.4.1 Struchlral Collapse.. ..................................................... ,331
1.4.2 Overhead Loads.. ......................................................... ,331
1.4.3 Dislodgment of Struts and Wales ...................................... ,331
1.5 Impcction ............................................................................ .331
1.6 Leaks ................................................................................... 332

2.0 MARINE OPERATIONS ........................................................................ .333

2.1 Other Publications.. ............................................................... .333
2.2 General ................................................................................ 334
2.3 Behavior on Floating Craft ...................................................... .334
2.4 Preparation for Transportation by Sea.. ...................................... .334
2.5 Tide and !%a Effects.. ............................................................. .335
2.6 Care of Tools and Equipment.. ................................................. .33.5
2.1 Housekeeping.. ...................................................................... .335

3.0 DIVING OPERATIONS.. ....................................................................... .337

3.1 Employment of Qualified Divers ................................................ 337
3.2 Diving Equipment.. ................................................................ .338
3.2.1 Compressors.. .............................................................. 338
3.2.2 ReserveAir 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...........34 5
3.5.1 Spats Divers.. ............................................................ ,345
3.5.2 Commercial Dnws.. ..................................................... ,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
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 Safetv. Health and Environmental Requirements ....................... .357
1. Compli&e With Safety Rules - Schedule ‘D’ .............................. .357
2. Deviations From Safety Roles .................................................... 357
3. Failure To Comply .................................................................. 357
4. Saudi Aramco Assistance .......................................................... 357
5. Lass Prevention Program .......................................................... 358
6. Work Pennits ....................................................................... .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 Operation ................................................. 360
17. Transportation ....................................................................... 360
18. Injury And Damage Reporting ................................................... 360
19. Excavations ........................................................................... 361
20. Work Over Or Adjacent To Water .............................................. 361
21. Fire Revention ..................................................................... .361
22. Fomnvork.. .......................................................................... .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.4HAZARD 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

Febnlary 1993 - Table Of CO”te”U hgc xix

Appendix B: EmergencylJGaster 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
Appendix C: Fire Safety Checklist For Evaluating
Construction Materials Store Yard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
C.l Fire Safety Chwkliit For Evaluating Construction Materials Store Yard . . . . . . . . . . . . . . 398
a Appendix D: Saudi Aramco Crane Safety Handbook.. ................. .402
D.l Crane Safety Handbook .......................................................................... .403

a
Appendix E: SuggestionForm . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . 404
Appendix F: Distribution Form . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . .. . . . . . . .. . . 406
Appendix G: Sanitary Code . . . .. . . . . . . . . . . . . . . . . . . .. .. .. . . . . . . . . .. . . . . . . . . . . . .. 408
Implementing The Saudi Ammax Sanitary Code - GI 151.006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
0 Appendix H: General Instructions Master Index . . . . . . . . . . . . . . . . .. . . . . . . . 410
General Instructions (Gl) Master Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
Appendix I: List Of Figures .................................................... 415
Lit Of Fv ............................................................................................ 416

Qebnun 1993 -Table OfCcaerds Page xxvii

a Appendii J: List Of Tables .. . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . 419
List Of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42tl
Appendix K: Forms . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. 421
Pmliiinary Accident Report . . . . . . . . . . . . . . . . . . . . . . . . . . . .,.............................................. 423

Contractor Monthly Safety Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424

Jqjory slmnnary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425

Lift Plan For Crans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426

Wii Rope Sling hspection Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421

cortJidge/Tool rssnance Contml . . . . . . . . . . . . . . . . . . . . . . . . . I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428

lhmgency Reporting Jmtmctiom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429

Project Managenmt And Contractor’s Safety Competition Site Registration

Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
I. Administration
1.0 SAUDI ARAMCO LOSS PREVENTION POLICY AND
PROGRAM
Saudi Aramco is committed to prevention of accidents to minimize loss of life or bodily injury to its
employees and damage to its physical assets.

In fulfilliig this commitment, which is BS essential and equally important as production objectives,
Saudi Ammco will provide and maintain a safe and healthful work environment and protect the public
against foreseeable hazards resulting from operations.

Loss in production and property resulting from accidental occurre.nces can be minimized through good
management. Loss prevention is one aspect of this loss control philosophy and is the direct
responsibility of line management.

All management functions, including business line and associated management, will comply with Saudi
Arab Government and Company loss prevention requirements applicable to the design, operation,
maintenance and construction of facilities and/or equipment. When conformity with any of these
requirements is not practicable or cast effective, an amendment to such a requirement will be
considered. Reviews for compliance with this policy will be performed on a selective basis.

1.1 Loss Prevention Policy Implementation

1.1.1 Compliance With Construction Requirements

The application of the best petroleum industry loss control practices minimizes
risk to personnel and property. The design, construction, modification,
operation and maintenance of facilities and equipment and construction as
practiced by Saudi Aramco and/or contractors, will meet Saudi Arab
Government and Saudi Ammco safety requirements as covered in this manual
and in relevant General Instructions, including the Company’s Engineering
Standards. When conformity with any of these requirements is impractical or
not cost effective, a waiver will be sought from the Chief Engineer.

1.12 Operating Standards and Instructions

Risks that cannot be eliminated through design are controlled by operating

standards and instructions. Compliance with safety standards and instructions
will be consistently enforced for both Saudi Aramco operations personnel and
contractors alike.

1.1.3 Personal Protwtion

Personal protective equipment, periodic environmental monitoring and bio-

surveillance will be used to help to protect all employees against exposure to
safety and health hazards (e.g., radiation, H$, etc.) which cannot be. eliminated.

1.1.4 IILVpdiOll

Inspwtions to detect and correct unsafe practices and conditions will be

conducted periodically by Saudi Aramco Pod/or contractor.
1.1.5 Education and Training

All employees shall be provided with ongoing safety education and training as
well as helping to develop those skills that are. required to perform, supervise and
manage assigned tasks without mishap.

1.1.6 Motivation and Recognition

Good communications, a viable suggestion system and the recognition of good

safety performance, encourages employee participation in loss prevention
programs.

1.1.7 Job Placement

Employees must only be assigned tasks that are consistent with their physical
capacities and job skills; this enable employees to work without endangering
themselves or others.

1.1.8 Response to Accidental Oeeurrences

Site specific effective emergency response plans must be established as per the
guidelines of Appendix B.2 of this manual. These should include. measures to
contain or control an emergency or disaster when an accident occurs to minimize
the loss of resources, a reporting and investigation system to determine the cause
of the accident, and the adoption of corrective actions to avoid a recurrence.

1.1.9 contractor Safety

Saudi Aramco proponent departments will monitor all construction activity to

ensure. that services are performed in conformity with Saudi Aramco loss
prevention policies, principles and practices and do not imperil any person or
property. Proponents will register each contractor employing 50 or more
persons in the Saudi Aramco Contractor Safety Competition. (See Appendix A -
Figures A.l, A.2 and A.3.)

1.1.10 Off-The-Job Safety

Off-the-job safety training (e.g. seat belt use) shall be vigorously practiced to
provide the meaas for all employees to protect themselves and their families from
harm during off-duty hours.

1.1.11 Traffic Safety

Operators of Company vehicles must receive defensive driving training and

driver evaluations and be in possession of a current Saudi Arab government
driver’s license. A vehicle operator will be held accountable for the vehicle
assigned to him and he must ensure that it is always operated in a safe and lawtid
 1.1.12 Accountability

All employees shall be held accountable for personal and functional safety
performance. An important factor in an employee’s overall job performance
evaluation will be bow well the employee meets his safety responsibilities.

1.1.13 Compliance Reviews

On a selective basis, compliance reviews will be conducted by teams that include

people with related expertise to determine compliance with this policy. In order
to ensure the credibility and effectiveness of the review, the team members must
be detached from the operation being reviewed.

1.2 Saudi Aramco Loss Prevention Requirements For Contractors

Saudi Aramco Loss Prevention requirements for contractors are contained in Schedule ‘D’
of contracts (See Appendix A - Figure A.4). The safe. practices specified in Schedule ‘D’
shall be followed by all contracton during the performance of all work under each contract
with Saudi Aramco.

The requirements in Schedule ‘D’ are the minimum acceptable to Saudi Aramco. Any
deviation from the requirements of Schedule ‘D’ must be signed in writing by the
Company representative. The contractor shall also take any additional measures which the
Company representative may d&tine to be reasonable and necessary to protect against
the injury (or death) of any Person, or damage (or loss) of any property during the
contractor’s performance of the work under the contract.

1.2.1 Non-Compliance

The Company representative .will notify the contractor, in writing, of any

violation of the requirements of Schedule ‘D’ and provide corrective action to
rectify the sihration. After receipt of such notice, the contractor shall
immediately take corrective action. Such notices when delivered to the
contractor’s representative at tbe site of the work shall be deemed sufficient
notice to the contractor under Schedule ‘D’. If the contractor fails to take
corrective action promptly, the company representative may issue an order
stopping all or part of the work until satisfactory corrective action has been
taken. The contractor will not be eligible to use any pat of the lost time
incurred as a result of such stop orders as the subject of a claim for extension of
time, additional costs or damages. Compliance with the provisions of Schedule
‘D’ by subcontractors shall be the responsibility of the contractor.

1.2.2 Assistance

The contractor may request advice on establishing feasible and effective safety
practices for the job. Tbe company representative will assist the contmctor*s
representative by providing guidance on good safety practices, pointing out
unsafe conditions, and applying his experience and judgment in helping to
improve the contractor’s overall job safety.
 1.2.3 Standivdsand htructiio~

All work and equipment must conform to Saudi Aramco Standards and General
Instructions. Where no standard or instruction is available to cover a particular
item, the contractor shall request that Saudi Aramco specify the standard of work
or equipment required. The term, “Approved Standards” in Schedule ‘D’ refers
to standards which are. approved by Saudi Aramco.

1.3 Contractor’s Los.5Prevention Program

The contractor shall develop and implement a loss prevention program that will conform
with Saudi Aramco loss prevention policies and procedures.

1.3.1 written Program

Prior to the commencement of contractual activity, the contractor shall submit B

written job-specific loss prevention program to the Saudi Aramco company
representative. The latter is required to forward a copy of the program to the
Loss Prevention Department. The Contractor’s written loss prevention program
shall address the following:

1. Title page (B.I.U.0.)

2. Project title and brief scope of work
3. Organization chart
4. Vicinity map and key plan
5. Hazard identification plan
6. Traffic plan
7. Safety polity and assignment of responsibilities
l Prime and sub contractors
8. Desert driving
. Search and rescue procedures
9. Safety inspections
10. Safety reports and records
11. Contractor camp sanitation and safety
12. Work permit
13. Welding and cutting equipment
14. Personal protective equipment
15. Tools and portable. power tools
16. Ladders
17. Cartridge operated tools
18. Electrical installation and equipment
19. Scaffolding
20. Cranes and rigging equipment
21. Mechanical equipment
22. Transportation
23. Saudi Aramca plant operations
24. Injury and damage reporting
25. Excavation
26. Fire prevention
27. Form work
28. First-aid facilities
l Medical evacuation procedures
 29. Dust control
30. Job site inspections
3 1. General safety rules
32. Emergency evacuation procedures
33. Hazardous material and waste management
34. seculity procedures
35. Ionizing radiation
36. Demobilization plan
31. Work over or adjacent to water
38. Explosives
39. Abrasive blasting &painting/coating
40. Lock out and tag system

1.3.2 Hazard Identification Plan

As part of tbe Contractor Loss Prevention Program, the contractor shall develop
a detailed Hazard Identification Plan based on the initial hazard identification
data supplied by Saudi Aramco Project Management Team.

Prior to the start of construction, the contractor shall conduct a hazard

identification tour with tbe Company representative and the Saudi Ammco Loss
Prevention representative. Once this has been completed, the contractor will
prepare and submit a Hazard Identification Plan. (See Appendix A - Figures A.3
and A.4.)

1.3.3 Safety Supervisor

The contractor shall designate one or more full-time safety supervisor(s) to

coordinate and monitor the loss prevention program. The names and addresses
of the Saudi Ammco approved safety supervisors shall be included with tbe
written program.

1.3.4 Safety Discussion

The contractor shall ensure that every craft and crew super&x holds a weekly
ten-minute. safety meeting with his men to discuss hazards on the job, and review
and update procedures to prevent accidents. These weekly meetings shall be
documented and such documentation shall be maintained and made available for
review at the Contractor’s on-site office.
2.0 SAUDI ARAMCO LOSS PREVENTION DEPARTMENT
SERVICES
A full complement of loss prevention services is provided by the area Loss Prevention divisions.

The area divisions are in hlrn provided support from the central Planning and Technical Services
Division consisting of Technical Services Unit, Support Services Unit and B Planning and Program
Group.

2.1 Loss Prevention Program

Loss Prevention superintendents ensure that a range of loss prevention engineering services
are provided to organizations within their assigned areas through such activities as:

2.1.1

Directing the review of new plant design in the assigned area of operation to
ensure conformity of facilities to loss prevention engineering standards.

2.1.2

Providing input to the Board of Engineers in the development of Saudi Aramco

Engineering Standards.

2.1.3

Managing major safety reviews and incident investigations with Saudi Arab
Government officials, US. Companies, and local area management.

2.1.4

Administering safety-related training programs for local area operations

management and personnel in an effort to enhance. the safety awareness of
operations personnel and proper acceptance of responsibilities.

2.1.5

Serving on special committees and task forces such as the Radiation Protection
Committee, and providing personnel to develop or assist in the development of
General Instructions, position papers and standards.

2.1.6

Directing in-depth program reviews of area operations involving procedures and

facilities with follow-up on implementation of recommendations resulting from
these reviews.
 2.1.7

Interfacing with Government Affairs to provide input on safety related issues to

“on-Saudi Aramco projects and providing monitoring of these projects to assure.
co”fomlity.

2.2 Program Management Services

Superintendents and their subordinates provide department heads with program
management services such as:

2.2.1

Assisting with the development of fomral loss prevention programs; ensuring

consistency with Company and business line policies, principles and practices;
and providing consultative services in their implementation.

2.2.2

Monitoring and evaluating loss prevention systems through the Compliance

Review Program.

2.2.3

Providing project review, waiver and other technical consulting sexvices;

recommending revisions to Saudi Aramco Engineering Standards; and
developing new hazard control standards as required.

2.2.4

Analyzing, interpreting and reporting accident statistical data.

2.2.5

Initiating and administering safety management training.

2.2.6

Coordinating response to government wncems about fire and safety issues.

2.2.1

Serving on special accident investigation committees.

2.3 Program Maintenance Services
Superintendents and their subordinates provide program maintenance services such as:

2.3.1

Providing technical interpretation of standards, procedures, princ$ples and

practices; and consulting services in their application from a loss prevention
standpoint.

2.3.2

Conducting loss prevention policy, program and procedural surveys and

inspections.

2.3.3

Identifying and assessing processes, operations and other risks (or hazards) and
recommending solutions.

2.3.4

Initiating and administering supervisory and highly specialized safety training

beyond the capability of operating management or training specialists.

2.3.5

Administering work petit and certain other safe work procedures.

2.3.6

Acting as Saudi Aramco’s representative to the Saudi Arab Government on local

safety issues.

2.3.1

Advising on proper selection and use of personal protective equipment and

evaluating its effectiveness.

2.3.8

Monitoring and providing input on other activities as required to ensure proper

response to accidental occurrences, including the development of containment
and mitigation methods for liquid chemical spills or vapor releases, conducting
accident investigations and recommending corrective measures.
3.0 ACCIDENT INVESTIGATION, ANALYSIS AND
REPORTING
Much is leaned through experience. A thorough investigation and analysis of an accident can help to
prevent future. accidents. To learn by experience, however, mans that B system for the retrieval of
information must be set up and statistical records must be. kept of injury, death and pmpaty damage.
With such a system operational, information can be collated and analyzed to show accident p&tents.
The contractor can then emphasize those. areas in which safety education and training is needed most.

The contractor is responsible for reporting accidents to Saudi Ammco and in some cases to the Saudi
Arab Gove-t as required. This section covers these repotting requirements and the principles
behind accident investigation and analysis.

INSTRUCTlONS AND STANDARDS

Saudi Ammco General lnstmctions:

GI 6.001 Notification Requirements for Incidents (Including Fires)

GI 6.003 Guide for Committees Investigating Major Incidents or Engineering Reviews of

Other Incidents

GI 6.029 Reporting and Recording Of Motor Vehicle Accidents

GI 7.026 Liftiig/Elevating and Mobile Equipment Accident Reporting Procedures

3.1 Reports Required by Saudi Aramco

Reports are required by Saudi Aramco as per Schedule ‘D’ of the contract.

Contractor shall ensure that 811immediate report is made to the Company Representative in
the case of all:

l Fatal injuries
. Injuries requiring medical attention which result in lost time
. Damage over SR 10,000 to contractor’s plant or equipment
l Damage, in any amount, to Saudi Ammco’s equipment or property
l Fires
. Damage and near misses to cranes and heavy equipment (GI 7.026)

For accidents involving Contractor employee fatalities, serious injury to two or more
Contractor employees, or damage to Saudi Aramco equipment or property, a preliminary
written report shall be submitted within 24 hours followed by a detailed written report
submitted within three days to the Company Representative. In addition, Saudi Ammco
may convene an engineering review or investigation committee in Bccordance with the
requirements of GI 6.001 and GI 6.003 (see Figure 1.1).
 Contractor shall maintain, in a format approved by tbe Company Representative, a current
record showing all:

l Work injuries

l Fires
l Incidents of property damage over SR 10,ooO
l Motor vehicle accident
l Incidents involving damage to Saudi Ammco equipment and propetty
l Damage and near misses to cranes and heavy equipment (GI 7.026)

The record shall be available for inspection at all times and shell be submitted to Saudi
Amnca on request. (See Figure 1.2.)

A final written report shall be. prepared and submitted to the Company as per the
pmvisions of GI 6.003. In tbe case of serious accidents, however, a detailed account of
tbe circumstances, wihwses’ statements and descriptive photographs are required.

In addition to the reports required above, tbe contractor must keep a record of all injuries
and damages on a form approved by the Company (Figure 1.2). A copy of this record
shall be sent to the proponent department and to the contractor’s project management.
Monthly summary reports are required in addition to the individual reports.

3.2 Accident Investigation

The point of an accident investigation is to prevent recurrence of similar accidents; to
determine facts rather than to find faults.

Tbe main reasons for conducting an accident investigation are:

1. To find the causes so that similar accidents may be prevented;

2. To d&&e. the point at which “unplanned” events tik over from the “planned”
sequence of events;
3. To recommend what corrective action should be taken.

3.2.1 Responsibilities for Investigation

3.2.1.1 Super&or/Safety
Representative
Tbe supervisor and/or safety representative shall carry out an
immediate investigation of any accident which occurs within his area
of responsibility. The preliminary accident report must be
completed and submitted within 24 hours to the Saudi Ammco
Company representative with a copy to the Loss Prevention
Department. A tinal report on the incident shall be submitted within
three days detailing any additional information and corrective action
needed.

3.2.1.2 F’roject Manager

The project manager shall review all accident reports to ensure. that
all the n-ry corrective action has been taken and that be has
addressed any items that may require action on his part.
3.3 Casesto be Investigated
Incidents that result in property damage or serious injuries to personnel and hospitalization
of hvo or more employees must he fully investigated and reported. Unless the real cause. is
known, the hazard cannot be controlled in the future. The near-miss incident is equally
important from the point of view of prevention and should also be thoroughly investigated.

3.4 Accident Investigation Guidelines

The scene of an accident must be left undishlrbed until Government Affairs, Industrial
Security, the Loss Prevention Department and the safety supervisor have conducted their
investigation. In some cases the accident site must be rendered safe so as not to contribute
to further accidents. However precautions shall be taken to keep the accident scene intact
as much as is possible, to assist local police. in their investigation. The investigation
should include, but not be. limited to the following:

1. Questioning the man in charge and finding out what was planned.
2. Finding out the injured man’s job or the normal configuration and function of the
damaged equipment or plant.
3. Questioning the injured man as wxn as possible.
4. Questioning the witnesses separately as to what they actually saw, not what they
think happened.
5. Studying the equipment or plant layout and noting any signs of misuse.
6. Finding the explanation of any irregularities.
7. From the information obtained, establishing the reason why the “unplanned” events
took over from those that were “planned”.
8. Recommending items of corrective action and methods of implementing them to
prevent the recurrence of the incident.
9. Making a scaled drawing of the accident scene and supplement that with supporting
photographs.

3.5 Accident Analysis

3.51 Classification

Contractors can use nine main classifications to analyze industrial accidents.

Every contractor should go through the following classifications and their
breakdowns to determine which of these (if any) apply to the incidents in which
they were involved. These records help to illustrate accident trends. In turn,
this helps the Loss Prevention Department (Saudi Aramco) evaluate their safety
program and modify or upgrade it as needed. This information is supplemental
to the fmdings and reporting requirements of the preceding “Accident
Investigation” sections.
 The. nine classifications with their individual breakdowns are:

1. Falls (Of Persons from Heights) 5. Equipment

To the ground or another level Moving Parts
From scaffolding Equipment in motion
From ladders Hot surfaces
Into boles, trenches, etc.
Into water

la. Falls (Of Persons on the Level) 6. Hand Tools

To the ground Cartridge hammers
Against objects Power to&
Non-power tools

2. Handling Objects 7. Tramportation

From lifting Road
From pulling or pushing Site
Handling materials
Electric shock

3. Striking Against Objects 8. Lifting Appliances

Protruding nails CCUleS
Scaffold tubes and fittings Hoists and winches
Stepping or kneeling on objects pull-lifts, pulleys, wheels, etc.
Piling frames
A-frames
Excavations

4. Struck by Objects 9. Hazardous Atmospheres

Falling objects Hydrogen Sulfide
Foreign bodies in eyes Others
Flying objects
0 FrcumI.1: FQELIMINARYACCIDENTREFORT

Detailed Repod Required Withia 3 Days Coatml NO

4eeidsot Location: Da!3 Of Aeeideot: Tim Of Accident:

3mpaoy: Pasoanel Injured: Badge Number:

Type Of Injuries: Property Damage And Estimated Cost Damage:

Description Of Accident:

Witness Statement(s)

a
What Caused The Accident:

What Corrective Action Has Been Taken

FIGURE1.2: CONTRACTOR
MONTHLYSAFETY REPORT

FROJFLT TlTLE: LOCATION:

CONTRACTOR:

R”ocxr lTEM No:. CONTRAcr No.: JOB No:-

7
1. Work Injuries:

2. Fires:

3. IncidentsOr PropertyDamage(OverSR 10,000):

4. Motor VehicleAccidents:

5. IncidentsInvolving DamageTo SaudiAramco Equipment:

6. Crane,HeavyEquipment & Manlift Accidents:

7. SafetyMeeting:

(A) TopicsDiscussed:

!.
1

(B) Attendance:

(C) Instructor(s):
4.0 RESPONSIBILITIES FOR SAFETY

The. Saudi Ammco proponent must ensure the company’s safety and accident prevention policies are
clearly understood by all employees and contractor personnel. The duties and responslbdltles of
employees, supervisors, and management must be stated in writing by the compaoy’s management.
AI1 employees should satisfactorily discharge tbe responsibilities of their job, and be aware that tbeir
safety record will be. taken into account during performance appraisals.

The main responsibilities of various members of B construction team are cited in the following:

4.1 Contractor Senior Management

1. Initiate the company’s policy for the control of injury, damage and fire.
2. Administer the policy himself or appoint a senior member of staff to do so.
3. Know the requirements of Schedule ‘D’ and the relevant parts of Saudi Arab
Government Workmen’s Regulations, and ensure they are observed by his company.
4. Ensure’ that all supervisors are qualified and that they receive adequate and
appropriate training.
5. Make sure that in tendering, at planning stages and throughout the contract,
allowance is made for suitable and sufficient equipment to enable (he jobs to be done
with minimum risk.
6. Coordiite safety activities behveen Saudi Aramco, subcontractors and any other
individual contractors who may be working on the same site.
I. Institute proper system for investigation, reporting and estimating the cost of injury,
property damage and fire. loss. Initiate analysis to discover accident trends and
promote action to prevent recu-reoce.
8. Reprimand any supervisor for failing to discharge satisfactorily the responsibility
allocated to him.
9. Set a personal example.
10. Ensure that a fomu.1 Hazard Identification Plan is prepared in order to identify and
correct hazards which may be encountered during construction. (See Appendix A.4.)

4.2 Design Engineer

Design for safety, taking into consideration those risks that might arise during construction
or in the operation of plant or equipment. Follow established process hazard analysis
techniques to evaluate and correct hazards during the design process.

4.3 Contractor’s Safety Officer

1. Advise management on the following:

. Ways to prevent injury to persmmel, damage to plant and/or equipment

and fires.
. Ways to improve existing work methods.
. Legal and contrachml requirements affecting safety, health and welfare.
. Provision and use of protective clothing and equipment.
. Potential hazards on site before work stats and on the safety organization
and fire. precautions required.
. Changes in safety requirements.
 2.

3.
cprry out site surw.ys to see.that only safe.work methods are in operation, that health
and safety requirements are being observed, and welfare and first aid facilities are
adequate and properly maintained.
Determine tbe cause of any accident (or dangerous occurrence), and recommend
a
means of preventing recurrence of such an incident.
4. Supervise tbe recording and analysis of information on injuries. damage and
production loss. Assessaccident trends and review overall safety performance.
5. Assist with training employees at all levels.
6. Take part in discussions on injury, damage and loss control.
7. Keep up-to-date with recommended codes of practice and safety literature. Circulate
information applicable to each level of employees.
8. Foster witbin tbe company an understanding that injury prevention and damage
control are an integral part of business and operational efficiency.
9. Attend job progress meetings where safety is an item on tbe agenda. Report on job
safety perfomlance.

4.4 Construction Manager/Superintendent

1. Understand the company’s safety policy and the responsibility allocated to each grade
of supervision.
2. Know the requirements of Schedule ‘D’ and relevant Saudi Arab Government
Workmen’s Regulations, and ensure that they are observed.
3. Ensure that tenders adequately allow for sound working methods and reasonable
welfare facilities.
4. Determine the following at the planning stage:

. Tbe most appropriate order and method of performing the job.

. Allocation of responsibilities for Saudi Aramco, subcontractors, and other
contractors.
. storage Breas, access, etc.
. Any hazards identified under the hazard identification procedure described
in Appendix A.4.
. Facilities for welfare, first aid and sanitation.
. Work pennit procedures and requirements.
. Basic precautions for dealing with fire hazards.

5. Provide written instmctions to establish work methods, explain the sequence of

operations, outline potential hazards at each stage, and indicate precautions to be
adopted.
6. Check over work methods and precautions with supervision before work starts.
I. Create safety awareness by promoting safety meetings, presentations, open fomm
discussions and by implementing safety training.
8. Set a personal example on site. by wearing appropriate protective clothing and
equipment at all times.
9. Ensure that all accidents are reported to Saudi Aramco in accordance with Section 3.
4.5 Site Safety Supervisor
(If difkent from contractor’s safety oflicer)

1. Understand the requirements of Schedule ‘D’ and the company’s loss prevention
policy.
2. Inspect the work site daily to report and correct unsafe methods and conditions.
3. Keep a permanent record of all injuries, fires, motor vehicle accidents @WAS),
property damage and crane/heavy equipment accidents which have occurred at the
site..
4. Keep a record of every weekly safety meeting on site complete with subject discussed
and a list of attendees.
5. set * perso”al exanlple.

4.6 Equipment Manager/Supervisor

1. Ensure that all equipment purchased or hired is safe, is guarded and equipped with
safety devices and has been subjected to all necessary tests.
2. Make certain that operators and attendants are employed only on equipment for
which they have been thoroughly trained.
3. Chwk that periodic tests, inspections and maintenance are carried out when due.
4. Attend promptly to all equipment defects and advise site management of the need for
any dangerous equipment to be taken out of service until properly repaired.

4.7 Engineer/Supervisor
1. Organize sites so that work is carried out to the required standard with minimum risk
to men, equipment and materials.
2. Know the requirements of Schedule ‘D’.
3. Be familiar with work pennit procedures.
4. Give precise instructions on responsibilities for correct work methods.
5. Plan and provide for good housekeeping.
6. Coordinate with sub-contractors and other contractors on site to avoid any confusion
about areas of responsibility.
I Position equipment effectively and ensure that electricity supply is installed, used and
maintained correctly.
8. Check that equipment and tools (both power and hand tools) are maintained in good
operating condition.
9. Make sure that all men know how to obtain and administer first aid properly and
efficiently to all injured persons. They should also know how to summon assistance
in case of emergency and nominate others to act in your absence.
11. Make sure that suitable personal protective equipment is available and that it is used.
12. Release supervisors and men when necessary for safety and tire training.
13. Cooperate with the safety engineer and the fire department, by acting on their
recommendations.
14. set * personal example.

4.8 Foreman
1. Be familiar with those parts of Schedule ‘D’ applicable to the work on which
subordinate workers we. engaged.

Febmmy 1993 - 4.0 Rclporuibiiiicr For Safety

 2. Incorporate safety procedures in routine tasks and see that they are obeyed.
3. Conduct weekly safety meetings with subordinates.
4. Conduct daily work site. inspections to identify and correct any existing unsafe
conditions. Document and coordinate the safety inspection activities and findings
with the job site. safety supervisor.
5. Correct unsafe acts, such as horseplay or the taking of unnecessary risks.
6. Ensure that new employees are properly instructed in precautions to be taken before
they are allowed to start work.
I. Commend men who, by action or initiative, eliminate hazards.
8. Report accidents, unsafe conditions and defects in equipment to immediate superiors.
9. Set * personal example.

4.9 Worker

1. Use the correct tools and equipment for the job. Use. protective clothing and
equipment provided.
2. Do nothing to endanger self or work mates.
3. Keep tools in good condition.
4. Refrain from horseplay and abuse of safety devices, equipment and welfare facilities.
5. Report any accidents, near misses or hazardous conditions to immediate supervisor.
6. Read the Company safety rules and take note of special safety precautions in
restricted *reas.
7. Obey all posted warning signs.
5.0 EMERGENCYPROCEDURES
Saudi Aramco departments and organizations have established disaster and emergency response plans
that are. documented in general instructions (GIs), department operating instruction manuals (OIMs),
terminal instruction manuals (TIM@, and retinery instruction manuals (RIMS), etc. All managers and
supervisors are expected to become familiar with the emergency procedures of the plants and areas in
which any of their staff are. working. Construction site-specific written emergency procedures shall be
prepared by the Contractor and submitted as part of the Contractor’s loss prevention program plan.
Details of the written procedures may be obtained from the Saudi Ammco representative, operating
supervisor, or loss prevention engineer.

General guidelines for preparing emergency response. plans can be found in the following Saudi
Aramco Loss Prevention Department publication:

Guidelines For Preparing Emergency Response Plans, October 1989

5.1 Action to be Taken

In an emergency, or on hearing the “Stop Work Alarm”, every supervisor shall ensure the
following:

1. All work is stopped at once.

2. All equipment is shut down.
3. All men are evacuated to a predetermined assembly point.
4. A roll call is taken and every man is accounted for.
5. No one is permitted to rehlm to work until notification has been received from
operations or from the company representative that it is safe to do so.

Refer to the specific procedures established in each Company operating area

5.2 Contact After Offke Hours

The. contractor’s supewisor shall give his home address and telephone number (and that of
his replacement) to the company representative so that he may be contacted after hours in
case of emergency involving the contractor’s job or equipment. These telephone numbers
are. to be kept current and posted at the job-site.

5.3 Help in an Emergency

5.3.1

In the event of an emergency sihution (serious personal injury, fire, critical

damage to operating equipment, etc.) help may be obtained by contacting the
nearest Saudi Aramco Main Gate or Security Control Center. This may be done:

I. By telephone: Dial the emergency telephone number 110.

2. By radio: Radio an operations group that has a telephone in the Saudi
Aramca system and ask them to dial 110 when the Main Gate or Security
Control Center cannot be contacted directly.
 3. By mgsenger: Send a messenger to the nearest telephone, radio, or
Saudi Aramw Main Gate or Security Control Center.

5.3.2

When transmitting a message by telephone, radio, or messenger, ensure that you

clearly identify yourself by giving:

. Your exact location

. Nahlre of emergency
. Service required and repeat the message
. Your name
. Your badge number

Stay on the telephone until you are told to hang up. If possible, post a lookout
to direct the ambulance, tire truck or helicopter to the right location.
6.0 SAFETY TRAINING
God safety training is important to employees who are learning a new trade but it is also necessary to
keep supervisors and skilled operators up-to-date with current safety technology and practices. Safe.
working practices are learned when employees understand how an accident was caused. Measures can
then be taken to prevent a recurrence. People who are trained to do their jobs correctly can also be
expected to do them safely.

INSTRUCTIONS AND STANDARDS

Schedule ‘D’:

Saudi Aramco Safety, Health and Environmental Requirements - Loss Prevention Program

6.1 Safety Training for Supervisors

6.1.1

The immediate job of preventing accidents falls upon the supervisor not because
it has been arbitrarily assigned to him, but because accident prevention and
production control are closely associated supervisory functions.

The most direct way to develop the desired attitudes and to impart the necessary
information about safety to supervisors is to give them safety training.

6.1.2

The course for supervisors should include legal requirements, company and
administrative policies and safety aspects of the work likely to be undertaken by
the supervisors. An outline of such a course is given in 6.3.1 of this section.

6.2 Safety Training for Workmen

Accident prevention training for workmen should incorporate the items listed in 6.3.2.

6.2.1 integrated Practiw

Safe working practices must be integrated into training for specific skills,

It is expected that those who have attended recognized training establishments

will have received the necessary safety instructions.

6.2.2 Specialized Training

Before their training is complete, new employees and new entrants to industry
are more susceptible to accidents. Contractor’s must provide safety orientation
and training for new employees.

Induction training should teach new workers to identify common on-site hazards
and how to guard against them. It should also cover the main requirements of
 the company’s accident prevention policy and instruct newcomers specifically in
those areas which affect them personally (e.g., if it is company policy that safety
helmets and protective footwear should always be worn, then this should be
made clear and they should be. told how and where to obtain them).

Suitable induction courses together with job training containiig an integrated

safety content will go a long way towards achieving safe working conditions.
Site supervision, however, must ensure that correct job methods are being
utilized and workmen are periodically reminded to be aware of hazards in the
work place.

6.2.3 Use of Pewmsion

The training providing skill and information should be supplemented by the

techniques of persuasion. Persuasion has an important function and should not
be overlooked in any comprehensive program. It is commonly applied by the
use of posters which graphically indicate bad habits, pin-point the advantages of
a safe working environment and give detailed information, advice, or instruction
on special safety points to remember.

Posters can be useful provided that:

. They are designed with due regard for the industry and its type of
operation.
. They are displayed where workmen spend some time when not working
and specific pasters are. displayed where most appropriate (e.g., ladder
hazards in ladder storeroom).
. They are mounted on properly designed and maintained bulletin boards.
. They are changed at frequent intervals.
. Only a few posters are displayed simultaneously.

Posters can stimulate thought on accident prevention, but they are no substitute
for organized training. The most effective posters are. those that help to reinforce
safety training.

6.2.4 Coune Requirements

An induction safety course for workmen should be. aimed at specific hazards
which they could encounter at a specific job site. A suggested outline of such a
course is given in 6.32.
6.3 Scopeof Training
Safety training needs to be ongoing if it is to accomplish optimum results. The program
material and presentation should cover the safety subject and be interesting enough to hold
the trainee’s attention. A limited training effort, such as an occasional safety meeting, may
prompt supervisors to do a better job for a short time, but interest starts to lag unless an
effective safety training program is in place.

Good job safety instruction not only produces more skilled workers, but also impresses
upon them the high value that the employer places on job safety. Frequent follow-ups and
attention by the supervisor to correct work practices also help to create understanding and
to eliminate resentment, which is a source of some undesirable work attitudes. (See
63.1.)
 6.3.1 Safety Training Topics For Supervisors

1. The Law and Safety 2. Policy and Administration

Statutory requirement Effect of incentive oo accident prevention
Appropriate regulations
Duties of employer and employee Human relations
Schedule ‘D’ (Contra&al Safety Requirements) Consultation
Safety Officer: duties, aims, objectives

3. Safety and the Supervisor 4. Principles of Accident Prevention

Safety and efficient production go together Attitodes of management, supervision and
operations
Accidents affect morale and public relations Methods of achieving safe operations
Accident and injury causes

5. Site Inspection 6. Human Behavior

The role of management Motivating agencies
Hazard Identification Procedure Individual behavior
Records results Environmental effects
Follow-up procedures Techniques of persuasion
Feedback

7. Site Tidiness
Site organization
Relationship of site housekeeping to accident
OCC”IIXllCe
Site access
Equipment storage
Material stacking
Materials handling

9. Personal Protective Equipment 10. Electricity

Eye, face, hands, feet and legs Appreciation of electrical hazards
Respiratory protective equipment Power tools
Protection against ionizing radiation Arc welding
Low voltage system
Lighting and power system on sites
Grounding/Ground fault circuit interrupters

11. Oxygen and Acetylene Equipment

Cylinder storage and maintenance
Condition and maintenance of valves, regulators,
and gauges
Condition and maintenance of hoses and fittings
PreSSUreS

Fcbmary 1993 - 6.0 Safety Training page 25

 13. Transportation 14. Excavations
Transport to and from site Method of shoring
Hazard connected with site transport Precautions while shoring
Competent drivers Precautions at edge of excavations
Dumpers Removal of shoring
Tipping trucks Sheet steel piling
Movement ntxu excavations

15. Working Places, Ladders, and Scaffolding 16. Cranes and other Lifting Machines
Hazards connected with the use of ladders Licensing, certification and training required for
operation of cranes
Maintenance and inspection Slinging methods
Type of scaffold Signaling
overloading Access to crane(s)
Work on roofs Maintenance. and examination
Fragile material Ground conditions
Openings in walls and floors Hazards and accident prevention methods
connected with the we of different types of
cranesiheavy equipment
Use of safety belts and nets Crane Lift Plan for all lifts

17. Lifting Tackle 1 18. Fire Prevention and Control

Slings - single and multi-legged 1 Principle cuse.s determining tire

19. Communications
Effective methods of communication (particular interest to non-English speaking workers)
Method and preparation of reports
Safety committees
Safety meeting

February 1993 - 6.0 Safety Tnining Page 26

6.3.2 Induction Safety Topics For Workmen

1. Hazard Identification Procedure

Hazards on site:
. Machinery
. Transport
. Flammables on site. (hydrocarbon)
. Fire
. Falls
. Electricity
. Site housekeeping
l Handling materials

2. Precautions Against the Above Hazards

l Simple precautions that can be. taken by workmen on site.

3. Personal Protective Equipment

l What is available
l How to obtain it
. Correctuseaadcare

4. Health

. Site welfare facilities

l Potential health hazards
. First AidlCPR

5. Duties of the Company

l Brief outline of the responsibilities of the Company by law

. Details of Company’s accident prevention policy
l Saudi Aramco Safety and Loss Prevention Requirements For
Contractors (Schedule ‘D’)
l Saudi Arab Labor Law

6. Employee’s Duties

. Brief outline of responsibilities of employee under law

l Explanation of how new employees fit into the Company’s plan
for accident prevention.
7.0 SITE PLANNING AND HOUSEKEEPING
This section outlines tbe procedure to be followed prior to and during a contract. It cannot claim to
cover every type of contract that is likely to occur, but it does provide a detailed logical process to
serve as a guide in deciding upon a plan of action.

INSTRUCTIONS AND STANDARDS

Saudi Ammco Standards:

GI 1021.ooo Street And Road Closure And Excavations, Reinstatement And Traffic Controls

SAES-P-123 Lighting; Illumination Requirements

SAES-B407C Portable, Mobile and Auxiliary Fire-Fighting Equipment

Appendix C: Typical Construction Materials Store Yard.

Fire Safety checklist for Evaluating Construction Materials Store Yard

Schedule ‘D’:

Saudi Aramco Safety, Health and Environmental Requirements (See Appendix A)

National Fire Protection Association:

NFPA80-A Protection of Buildings from Exterior Fire Exposures

NFPA 231- Appendix ‘C’

Protection of Outdoor Storage

7.1 Initial Planning

Prior to tbe start of any contract, an analysis is made by the contractor to ensure that
construction will be conducted in a safe manner. Similarly, accident prevention is
analyzed, both at the planning stage. and throughout the contract, so that the contractor will
be able to eliminate or reduce accidents. Accident prevention is a real factor in the
economic S”CCesSof all contracts.

Among other factors that must be considered at the initial planning stage are: results of a
Hazard Identification Plan, loss prevention program, protection of employees and
equipment, transportation, lifting equipment, excavation, scaffolding and work in
restricted areas requiring work pennits.

7.1.1 Hazard Identification Plan

The contractor shall conduct a Hazard Identification tour with the Company and
Saudi Ammco Loss Prevention representatives to identify potential hazards prior
to construction start-up.
 7.1.2 Los m3vention Program

A loss prevention program required in Schedule ‘D’ for specific job-related

activities part of proposed construction work will be. developed and coordinated
by the contractor’s safety supervisor. Part of this program will be. a ten-minute
safety discussion with the workmen, at least once a week, on the hazards at the
site and the procedures to be followed to prevent personal injury and minimize
propelty damage.

7.1.3 Protection of Employees and Equipment

Schedule ‘D’ details the requirements to be followed by the contractor to reduce

losses. It places the responsibility for the protection of men and equipment on
the contractor and outlines general minimum acceptable standards.

7.1.4 Transportation

The contractor must provide transportation to and from the site for his
employees.

Saudi Aramco requires that employees must be. transported only in the passenger
compartment of vehicles. (See Section 1.13.) The provision of buses for larger
sites will have to be considered. Inspection and maintenance of vehicles and the
selection and training of drivers are other major considerations.

7.1.5 Lifting Equipment

Cranes, hoists and lifting equipment should be considered well ahead of actual
requirements both from the paint of view of economical use and the safety of
personnel and equipment. Lift plans shall be submitted as required. (See
Section III. 1 and 111.2.)

7.1.6 Demolition

Some contracts in existing plant areas may require demolition before new work
can begin. Only minor demolition should be done by construction personnel.
Specialist contractors should be employed for the demolition of larger stnxhwes.
(See Section 11.3.)

7.1.7 Excavation

Timber for shoring, steel sheet piles, etc. should be present on site prior to
starting excavation work. All excavation work will be closely supervised by
experienced staff. (See Section 11.2.)

7.1.8 Scaffolding
For all work carried out above ground level where no permanent work place is
available, temporary work places in the form of scaffolding must be provided.
An adequate supply of scaffold material must be on site. There must be
sufficient experienced men capable of erecting and dismantling the scaffolding
properly. Ladders, built to an acceptable standard, must be supplied and readily
available for access to elevated work areas. (See Section 11.9.)

Fcbmay 1993 - 7.0 Site Ftmning And Hmsclrceping hgc 29

7.2 Site Layout
The site. layout must be planned before any work is started. This will assist in making the
job easier and more efficient, thus increasing productivity and profit.

Items to be considered under site layout include the following:

7.2.1 Site Accommodation

This includes shacks, storage huts, compounds, racking areas, lock-up boxes,
oftice buildings, etc.

7.2.2 Adequate Access Roads

To be kept clear and unobstructed at all times.

7.2.3 Project Sign

Erect project sign at the main entrance to the construction site. and other sites,
IS., office, laydown yard, fabrication yard, etc., as designated by the Company
representative.

The sign shall be a minimum of four feet in height, and eight feet in width. The
printing on the sign shall be black and white and shall be in both Arabic and,
English. The Arabic text will be above, or to the right of the English text.

The sign shall list:

. PROJECT MANAGEMENT ORGANIZATION.

. PROJECT TITLE
. BUDGET ITEM NUMBER (BI NO.)
. PRIME CONTRACTOR NAME, ADDRESS, AND TELEPHONE
NUMBER
. HOUR EMERGENCY PHONE NUMBERS FOR COMPANY
REPRESENTATIVE AND CONTRACTOR

The sign shall be. erected within hvo weeks after the contractor has started work
on site. Contractor shall also erect and maintain sufficient signs on or near the
site to direct delivery vehicles and visitors to the work site.

Example of Job Site Sign:

SAUDI ARAMCOICENTRAL AREA PROJECTS

SAUDI ARAMCO BUILT GOVERNMENT SCHOOLS
BOYS SECONDARY - DAMMAM BI (2.510) (ERC. 1990)
CONTRACTOR:
NAME
PO. BOX
LOCATION
TELEPHONE NUMBER
SAUDI ARAMCO REPRESENTATIVE
TEL. - OFFICE/TEL. - HOME
 7.2.4 Safe Means of Accw and Egress

To be provided on site wherever employees are likely to go; these must be kept
clear and unobstructed at all times.

7.2.5 F’arking Facilities

To be provided in clearly defined areas on site.

7.2.6 Drainage

The site should have good drainage and be graded in such a way that water does
not pool up during construction.

7.2.1 Vehicle I Heavy Equipment Paths On Site Vs Pedestrian Paths

Pathways for workmen must be clearly marked and distinct from vehicular travel
route.9 on site.

7.2.8 Sand

In sand dune areas that might lie adjacent to or around a construction site,
consideration should be given to the movement or build up of sand.

7.2.9 Fire Prevention

Suitable tire extinguishers must be readily available on site. The area around tire
extinguishers or hydrants must be kept clear so that ‘hey are readily accessible in
case of emergency. They must be regularly inspected and maintained. Site
personnel must be trained in the use of tire fighting equipment. (See Section
1.11).

7.2.10 Site lllomination

Adequate lighting must be provided in all areas of the job site in accordance with
s.‘ws-P-123.

The National Electric Code and National Fire Protection Association standards
should be consulted for specific areas. Grounding requirements will be per
NFPA. In hazardous areas (e.g., tank farms and indoor fuel areas), NFPA 30,
37,58 and 70 will be. enforced.

7.3 Storage Areas

Note: See Appendix C. Fire Protection Checklist for Evaluating Construction Materials
Store Yard; and Figure III.13 (Typical Construction Materials Store Yard).

7.3.1

Storage areas must be adequate for all material and equipment to be stored.

~ecbrum-y
1993 - 7.0 Site Henning hd Housekeeping Page 31
 7.3.2

They should not be within 1.5 meters (50 feet) of permanent or temporay
stmchlTeS.

7.3.3

Storage areas should be clearly marked.

7.3.4

They should have dir&ional signs to facilitate speedy delivery.

7.4 Welfare Facilities

Adequate welfare facilities must be provided. The following are. minimum requirements:

7.4.1

Canteen or eating area adequate for total work force must be provided. This area
shall be clean of refuse and meet Saudi Ammco Sanitary Code. requirements.

1.4.2

Rest area must be provided.

7.4.3

Adequate toilet and washing facilities must be provided. Toilets shall be

provided in places where they may be easily accessible at the rate of one. toilet
for every fifteen workmen or less. These shall be maintained in a sanitary
condition.

7.4.4

An adequate supply of drinking water must be available. Common drinking cups

or dips are prohibited.

7.4.5

First aid facilities must be supplied and arrangements made for medical care and
for emergency sihmtions.

7.4.6

Where II-, safe smoking areas must be provided, with the concurrence of
the responsible area Loss Prevention office.

February1993- 7.0 Si PIann@ A4 HaucLccping Fage32

7.5 Good Housekeeping
The required standard of housekeeping must be. established on site. and all personnel
informed of this standard. Trash, debris and refuse should be collected daily. AI1
employees shall clean their respective work areas daily before quitting.

Covered containers, drums, etc., should be provided at various, clearly marked locations
throughout the work site. The containers should be emptied daily at approved rubbish
dumps.

7.6 Construction Sitesand Materials Storage Yards

6= Appendix C)

7.6.1

The contractor’s engineer shall establish the perimeter of the site by agreement
with the proponent department. He may consult the Loss Prevention Department
for assistance.

7.6.2

The perimeter fence for construction sites and materials storage yards shall be
properly grounded and of sound construction and design appropriate for the
intended protection of the area. The Saudi Aramco Industrial Security
organization should be consulted for details.

7.6.3

The fence shall be frequently inspected by a representative of the contractor’s

engineer.

7.6.4

Any access paths through the proposed site shall be rerouted outside the
perimeter. Loss Prevention Department is to be consulted on any such
rerouting.

7.6.5

Where B fence crosses existing roads, red and white, blue and white, or black
and reflective yellow (or white) flags shall be fastened to the fence. If access is
blocked, a dead-end sign will be erected on the approach to the fence with the
distance of the obstmction marked below the sign. However, if there is a
temporary by-pass, a “DIVERSION AHEAD” sign shall be erected on the
approach to the fence and diversion arrows showing the mute shall be displayed
on the fence in black and yellow (or white) reflective material.

7.6.6

A suitable number of soundly constructed access gates shall be provided. The

number of accew gates will be. kept to a minimum on main thoroughfares (See

Febnury 1993 - 7.0 Site Planing And Hwrkeping Page 33

 NFPA 231 Appendix ‘C’). A minimum of hvo fifteen-foot wide gates are
required.

1.6.1

Standard Saudi Arab Govemmeat stop signs will be fixed to the inside. of the
vehicle alxe.w gates.

IA.8

Temporary signs should be. erected to route traffic in the safest manner to, from,
and within the site. Temporary signs shall not be placed on public highways and
roads (reference Saudi Arab Government traffic regulations).

1.6.9

While not in use all power driven construction equipment must have the ignition
locked and key removed. If there. is no lock for the cab and access can be readily
made into the engine compartment, then the. machine. must lx made immobile by
disconnecting the battery or by any other means especially if the equipment is
left outside the perimeter. This must be carried out before. leaving the equipment
unattended.

7.6.10

Crane booms, bulldozer blades, and front end loader buckets on all construction
equipment should be lowered when the equipment is left overnight. For a crane
boom where this is not possible, the boom will be locked off in such a manner
that it cannot be dropped or blown over by the wind.

7.6.11

Job site electrical power must be. de-energized at night unless required for
specific lighting facilities or used by a night watchman.

7.6.12

The project will provide its own barricades. Barricades will only be supplied by
the area Industrial Security Departments on a short term emergency basis.

7.6.13

Any excavation or obstruction of any kind likely to create a hazard to vehicular

traffic at night will be adequately lit and a sign posted. (See GI 1021.000.)

7.6.14

If large pools of water are formed which cannot be adequately drained, these
shall be separately fenced or barricaded if they constitute a safety hazard.
7.6.15

There shall be no indiscriminate dumping of excavation spoil or building

materials. Fire hydrants, manholes and electrical conduits will be kept clear at
all times. The contractor’s engineer shall designate sites for dumping.

7.6.16

AI1 manhole covers will be replaced or the manhole properly barricaded.

7.6.17

Guy ropes will be. clearly marked day and night as will any rope used as a
barricade.

7.6.18

Refuse must he. disposed of at a job site approved for such purposes and the
contractor must have petission to we the site. Approved disposal sites can be
those of Saudi Ammco or local municipalities. It is forbidden for contractors to
dump refuse in any unauthorized area.

7.6.19

Clock stations can be requested from Industrial Security provided sufficient

notice is given to ensure their availability.

7.6.20

The Saudi Aramco Project Representative shall notify the Loss Prevention
Department representative and also the area Industrial Security Department about
the time and place for the preconstruction meeting and also the first weekly site
meeting which the-se.departments should plan to attend.

7.6.21

It is the responsibility of the Company representative to initiate road closure

requirements on work activity to ensure that all construction/maintenance
adheres to the conditions of GI 1021.000 (See Appendix D) and that a notice of
intent is placed in the company “Highlights and Notices” publication before
work start-up.
8.0 FIRST AID

First aid is the immediate help that is provided at the site to 811injured or seriously ill person before
professional medical help can be obtained.

It is the responsibility of all contractors to ensure that proper first aid is available to their employees on
all job sites.

Provisions shall be made prior to start-up of the. project for prompt medical attention in case of medical
emergencies.

INSTRUCTIONS AND STANDARDS

Saudi Ammco General Instructions:

GI 1321.015 Request for Air Medical Evacuation

GI 150.002 First Aid / CPR Training and First Aid Kits - Remote Areas

Schedule ‘D’:

Saudi Ammco Safety, Health and Environmental Requirements -

Injury and Damage Reporting

First Aid Facilities

8.1 Provision of First Aid Facilities

Every contractor shall provide first aid facilities on all sites for his employees. The tirst
aid facility shall te kept in a sanitary cdndition at all times. Minimum requirements shall
include tbe following: a telephone; desk; hot and cold water; wash basin; examining table;
air conditioning; adequate lighting; and dust tight medical supply cabinet.

8.1.1

First aid supplies shall be kept readily available in a cabinet designated for those
supplies only. (See 8.3 for a recommended list of cabinet contents.)

8.1.2
This cabiiet shall be placed under tbe charge of a first aid attendant, who shall
ensure the cabinet is well stocked at all times.

8.1.3

A suitable type of stretcher must be available on all sites.

 8.1.4

Contractors shall post notices indicating the following:

1. The oame of the person who is in charge of the first aid cabinet.
2. The hospital to which any injured person who requires hospital treatment
is to be sent.
3. The telephone number of the doctor or first aid attendant employed by
the contractor.
4. The emergency telephone number to be called for assistance.

8.1.5

Contractors on pipeline and paver line work or who are. working in remote areas
shall ensure that one vehicle is equipped with a well-stocked tint aid kit for each
crew, and that at least one man in every crew is trained in first aid. The vehicle
shall be marked to indicate that it carries a first aid kit. (See.GI 150.002. First
Aid Training and First Aid Kits - Remote Areas.)

8.1.6

A site register shall be maintained by all contractors listing all injuries treated.
(See Figure I.3 Example.)

8.2 Fit Aid Attendants

8.2.1

When more than 50 persons are employed within a radius of 15 kilometers, tint
aid facilities run by a nurse familiar with first aid cardiopulmonary resuscitation
(CPR) requirements and exclusively assigned to medical duties.

8.2.2

Those persons in charge of first aid supplies on smaller sites with less than 50
workers should be trained in first aid procedures.

8.2.3

Tbe contractor shall provide, or make. arrangements to provide, a dedicated

emergency vehicle (ambulance), properly supplied and marked, to transport
injured persormel to the nearest designated health care facility.

Each ambulance shall be equipped, as a minimum, with the following supplies:

. Stretcher and blankets

l Portable oxygen
l Splints for bone frach~res
l Bandages/rubber tourniquet
. Sterile wash water

Febnwy 1993 - 8.0 First Aid

 8.2.4 MedicalEvacuation
Capabilities

Saudi Aramco has the ability to provide. air medical evacuations (Medevac) for
both ooshore and offshore medical emergencies with helicopters or tixed wing
aircraft. The procedures to initiate P Medevac are covered in GI 1321.015 and
shall be incorporated in the Contractor’s Loss Prevention Program plan.

8.3 Fii Aid Facilities At Work Site

(Originally Publiibed in Umm al-Qua, No. 2534 July X,1974)
Decision No. 404 Bawd on Artides 245 of Labor Law

Article I

An employer who employs less than fifty workmen shall provide at the work site a first aid
cabinet containing bandages, medicines, and disinfectants as follows:

1. A sufficient number of not less than 12 sterile, small-size fmger dressings.

2. A sufficient number of not less than 6 sterile medium-size hand dressings.
3. A sufficient number of not less than 6 sterile large-sim hand dressings.
4. A sufficient supply of absorbent cotton wool for packing and firming up
splints. Such supply shall not be less than 200 grams of cotton wool in
small 2.5gram packages and hvo SOO-gram packages.
5. A sufficient number of not less than 12 gauze bandages 7 cm. in width.
6. A sufficient number of not less than 12 gauze bandage 11 cm. in width.
I. Not less than 4 yards of adhesive tape in rolls, 1 cm. in width.
8. Not less than 100 grams of Mercurochrome in aqueous solution.
9. Two IO-gram shakers of sulfa powder for sterilization of wounds.
10. 100 grams of aromatic ammonia solution in a glass bottle with a glass
Stopper.
11. A medium-sized Thomas’ thigh splint, a wooden posterior leg splint, a
wooden elbow splint, a wooden Carr splint for the forearm, a wooden
palm splint, and other types of ready-to-use splints.
12. A minimum of 6 triangle bandages.
13. A minimum of safety pins.
14. Oiitment for bums containing a disinfectant and an analgesic.
15. A minimum of ten 70 x 70 bandages for bums.
16. A pair of scissors with blunt ends.
17. A sufficient number of stretchers for moving injured persons.

If work is carried out in scattered locations which are more than 300 meters apart, a
separate cabinet shall be provided for every group consisting of more than ten workmen.

Article II

The employer shall assign one or more persons to be responsible for administering first aid
to the injured at all times during working hours, provided that the person-in&arge. shall
be one of the establishment’s employees who will either be trained in first-aid procedures
in accordance with a program to be agreed upon with the Saudi Red Crescent Society, or
who holds a certificate from a hospital attesting that he has practiced first-aid and is
qualified to administer it.

Febmuy 1993- 8.0 Fti Aid hge 38

Artide III

An employer who employs 50 or more laborers shall provide at the work site. a first aid
room which me& the following standards:

It shall meet all sanitary specifications.

It shall be conveniently located and readily accessible to injured persons
and stretcher-bearers.
Where quick means of transporting for tbe injured are not available, tbe
said room shall not be more than 300 meters from the farthest work site.
An adequate number of stretchers shall be available for moving the. injured
to the first aid room.
First aid materials and supplies shall be no less than those specified under
Article I, provided that they are in proportion to the number of workmen.
A licensed nurse. shall be on duty at all times during working hours under
the supervision of a physician.

Article IV

Supplies of any item in the first aid cabinets and rooms shall be replenished whenever they
fall below the levels specified herein.

Article V

Tbe first aid cabinet shall be of hard wood or sheet metal, measuring 85 cm. in length, 45
cm. in width, and 30 cm. in depth. They shall be painted white and shall be provided with
one lock and more. than one key. The cabinets shall bear the Red Crescent insignia and tbe
words “First Aid Cabinet”. All first aid cabinets shall be conveniently located in clean
place above floor level and shall always be ready for use and easily accessible at all times.
Sigas shall be. posted in conspicuous places at the various work sites to indicate the
location of the cabinet and the name. of the workmen in charge of first aid.

Article VI

An employer who employs less than fifty workmen shall assign an appropriate number of
his workmen to receive first aid training in accordance with Article II.

Article VII

The Director General of the Department of Labor Inspection shall be charged with
implementing this decision. He is authorized to increase the contents of the first aid
cabinets or rooms in those industries and trades requiring such an increase, to stipulate
special first aid procedures to implement the above articles, to determine the placing (if he
deems it necessary) of first aid cabinets for any group comprising less than ten workmen,
and to fix the number of stretchers and the number of workmen to be trained.
8.4 Labor And Workmen Law
Saudi Labor And Workmen Law
chapter 7
Protection An SachI Services
Labor And Workmen Law
ArticIes 134-6

Anti& 134

The employer shall provide first-aid services for the workmen in accordance with the
standards to be determined by the Minister of Labor in collaboration with the Minister of
Health. If the number of his workmen in a single location or town, or withio a radius of
fiIkm kilometers, exceeds fifty, he shall employ a nurse who shall be familiar with first-
aid services and shall be exclusively assigned to rendering such services; the employer
shall assign a physiciao to examine and treat the workmen at the place to be. provided by
the employer for this purpose, and the employer shall provide them with the medicines
necessary for their treatment. The aforementioned services shall be free of charge whether
during work hours or otherwise. If in the cases mentioned above, the number of workmen
exceeds a hundred, the employer shall, in addition, provide them with all other means of
treatment in cases requiring treatment by specialists, or performance of surgical other
operations. In case operations are performed, as well as in caws of incurable diseases, the
expenses shall be taken from the Social Insurance Funds. The costs of treatment,
medicines and hospitalizations in government or charitable hospitals, as well as the party
who will assume such costs, shall be determined pursuant to the decision to be made by the
Minister of Labor in agreement with the Minister of Health, or to the rules laid down in
the Social Insurance Law.

However, if the number of workmen is less than fifty, the employer must provide the
workmen with a medical aid cabinet which shall be maiotaioed in B good condition and
shall contain the bandages, medicines, and antiseptics to be determioed by the Minister of
Labor in agreement with the Minister of ,Health, in order to provide the workmen with
first aid.

ArticIe 135

Every employer who employs more than fifty workmen shall inform the appropriate Labor
Office of the name of the physician who he has selected to treat his workmen. In case he
employs more than 811hundred workmen, he shall inform the Office. of the names of the
physicians and specialists whom he has selected to treat his workmen, and of the. names of
the hospitals which he has designated for that purpose. In both cases, he must notify the
appropriate Labor Office of the minimum number of days fixed for the examination of
workmen, provided that this minimum shall not be less than three times a week.

Art& 136

Every employer shell prepare. for each workman P medical file showing the result of the
medical examination performed on the workman upon his employment, a description of the
cases of his ilbxss, the stages of his treatment, and the. periods of his absence from work,
provided that mention shall be made in the file of the kiods of ordinary and occupational
diseases and labor injuries.

February 1993 - 8.0 Fun Aid

FIGURE 13 INJURY S-Y

Injury Summary (Pw -ofA

Reject: Project No.: Month & Year:
contractor: File No.:

Report Prepared By:

Signature:
Title And Telephone:

l
9.0 PERSONALPROTECTIVEEQUIPMENT
When a hazardous situation is recognized, steps should be taken to eliminate the hazard by engineering
controls. Should it prove impractical to eliminate the hazard, then personal protective. equipment must
be wed that meets the requirements of ANSI or equivalent standards. When it has been decided that
personal protective equipment is required, steps must be taken to select the proper type of equipment
and ensure that the supervisor instructs his employees io tbe use and care of that equipment, in
accordance with the instructions provided by the marmfachrer and Saudi Aramco. (See Table I. 1.)

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 6.020 Personal Flotation Devices For Work Over, On Or Near Water

GI 7.027 Personnel Work Platform Operations

GI 8.002 Prescription Safety Glasses

GI 8.883 Breathing Apparatus

GI 8.885 Protective (Safety) Footwear

Saudi Aramco Engineering Standards:

SAES-A-105 Noise

SAES-H-102 Safety Requirements For Painting

Schedule ‘D’:

Saudi Aramco Safety, Health and Environmental Requirements

OSHA:

Code Of Federal Regulations 1910, 1915 and 1926

ASTM D12O.El-87

Standard Specifications For Rubber Insulating Gloves

ANSI Z 41-83 Perscumel Protection - Protective Footwear

ANSI Z 87.1-89 Practice for Occupational and Educational Eye and Face Protection

ANSI Z 89.1-86 Personnel Protection - Protective Headgear For Industrial Workers - Requirements

Qebnuq 1993 _ -ticm safety M.mul - RnoMl Pmleclivo Equipmellr Page 41

9.1 Head Protection
Safety hats or helmets are rigid headgear made of materials designed to protect the head
from impact, flying particles, electric shock, etc. Each helmet consists of a shell, a
suspension cradle, and a chin strap.

9.1.1

Employees working in areas where there is danger of head injury from impact;
from falling or flying objects; or from electrical shock and bums, shall be
protected by protective helmets as per ANSI referenced standards or equivalent.

9.12

The suspension cradle gives a helmet its impact distribution qualities. It is

therefore essential that it be properly adjusted to the wearer’s head so there is a
gap of at least one and a half inches behveen tbe top of the suspension cradle and
tbe helmet shell.

9.1.3

Ancillary equipment such as ear muffs, welders shields, etc. can be obtained to
fit on helmet shells. Holes should not be drilled into helmet to facilitate use of
such equipment as this can seriously impair both the mechanical strength and the
electrical resistance of the helmet.

9.1.4

Safety hats or helmets shall not be painted.

9.1.5

The complete helmet should be. cleaned regularly with soap and water. Helmets
should be swapped following any penetration, high impact, or subjection to
extreme heat.

9.1.6

A safety helmet should be worn by all persons at all times when on a

construction job site, in an operating plant area; or whenever there. are overhead
hazards. Metal hard hats do not afford proper impact or electrical protection
and, therefore, are. prohibited from all Saudi Ammco work areas.

9.2 Eye and FaceProtection

Protection of the eyes aad face from injury by physical x chemical agents or light
radiation, is of prime importance in 80 industrial environment. The type of protection
selected will depend cm the hazard, but it should be. borne in mind that all eye protection
and most face protection devices must be considered as optical instruments. They must be
selected, fitted, and wed with regard to both the type of hamrd and the optical condition

February 1993 - 9.0 pCmd Racotivo Eq,ip,,ed Page 43

 of tbe user. (See Figures I.9 and 1.9A.) The wearing of contact lenses is not
recommended in areas where eye protection is required.

9.2.1 Eye Protection from Impact

Factors to be considered in selecting impact resistant eye protection include tbe

degree of protection required and the comfort provided as required by ANSI or
equivalent requirements. Four basic types of protection am:

1. S0ectacle.s used for umtection anainst frontal m. When fitted with

side shields, they afford limited protection against side impact and should
not be worn while driving if they interfere with peripheral vision.
2. Flexible fitting noedes. A flexible frame sumxmdiig the. leas gives
protection against flying objects.
3. Cushion fittine nweles. A rigid plastic frame swmundiig the lens and a
sepamte cushioned fitting surface 011 the facing COntact area gives
protection against flying objects.
4. Chitmine eon&s. Separate rigid plastic eyecups with lens. Designed in
hvo shapes, one for individuals who do not wear spectacles and one to fit
over prescription spectacles.
5. chemical eoeeles.

9.2.2 Eye F’mtection from Radiant Energies

In addition to damage fmm physical and chemical agents, the eyes are vulnerable
to the effects of radiant energy such as that produced during welding. Visible
and non-visible bands of the light spectrum can produce harmful effects upon the
eyes and special attention must be paid to the selection of eye protection fmm
these hazards.

9.2.3 Face Protection

Face shields protect tbe fack and neck fmm flying particles, sprays of hazardous
liquids, splashes of molten metal, and hot solutions. Where required, safety
sp&acles and chemical goggles shall be worn under the face shield.

9.3 Hand Protection

The kind of gloves used depends primarily upon the material or equipment being handled
and can be resistant against one or mom of the following: heat, acid. caustic, slipping,
wear, fire, oil, sharp edges, general wear and tear, cold, etc. (See Figure 1.5.). Gloves
should not be used near moving machinery as they can be caught end trap the hand before
it can be withdrawn fmm the glove.

9.4 Foot Protection

Foot protection used must be. manufachwed to tbe referenced ANSI standard 241-83 (or its
equivalent). Safety foohvear is available in many styles, with special soles to resist oil,
abrasion, heat, and other abuses to which the foohvear may be subjected. Comfort is
particularly important for the wearer, 80 safety footwear must fit pmperly.

Fcbmuy 1993 - 9.0 Rd Racotiw iLqGp,,ea RncU

 Approved safety foohvear are shudy work shoes with leather uppers and/or leather
comp&tiw with steel toe caps. Soles and heels ate ‘non”-slip type. B type safety
‘toe” shoes with canvas, nylon and/or other SC& composition uppers or s&s arz not
considered safety shoes and are not approved by Saudi Ammco.

9.5 Hearing Protection

Increasing attention is beiig paid to the problem of excessive noise in industry. Noise can
be defined as ‘any wnva&d sound’. The intensity of noise is commonly expressed in
terms of decibels (dBA) and measured by a sound level meter. Medical authorities state
that continual exposure to noise levels above 90 dBA for an eight hour day, five day work
week may endanger P person’s hearing. The safe. period of exposure to a noise level is
inversely proportional to the level of the noise. (See reference SAES-A-105, Noise.)

Hearing loss will result fmm over-exposure to excessive noise levels. only after
engineering and me&anical methods of reducing noise levels have been explored, should
consideration be. given to providing hearing protection to individual workmen.

Exposure to impulsive or impact noise shall not exceed the requirements of SAES-A-105,
Noise.

Whenever it is infeasible to reduce the noise levels or duration of exposure to within the
limits of SAES-A-105, hearing protection devices shall be. provided and wed. There are
hvo types of hearing protection available, the plug type and the cup (or muff) type. The
proper individual fitting of both types of hearing protection is critical as any sound leakage
can seriously impair efficiency of these. devices.

9.5.1 Ear Plugs

Ear plugs are placed into the canal of the outer ear. Materials used for these
plugs are rubber, plastic, wax, foam or Swedish wool. Disposable types are
preferred as they give good protection and are very sanitary.

9.52 EarMuffs
Ear muffs cover the external ear to provide an acoustic barrier. The
effectiveness of ear muffs varies considerably due to differences in manufacturer,
size, shape, seal material, shell mass, and type of suspension. Head size and
shape can also affect their performance. Liquid or grease filled cushiotw
between the shell and the head are more effective than plastic or foam-filled
types, but they would present material leakage problems.

The use of hearing protection devices shall be properly evaluated to ensure that
the s&&d devices give the necessary noise attenuation and protection.

9.6 Fall Restraining/Arresting Devices

There are several types of fall restraining devices used throughout the construction
industry. The two most commonly wed ortes are the full body safety harness and the
safety belt. Harnesses are used for above ground work, where fall restraining and

February 1993 - 9.0 kd F?vkctivc Equipmel* Page 4s

arresting protection is required. Safety belts are used to restrain the wearer at his place of
work. Safety belts should not be used as part of the fall arrest system. (See Figure 1.6.)

9.6.1

Full body harnesses are required when working in areas with no guard rails at
heights above 1.82 meters (6 feet) or for potential falls of six feet or greater.
Exceptions shall require the review and concurrence of the Lass Prevention
Department.

9.6.2

Special attention should be given to achieve a snug tit of the safety harness as it
is easy for a man to slip through sound but badly adjusted equipment and fall.

9.6.3

No fall restraining or arresting device is any stronger than the point of

attachment. Therefore, all users should be carefully instructed in the importance
of a firm anchorage.

9.6.4

Fall restraining/arresting devices must be. stored in clean and dry conditions
away from sunlight, and must be thoroughly inspected both on issue and at the
start of each shift.

9.6.5

Fall protection devices shall be capable of supporting a minimum dead weight of

2450 kilograms (5400 pounds). (Refer to OSHA 29 CFR 1910.66, Appendix C
- 1991.)

The maximum length of standard lanyards shall be limited to provide for a fall of
no greater than 1.82 meters (6 feet) w in the case. of mechanical fall
arresting devices which have been reviewed and received concurrence by the
Loss Prevention Department. The lanyard shall have a minimum breaking
strength of 2,450 kilograms (5,400 pounds).

All fall arresting/restraining devices and hardware shall be manufachred to

ANSI or equivalent standards and fully described in the Hazard Identification
Plan (HIP), including type, model and manufachxer.

9.6.6

During all operations conducted from a personnel platform (man basket) at any
height above ground level, fall protection devices (lanyards) shall be secured to
an anchorage point or a structural member located on the basket which can
support a minimum dead weight of 2,450 kilograms (5,400 pounds).
TABLE1.1: BASICPERSONAL PROTECTIVE
EQUIPMENT

The table below is a list of basic personal protective equipment. Many job classifications may require
additional personal protective equipment depending on the work location, type of job, local hazards,
conditions, etc. The Loss Prevention or Industrial Hygiene office in your area should be contacted for
further details.

Typical Job Classifications BasicPersonalProtectiveEquipment To

Be Worn (seekey below)
Abrasive blast cleaner See Section II. 11, Table 11.7
Boiler maker 1.8.9, IOD, 15B
Carpenter 1, 8, 9, lOC, 15A
Electrician 1, 2, 8, 9, lOB, 15A, or B
Iron worker - structural 1, 8.9, lOD, 12113, & 14 A/B, ISA
Lineman 1, 8, 9, lOC, 12113 & 14 A/B, 15A
M&SOll 1, 8, 9, lOCIA, ISA
Material Control Man 1, 8, 9, IOC, 15A
MechnniclMarhiniat -, 8~
1~ -, %_, 1nClA
_- _..., 1SA
_-._
Painter See Section II. 11, Table II.7
Pipe fitter 1, 8.9, 10 CID, 15A
Plumber 1, 8.9, lOC, 15A
Rigger 1, 8.9, IOC, 15A
Roof worker 1, 8, 9. lOC, 12/13 & 14 A/B, 15A
Scaffold erector 1, 8, 9, lOC, 13 & 14 A/B, 1.5A
Sheet metal worker 1, 8,9, 10 CID, 15A
Welder 1A &B. 4, 8,9, lOD,/E, 15B

Key TO PersonalProtectiveEquipment
1. Safety glasses with side shields (lA=Clear, lB=Shsded)
2. Face shield
3. Goggles, safety impact (3A=Clear, 3B=Shsded)
4. Welding hood and skull guard (Lens shaded to wit work)
5. Respinblc air fed hood with filter
6. Respirator, chemical canridge
7. Respirator dust
8. Safely hat helmet
9. Safety foot wear (PA=shoes, PB=bm,s)
IO. Gloves. (lOA= Rubber coated, IOB= Rubber molded, IOC = General purpose, IOD= Leather, lOE=Hsat resistant)
11. Ear protection (I 1A=Ear plugs, IlB=Ear muffs)
12. Standard safety bell
13. Full body harness
14. Lanyard I .82m (6FD). (I4A=Standard, 14B=Shwk Absorbing)
IS. One piece ~ovem.II (lSA=Stmdsd, 15B=Fire Resistant)

Notes: AI1 personal protective equipment shall meet ANSUOSHA or their equivalent requirements.
Any worker 1.82 m above ground without the protection of a guard rail system, or in a confined space,
shall wear a full body harness and standard lanyard. Respiratory protection shall be used anytime
workers could inhale air contamin.u~ts exceeding permissible exposure limits (PEL), and when an
oxygen deficient atmosphere could be. encountered. Breathing quality air shall be supplied to the
worker through the use of an air fed hood or self contained breathing apparatus.

Fcbmary 1993 9.0 Personal RMeetivc Equipmsnl Page 47

 FIGURE 1.4: PROTECTIVE GOGGLES, SPECTACLES, FACE SIIIELDS AND HELMETS

A. Typical snkty glmerkide shields B. Safety glosreskide sbi&ls (others) C. F~cesbields

D. Weld goggles (cup) E. Weld goggle (chip) F. Weld goggles (soft)

G. Tyfipl spfety goggle Il. .%ffly goggles (otben) 1. w&llng bebufi

TVPICAL EYF. PROTECTION APPLICATIONS

Opemtiotj Ho72l4.S Protection

Acetylene-welding, Sparks, molten metal, harmful D, E, F
cutting burning rays. flying particles
Electric arc welding Sparks, molten metal, intense I
I rays, flyin g particles
Chemical handling SpM I, acid bums, fumes G, H (Severe +
Chipping il.Alr “^A:^ln” ADPCT:
Furnace operations , heat, molten metal ! D. E, F
Grinding (light)
Grinding (heavy) Flying pa ,...-.- -9 -9

L&oratory Chemical splash, glass breakage G,H(AorB +C)

Marhinino Flvino nn,fiioles A, B, G G
Molten metals Heat, glare. sparks. splash D, E (A or B tinted + C!)
t Spot welding Flying particles, sparks A. B, C. G

Febnwy 1993 - 9.0 Penoml Rocective Equipment page 4a

FIGURE 1.4A: PROTECTION AGAINST RADIANT ENERGY

Protection against radiant energy requires the selection and use. of the pqer shades of
welding filter lens or plate.

The table below shall be used as a guide for the selection of the proper shade numbers of
filter lenses or plates wed in welding. Shade.smore dense. than those listed may be used to
suit the individual’s needs.

FILTER LENS SHADE NUMBERS FOR PROTECTIONAGAINST RADIANT ENERGY

Welding Operation Comfort Shade number

Shielded metal-arc welding l/16-, 3/32-, l/8-, 10

5/32-inch diameter electrodes
Gas-tungsten arc welding and gas-metal arc 11
welding (nonferrous) l/16-, 3/32-, l/8-, 5/32-
inch diameter electrodes
Gas-tungsten arc welding and gas-metal arc 12
welding (ferrous) l/16-, 3/32-, l/8-, 5/32-i&
diameter electrodes
Shielded metal-arc welding 3/16-, 7/32-, l/4- 12
inch diameter electrodes
Shielded metal-arc welding 5/16-. 3/8-&h 14
diameter ele&des
Atomic hydrogen welding
FIGURE 1.5: SPECIALIZED HAND PROTECTORS

Heat Re&tant Gloves

mslcrials that provide insulalion to hot or cold objects. The purpose of this material is to give the
handling the object before his hand is injured.
FIGURE 1.6: TYPICAL SELF-POWEREDPLATFORM FOR BUILDING MAINTENANCE l
Suspension
Wire Ropes

Euildng Fam
Rollers

Hoisting
Machine
10.0 BREATHINGAPPARATUS
Where. industrial p’ocesses create hazdow atmospheric cwtaminants, the first consideration should
always be the application of engineering measures to control the contamioants. In those cases where.
engineering control measures are not possible, affected personnel must be supplied with personal
respiratory protective equipment.

INSTRUCTIONS AND STANDARDS

Saudi Ammca General Instructions:

GI 6.021 Safety Requirements For Abrasive Blast Cleaning

GI 8.003 Air Supplied Breathing Apparatus

TM-3 Technical Memorandum And Attachment - Oil By-Products Protection Program

(Saudi Ammco Medical Services Organization, Dhahmn, Saudi Arabia)

Schedule ‘D’:

Saudi Ammco Safety, Health and Environmental Requirements - Personal Protective

Equipment

American National Standards:

ANSI 288.2. - 1980

Practices for Respiratory Protection

US. Bureau of Mines:

Respiratory Protection (See 30 CFR Part II)

10.1 Selectionof Equipment

A wide variety of respiratory protective equipment is available. As each type. is suitable

for certain applications, it is necessary to develop an orderly method for determining the
appropriate device to be employed.

Persons should not be assigned tasks requiring the use of respirators unless it has been
predetermined by medical examination that the worker is physically able to Perform the
work and use the breathing appamhls properly.

Each user must receive instructions on the proper use. and limitations of the device, BSwell
as demonstrations and practice in how to fit and wear it. Personnel shall not be placed in a
hazanlous environment for which the respirator is not designed, such BS a location where.
there is a lack of sufficient oxygen.
Consider the following tiwtors when selecting P suitable respiratory protective. device:

1 The. mhm of the hazardous operation or pmces.

2 The type of air contaminant, including its physical properties, chemical properties,
physiological effects on the body, and its concentration.
3 Tbe period of time for which respiratory protection must be provided.
4 The. location of the hamrd with respect to P source of uncontaminated respirable air.
5 The state of health of the personnel or users involved.
6 The. hulctional and physical characteristics of the respiratory protective devices.
7 The we of approved respirators only.

The contractor must know the specific hazards for which a given type of respiratory
equipment is approved. He should not permit respiratory equipment to be used for
protection against hazards for which it was not designed.

10.1.1 Requirements For Use

As with all personal protective equipment, respirators only work if you use tham
correctly. For face mask respirators, always make. sure that tbe mask fits
properly, that there is a tight seal and no air leakage. Proper fit is important to
prevent contaminants from leaking in. Beards, dentures and facial bone structure
can affect the fit of tbe respirator. Be sure to wear tbe right respirator for the
hazard. Always keep the respirator clean and well-maintained. Never alter or
modify tbe respiratory equipment. Finally, follow manufacturer’s specifications
for proper cartridge use and established safety procedures. Do not hesitate to
consult your supervisor if there are any questions concerning your personal
respiratory protection.

10.1.2 Misuse

Workers sometimes consider respiratory equipment a nuisance, not reaiizmg that

failure to wear it may endanger their lives. This attitude can be changed by
education and training. However, as the risk of injury or death is very real when
safety precautions are ignored, any worker refusing to wear tbi: necessary
respiratory equipment will not be allowed to work without it.

Common misuses of respiratory protection equipment include:

a. Using air-purifying (chemical cartridge type) respirators when toxic levels

are above the respirator-rated capacity.
b. Using air-purifying (chemical cartridge type) respirators in oxygen
deficient atmospheres.
c. Using incorrect cartridges or filters for the type contaminant and tbe
concentration eocountered.
d. Using defective or improperly inspected equipment.
e. Using equipment without having received adequate on training on it.
 10.1.3 Hamrdous Substances

Protection is required against those hazardous substances which can be inhaled

into the respiratory system, ingested via the digestive tract and absorbed into the
skin causing systemic injury to the human body. Hazardous substances which
can enter the body through the respiratory system, the digestive tract and the skin
include, but are not limited to, the following:

ASbStOS
Crmsol (cresylic acid)
Hydrogen cyanide (bydrocyanic acid)
Tetrsethyl lead and its compounds
Mercury and its compounds
Nitroglycerine
Organic phosphate insecticides
solve”ts

10.1.4 Contaminants

Air supplied to respiratory equipment must be free from contaminants. (See GI

8.003.) Respirable air shall be controlled to the following conditions at all
times:

1 Oxygen, not less than 19-23% vol.

2 Carbon monoxide, not more than 10 parts per million @pm)
3 Carbon dioxide, not more than 0.10% vol.
4 Oil mist, not more than 5 mglm3 @ NTP
5 Water vapor, not more than 0.76 mg/l
6 Particulates, none

The above standards are based on Compressed Air Gas Association (Table No.
1) and referred to as Grade ‘D’ breathing air. Respirable air quality must meet
this standard, at a minimuq.

The air delivered to the user must he less than lOOoF (38%) and supplied at 6
standard cubic feet per minute (6 SCFM). Air cooling devices (e.g. vortex
hhes) my be necessary.

10.2 Respiratory Protective Devices

Respiratory protective devices can be. classified as follows:

1 Air purifying respirators

2 Supplied air respirators
3 Self-contained breathing devices

10.2.1 Air Purifying Respirators

10.2.1.1 GasMasks

The gas mask type of respirator consists of a face piece and filter.
No one chemical agent has been found that will remove all gaseous
 contaminants, so the canister must be carefully chosen to fit the
specific need. A canister designed for a specific gas will give longer
protection than a canister designed for a multitude of gases and
vapors. Canister gas masks with full face pieces are effective against
higher concentrations of contaminants. However, they do not
provide protection against oxygen deficiency.

10.2.1.2 Chemical Cartridge Respirators

Chemical cartridge. respirators consist of a face piece (usually half
mask) connected directly to one or hvo small containers of
filterslchemicals. The chemicals wed are similar to those found in
gas mask canisters, but cartridge respirators are for use only in
atmospheres not immediately dangerous to life or health. An area
where the chemical cartridge respirator works very well is in spray
painting. It is critical that the cartridge be matched to the specific
application.

10.2.1.3 Particulate Filter Respirators (Dust Respirators)

A particulate filter respirator protects against the inhalation of

nonvolatile particles. The major items to be considered are.:

1 The resistance to breathing offered by the filtering element;

2 the adaptation of the face piece to faces of various siles and
shapes;
3 the fineness of the particles to be filtered out, and their toxicity.

10.2.2 Supplied Air Respirators

A supplied air respirator permits the user to breathe respirable air while working
in a hazardous atmosphere. Important advantages are simplicity of design, usage
under diverse conditions, and good protection (when properly selected,
adequately supplied with respirable air, and used for the purposes for which they
were designed and approved).

10.2.2.1 Air Line Respirators

The air line respirator (see Figure 1.8) is suitable for respiratory
protection in atmospheres not immediately hazardous to life.
Equipping the respirator with a small cylinder of compressed air to
provide an emergency air supply qualities the respirator for use in
immediately hazardous atmospheres. It is particularly suited to some
types of jobs because it is light and may be worn for long periods of
time without appreciable discomfort. For example, it is often used
for spray painting, insecticide spraying, welding, metalizing and
prolonged production work in hazardous areas.

There are two basic types of air line respirators:

1 the continuous flow,

2 the pressure demand flow.
 The continuous flow respirator may be assembled to a half mask, full
face piece, or hood, whereas the demand flow type must always be
used with a tight-fitting face piece..

1 In the continuous air line respiratoc a set amount of air is

continuously fed to tbe face piece. The amount is regulated by
an air control valve of special inlet design which is not
susceptible to accidental changes of the. setting even when
jarred. A slight positive pressure on the inside of the mask is
always maintained to prevent inward leakage of the
contaminated outside atmospheric air.

2 The pressure demand flow air line remirators are normally used
when air must be conserved, as may be the case when the supply
is from a cylinder of compressed air. They contain a regulator
at the lower end of the breathing hlbe. This permits air to flow
under slight preset positive pressure to the face. piece only when
the wearer breathes.

10.2.2.2 Abrasive Blasting Respirators

Abrasive blasting respirators we used to protect personnel engaged

in sand or other abrasive blasting operations.

The requirements for this type of respirator are the same as those. for
an air line respirator of the continuous flow type with the addition
that mechanical protection from abrasive particles is needed for the
head and neck.

10.2.2.3 Air Supplied Suits

The most extreme condition requiring respiratory equipment is

rescue or emergency repair work done in atmospheres which are
extremely corrosive to the skin and mucus membranes, in addition to
being acutely poisonous and immediately hazardous to life.

For these. conditions, full suits of impervious clothing with

respirable air supplies are available. Tbis equipment must be used
only by well-trained and qualified personnel. Consideration must be
given for the clearance. of safety equipment through manholes and
other accessways. (See Figure 1.9.)

10.2.3 Self Contained Breathing Apparatus (SCBA)

When entry into a hazardous atmosphere is necessary, self contained breathing

apparatus shall be wed. This equipment typically consists of a high pressure
cylinder of air, a cylinder valve, B regulator, a face. piece and tube with an
exhalation valve. The need to have the mask properly fitted before use is
important. A person who wears glasses or who has a beard cannot wear tbis type
of breathing apparahts as a proper seal cannot be obtained behveen the mask and
face.
 SCBAs must be. used in lieu of airline respirators when the distance. from the
source of fresh air supplied via the air line hose is greater than 91 meters (300 8)
per ANSI 288.2-1980. However, an exception from this requirement is made in
an emergency situation where use of such equipment is necessq to escape from
a hazardous condition.

10.3 Training
In many cases, respirators are used in emergency sihlations where there is heightened
physical demands on the body, due to stress and excitement. Under such conditions, it is
essential that the potential users have been thoroughly trained and are medically fit @er
TM - 3 OTequivalent) to cope with the increased level of physical activity and stress. The.
local Loss Prevention Division and the Industrial Hygiene Unit will assist contractors in
the selection and we of respiratory protective equipment.

10.4 Safety Precautions

When air supplied respirators are. used, the following safety precautions are required:

1 Breathing air compressors shall have:

. Pressure Relief Valve
. High temperature alann
. Periodic carbon monoxide (CO) testing to ensure it meets the CGA Grade ‘D’
limit
. Breathing air tested to meet requirements. (See section 10.1.4.)
Proper training of employees in the use of this equipment.
Fit testing of mask/hood prior to each use.
Employees determined by a medical evaluation to be physically tit to use equipment.
Proper cleaning and inspection program for equipment.
Written standard operating procedures for using the equipment.
A rescue man with a self-contained breathing apparatus (SCAB) is required when
equipment is used in immediately dangerous to life and health (IDLH) atmospheres.
8 Life lines shall always be attached to the safety belt worn by employees using a
respirator.

10.4.1 Air Compressors

. Air compressors shall operate at 245°F and 150 psig maximum. (See
manufacturers’ specifications.)
. Intake air filters to compressors and outlet filters to operator maskmood
me. required.
. Air supplied respirator’s maximum intake temperature and pressure are
140°F (60°C) and 125 psig respectively. Filter outlet temperatire to
operator’s mask/hood is lC@F maximum. The airsupply rate is 6 CFM
far hoods without vortex tube and 25 CFM for hoods with vortex tube.

Febmuq 1993 - 10.0 Bmthing Appmtus Rgc 57

Flcut~I.7: RESPIRATORYPROTECTION

Self Contained Breathing Apparatus Airline Respirator

(SCBA)

Chemical Cartridge
Respirator

Airline Hood With A Full Face Piece Gas Mask Used In HC

Atmospheres
 FIGURE 1.8: CLEARANCE CONSIDERATIONSFOR SAFETYEQLNPMENT

Deck-mounted batch dimension. As angle

X increases, depth of hatch must increase

Febnury 1993 - 10.0 Brathing Appantur Page 59

11.0 FIREPREVENTION
This section covers measures to prevent fires and protect against all their possible harmtid effects, in
order to avoid injury to persomwl end loss of time and materials.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 2.100 work permit System

GI 2.711 Fire. and Safety Watch

GI 1781.001-l Inspection/Maintenance - Fire Protection Equipment

GI 1787.000-l Fire Reports

Abqaiq Plants Operations Instruction Manual:

No. 2.102 Fire Fighting Dispatching Procedure

Refinery Instnrction Manual:

No. 1.806 Fire Watch

Saudi Aramco Engineering Standards:

SAES-B-‘IA Fire. Water System and Design

SAEZS-B-7C Portable, Mobile, and Auxiliary Fire Fighting Equipment

Saudi Ammu, Sanitary Code

Schedule ‘D’:

Saudi Aramca Safety, Health and Environmental Requirements - Fire. Extinguishers

National Safety Council Accident Prevention Manual for Industrial Operations

NFPA:
National Fire Codes
NFPA 231-Appendix C, Protection of Outdoor Storage.
“Fire Safety Checklist for Evaluating Construction Materials Store Yard”

11.1 Before the Job Starts

Construction witbin a petroleum industry complex requires careful planning since plants
and support facilities being constructed are frequently next to those. already in operation.
An accident at a construction site can bwe serious effects on a nearby oil or gas tkiity
and vice-versa, because. of a large. amount of fuel present at both locations. The. factors
which must be considered before the job starts include site preparation, work permit
schedules, types of work permits required and type/quantity of equipment required on-site.
 As pmi of this process, the contractor must take into account tbe potential hazards that can
be encou&zed on site; pmtection of machinery and equipmeat; control of ignition
so-; storage of flammable and combustible materials; housekeeping; staff training; and
end-of-shift checks. ‘these subjects are. addressed in the Huxds Identification Procedure
prior to construction start-up in Appendix A of this manual. Tbis section focuses on
meptls of avoiding and contmlling tires.

11.2 Layout
Good layout helps ensure the project can be carried out efficiently. Gverall requirements
for site planning are in Section 7. (See Appendix C attachment). The. following principles
of project layout and organization can help minimize fire risks:

11.2.1

Avoid congestion around machinery and equipment where. there is a high level of
activity and traffic.

11.2.2

Operations having a high fire risk, such as welding and spray painting, should be
isolated from flammable and explosive materials or specially protected.

11.2.3

Be sure to provide adequate emergency access and egress.

11.2.4

Storage of flammable and explosive materials in the plant site should be

restricted to minimum quantities necessary for an uninterrupted cycle of
operations; use a larger, secondary storage site outside the plant area where.
possible.

11.3 Equipment Protection

Some items of plant equipment need special handling and care after they arrive on site and
until they we commissioned. Examples are. computer (and other electronic instrumentation
and control gear) and large pumps and compressors. Such equipment should be covered
and protected against possible damage that could result from its exposure to normal
construction activity, dust, paint spray, etc. Consideration should also be. given to
protecting it against fire, which could be caused by storing it near combustible material
and against water or other fire fighting agents that might be wed to put out a fire.
11.4 Control of Ignition Sources

Compliance with work permit procedures and conditions protects against possible ignition
of oil or gas from process operations. The. contractor must also take steps to prevent
ignition of construction materials, lubricants, and fuels used in the job itself.

11.4.1

Electrical equipment should be checked regularly for defects.

11.4.2

Smoking is permitted only in designated areas.

11.4.3

Welding equipment, asphalt kettles, heating appliances and other open flames or
hot surfaces should be segregated from combustible materials.

11.4.4

Beware of indirect sources of ignition: hot welding slag dropped from a height
for example, or sparks from a fire under an asphalt kettle are familiar examples
of this.

11.4.5

Open fires and/or open burning of materials are strictly prohibited.

Authorization must be. obtained from Saudi Aramco Fire Protection Department.

11.4.6

Proper bonding and ‘grounding techniques shall be used for any operation where
static electricity could become an ignition source.

11.5 Flammable Liquids

Flammable liquids are those that can produce a flammable mixhlre in air at ambient
tempemhwe. In Saudi Aramco, this is detined as a fluid (liquid or gas) having a flash
point of SST (1300F) or lower. Care in handling flammable. fluids is of prime
importance.

11.5.1 storage

All flammable liquids must be kept in securely capped metal containers or steel
drums on which the contents are clearly marked. Gasoline, acetone, spirits and
other volatile liquids with flash points below 32%! (WF) should be kept in
strong metal lockers located in well-ventilated, non-.xmbustible huts or sheds.
Drums containing flammable fluids shall be provided with proper bung vents.
Flammable storage weas must be securely locked (or fenced), posted with a
weming sign ‘Danger: Flammable Area’ and must be located at least 15 meters
 (50 feet) away from the nearest building or storage area for combustibles. No
other materials should be. stored with flammable liquids.

Flammable gases in cylinders (acetylene, propane. etc.) shall be segregated from

other materials, preferably under an open, well-ventilated sun shade. Oxidizing
gases (oxygen, chlorine, nitmus oxide, etc.) shall be stored separately.

11.52 Handling of Flammable Liquids

(Reference NFPA 30)

In handling, the following precautions should be observed:

1 Transportation must always be in (closed) metal containers. (Plastic

containers are prohibited.)
2 Transfer operations should be carried out with funnels and there should be
no open flames within 15 meters (50 feet) of the operation unless
conditions warrant greater clammce.
3 Containers are to be grounded and bonded during transfer operations.
4 Screw tops and stoppers should be replaced immediately.
5 Any metal container holding flammable liquid must be a FM (or UL)
approved type of safety container.

11.5.3 Ventilation

Gasoline and diesel powered equipment should only be. used in well-ventilated
areas. Exhaust pipes should be kept away from combustible materials. Engines
must be stopped before refueling takes place.

11.6 Combustible Materials

Although the main material used in the construction of plants for the petroleum industry is
non-combustible. steel or concrete, on a construction site many materials are potential fuel
for a fire.: packing material, scaffold planks, form lumber, electrical insulation, tires and
other rubber goods, lubricating oil and grease, and diesel fuel, in addition to the
flammable liquids (fuels, paints, solvents) mentioned above. Therefore, daily site clean up
of combustible materials is required to reduce tire hazards.

11.7 Housekeeping
Rubbish, accumulated at a job site, provides a good starting point for a fire.. Waste should
be removed at regular intervals and always at the end of a working day. Metal bins with
close-fitting lids should be provided for oily rags. wood shavings, and other highly
combustible wastes. Use non-combustible absorbents to remove spills or leaks of oil.
Contents of ash trays should not be. mixed with other waste. Good housekeeping on the
site can eliminate many of the situations where a fire can start.

11.8 EmergencyEquipment
The Fire Protection Department area offices can assist in training Saudi Ammco employees
in the proper use of fire fighting equipment. (See GI 1781.001. Inspection and
Maintenance of Fire Protection Equipment.)
Each contractor has a contractusl obligation to provide and maintain adequate, easily
accessible fire extinguishers on the job site (Schedule ‘D’). The contractor should consult
with the local Fire Protection Unit for advice on selection of such equipment. There are.
three types of fire extinguishers normally found on construction sites: water, carbon
dioxide and dry chemical types. Contractor personnel should be aware of the fire fighting
equipment available on site and be familiar with its use.

11.8.1 Water-Type Fire Extinguisher

Water extinguishers should be available around sites where there will be Class
“A” material, such as wood, paper, waste material, or packing crates. The.
typical portable water extinguisher comes in a 9.5 liters (Z-112 gallon) size. On
construction sites within Saudi Aramco facilities a pressurized system of fire.
water hydrants and hoses will normally be available, so this type of extinguisher
will have limited use.

11.8.2 Carbon Dioxide Type Extinguisher

The carbon dioxide (CO2) type extinguisher is normally used for controlling
electrical fires. These fires take place in motors, switch-gear, and so forth and
are usually very easily controlled by de-energizing the circuits that supply the
power. The advantage of using CO2 in this particular instance is that it leaves
no residue in the mechanisms of the electrical equipment and, therefore, does not
further contribute to the damage.

11.8.2.1 CAUTION

A CO2 extinguisher should never be used in enclosed areas where

people are present, because the gas displaces oxygen from the
immediate environment. When the oxygen level in the. environment
is reduced sufficiently to put out a fire, the oxygen level is also
incapable of supporting human life.

11.8.3 Dry Chemical Type Extinguisher

A dry chemical type extinguisher is normally used in controlling Class “B” fires
in flammable liquids. A dry chemical extinguisher nornully comes in portable 9
kilograms (20 pounds) and 13.6 kilograms (30 pounds) sizes. A larger wheeled
extinguisher of 68 kilograms (150 pounds) and above is available, but is usually
found only within petroleum operating areas. Some dry chemical extinguishers
today have a powder which is good in controlling Class “A”, “B”, and “C” fires.
This multipurpose ABC powder gives this particular fire extinguisher a good
chance of controlling any type of fire involving a wood, a petroleum liquid, or
electrical equipment.

11.8.4 Pressurized Water

Where a pressurized water system is available on site, the contractor is

responsible for supplying hoses and nozzles. Since most fires at construction
sites involve Class “A” materials. they can be fought wifh water. Charged water
hoses, ready for use, are a necessity. If there is no permanent system installed at
 a particular location, a water tanker and portable water extinguishers will have to
be supplied in order to take care of any Class “A” fires.

11.9 Reporting a Fii

Every fire, including those extinguished by contractor personnel, should be. reported to the
Saudi Ammco representative. The Fire Protection Unit will inspect the area, to offer
suggestions for preventing a recurrence, and to ensure the contractor has reestablished his
tire fighting capability by recharging extinguishers or replacing equipment.

The emergency telephone number used for reporting a tire. or any emergency that requires
Saudi Aramco assistance is 110. The contractor must ensure that this number is posted at
all telephones and that instructions are. placed indicating how to report the emergency
correctly.

11.10 End-of-Shift Checks

A routine inspection shall be made. at the end of the working day to see that everything is
left in a safe condition. The following itemized checklist shall be followed:

. Clean-up and removal of rubbish and waste materials.

. Switch off electrical equipment at the mains. Separate circuits should be
provided for security lights and other equipment that has to be left turned
on.
. Cover valuable equipment to protect it against dirt and against the effects
of water that might be used in an emergency.
. Make a special check of smoking areas, hot equipment, welding areas,
etc. to be sure there. is no possibility of delayed ignition resulting in a tire.
. Return flammable liquids and gas cylinders to designated storage areas.
 0 0 0
FIGURE 1.9: KNOW YOUR FIRE EXTINGLIISHER
Dry Cl mica1
Water Type Carbon Dioxide CO1 Sodium or Potassium Multi-Purpose ABC
Bicarbonate

Stored Pressure stored Presure Cartridge Operated Cartridge Operated

AA
CLASS A FIRES
chdhmy Combustiblu Yes No No Yes
Woodpapa.~

CLASS B FIRES
Flammable Liquids ml Gasa No Yes Yes Yes
Gasoline, oil. paints. grease, etc.

m \’

METHOD
CLASS
Enqized
c FIRES
electtical quipmau

OF OPERATION
@
No

pull pill. tmclip nonle,

Squeeze handle and dkc
at base of fm
Yes

Full pin. tmclip

dischqe horn. squewx
handle and blanket ftre
Yes

Unclip hose to break

sealandsnikeactuatm
squeeze nozzle and
Yes

with co2 direct at base of names.

SWcetlhlR from side to
side.- -
RANGE 30’-40 3’-8 S-20

STOCK NUMBER 21-104-550 21-102-223 21-102-820 21-102-775

MAINTENANCE:
Maintenance should comprise of a monthly check by proponent organization - Check extinguisher is in correct location, access is uaobstruc&d
and extinguisher is clearly visible Check contents gauges, where fitted, indicate extinguisher is seviceabie. Check for signs of leakage, corrosion,
or physical damage. Check seals are unbroken and up to date inspection tag is fitted. If in doubt, contact your local fire control unir
12.0 RADIO COMMUNICATIONS

In a widespread area such as that covered by Saudi Aramco operations, it is not cost effective to lay
down telephone lines and establish subsidiary installations for communication. It is more feasible to
develop a radio communications nehvork instead. The continuous development of the Saudi Aramco
radio communications system has enabled us to convey messages to the most remote comer of the
Company’s operational area.

This section is mainly concerned with the hvo-way radio network which is installed in vehicles,
offices, outlying plants and allied facilities. This network is extensively used by many employees in
their day-to-day business. Standard procedures must he followed in these. radio operations.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 70.500 Disaster Contingency Plan - Dhahran Area

GI 80.500 Disaster Control - Refinery and Terminal - Ras Tanura

GI 1600.003 Destruction Of Obsolete/Damaged, Unneeded Communication Equipment

GI 1601.002 Radio Asset Control And Accountability Program (RACAP)

GI 1602.001 Residential Telephone Service

GI 1602.002 Business Telephone Service Inside Aramco Communities And Facilities

GI 1602.003 Business Telephone Service Outside Aramco Communities And Facilities

GI 1603.001 Data Circuits, Message Switch And Facsimile Terminals

See also OIMs, RIMS, and TIMs.

No. 525.001 Disaster Control Plan - Plants and Pipelines Department - Abqaiq Producing and
Udhailiyah Producing Divisions (also in Saudi Aramco GI Manual)

No. 85.001 Disaster Control Plan - Safaniya (also in Saudi Aramco GI Manual)

No. 554.001 Disaster Control Plan - Udhailiyah Area

No. 554.002 Disaster Control Plan - Qurayyah Seawater Treatment Plant

February 1993 Construction SafetyManual: Radio Communications Page 67

Radio Telephone Prcnxdure Guide:

12.1 Equipment
There are a minimum of three types of radio sets used in the Saudi Ammco network today:
the mobile radio set, the stationary radio set with remote control, and the portable hand
radio set.

12.1.1 Remote Control Unit

The remote control units locatexl in offices are. used to control radio equipment at
some other location. Tbe unit controls used by operating pewxmel are the
volume control, hand set switch, and the frequency switch. All other controls
must be set by technical personnel.

12.2 Safe Operation

Adjustment of equipment must always be carried out by authorized personnel.
Unauthorized tampering with equipment can result in electric shock or equipment
malfunction leading to circuit interference.

Under certain circumstances, radio waves can cause ignition of electric blasting caps.
Radio equipment must be shut down within 91 meters (100 yards) of any blasting
operattons or where electric detonators an used or stored.

Water Damaged Equipment:

Vehicle. drivers and maintenance personnel are requested to exercise great caution when
washing vehicles containing radio equipment.

12.3 Radio Phrases

AFFIRMATIVE: 7% tmm Yes

BREAK: The work BREAK means the message will continue, but due to the length of the
message the operator will break the circuit to allow the reception of EMERGENCY
messages.

CORRECTION: ‘lhis mems thaf An error has been made; the correct message is .

DISASTER: When used on Company communications systems, DISASTER warns all

operators that a sudden misfortune has occurred, causing either loss of life, property, fire,
or a combination of the three. All operators must stop transmitting u&.ss involved in the
disaster and should standby unless told to transmit by Disaster Control or the Disaster
Control Post.

DISASTER DRILL: This is an exercise for training personnel to handle disaster

situations.
 HOW DO YOU READ?: This means that the operator is trying to determine if the
message is being received well.

MAYDAY: This is an international radio distress signal which is primarily intended for
ships and aircraft requiring assistance to save human lives or property.

NEGATIVE: lhis menns No.

OUT: An operator using the word OUT at the end of a transmission indicates that he is
finished with the communications circuit and any other station may begin its call.

OVER: This means that the transmission of a message has ended, hut one station is
waiting for the other to transmit.

OVER AND OUT: Do not use this phrase.

PRIORITY TRAFFIC: This is a message having preferential rating over the routine. The
expression “I have priority traffic” means the operator has listened to the messages being
transmitted and has determined that his message is of greater urgency.

READ BACK: This means that the. operator wants to make sure that his message has been
correctly understood.

RESUME TRAFFIC: All stations are free to transmit routine messages.

ROGER: This means that the operator has received and understood the message and
accepts responsibility to carry out any instructions therein.

SAY AGAIN: Do not use the word “repeat”. If a message is to be repeated, the operator
shall instruct the station to ‘say again your message”.

SAY EVERY WORD TWICE: This phrase is used when the operator is having trouble
understanding, and wants each word said hvice.

SPEAK SLOWLY: This phrase is used mostly in cases where technical difficulties are
causing the circuit to cut in and out.

STANDBY: Any or all operators told to STANDBY shall cease further use of the
communications circuit until further notice.

TRAFFIC: The information or signals transmitted over a communications systems.

URGENT TRAFFIC: A message requiring the attention of all operators.

VERIFY: Check with originator and make certain the message is correct.

12.4 Phonetic Alphabet

In a radio message, some letters of the alphabet are likely to be confused with others: as
“B” with “P” and “D” with “T”. A standardized international phonetic alphabet for radio
operators is in use to clear up such ambiguities. Whenever a word is not properly
understood by the receiver, it is advantageous to utilize the Phonetic Alphabet. For
 example, an operator intends to make clear ‘ABQAIQ’. He will spell it out like this: “A”
as in “ALPHA’; “B” as in ‘BRAVO”; ‘Q” as in ‘QUEBEC”; “I” as in “INDIA”; and, so
on. Use the phonetic alphabet which is listed which foIl0Ws:
PHONETICALPHABET

Word Pronunciation
1
CH,
--

12.5 International Communications Union Agreement

All Company communications systems and nehvorks crime under the regulations of the
International Communications Union Agreement. The Saudi Arab government is a
signatory of the Communications Agreement and a member of the International
Telecommunications Union (ITU). Regulations which shall be binding on all members
include the operating of telegraph, telephone and radio. Any violation or infringement of
any communication system or nehvork shall be reported to the violator’s administration by
the control organization, stations, or inspectors detecting them.

All stations must be established and operated in such a manner as not to result in harmftd
interference to associated members or members of recognized private operating
organizations.

PcbNal-y1993- 12.0 RadiocklwwniCUt0~ hga70

 NOTE: All stations we. forbidden to carry out the following: unnecessary transmissions;
the transmissions of supertluous signals; or False (or deceptive) distress, safety, or
identification signals.

Use of profane or obscene language is a violation of the International Agreement.

Tampering with equipment is highly dangerous because of the high voltage involved.
Adjustments to equipment are. only to be. made by competent and authorized personnel.
Tampering can also cause off frequency operation and other technical problems which are
violations of the ITU Agreement.

12.5.1 Monitoring of Ciretits

Most voice transmissions are transmitted by radio waves and can easily be
monitored by outside agencies. It is forbidden to disclose or divulge any
information intercepted over the Company communications systems.

12.5.2 Secrecy Act

AI1 member nations of the ITU bind themselves to the Secrecy Act which states:
“They will take the necessary tneasures to prohibit and prevent:

* The unauthorized interception of radio communications not intended for

public use.

* The divulgence of the contents, simple disclosure of the existence,

publication, or any use whatever, without authorization, of information
of any nature obtained by the interception of radio or t&phone
communications. ”

Supervisors should be especially alert for violations of this kind and use
maximum disciplinary action toward violators.

12.5.3 Penalties

All persons operating the communications systems will be. held responsible for
anyimproperoperationandwill be heldsubjectto disciplinaryaction.

12.6 MessagePriorities for Company Operations

1 MAYDAY

2 PAN/DISASTER

3 DISASTER DRILL

4 SAFETY SIGNAL (Number 3 Priority - International Frequencies)

5 PRIORITY TRAFFIC

6 ROUTINE
12.6.1 MAYDAY

(Broadcast to all stations)

When MAYDAY is spoken three times and followed by the words: “this is (the
call station, station identification, or other identification of the mobile station)“,
indicates that a ship, aircraft, or other vehicle is threatened by grave and
imminent danger and requires immediate assistance to save human life or
P=v=tY.

The message has absolute priority over all other messages. when the message is
heard, all stations shall stop transmitting and listen to tbe message. The nahwe
of distress may be such that the operator may not be able to complete the
message.or repeat.

International Search and Rescue Monitor Stations shall ‘fix’ the bearings of the
signal and alert ships and aircraft in the area to assist with the rescue.

AI1 persons operating radio equipment must be thoroughly acquainted with this
type of priority message.

12.6.2 URGENCY SIGNAL

(International PAN; Company DISASTER)

This message is usually directed to B particular station. PAN/DISASTER, when

spoken three times and followed by tbe words: “This is (the call sign or station
identification)“, indicates that tbe station has a critical emergency concerning
injury, oil operations or other extreme operating situation.

Messages of this natllre carry priority over all messages except MAYDAY.
Company operators use the word DISASTER. Within Company operations
DISASTER has the same priority as the word PAN for those operating oo
international circuits or frequencies.

12.6.3 DISASTER DRILL

At various times the Company conducts training exercises which are associated
with familiarization and indoctrination programs. At tbe beginning of such a
drill, radio stations will announce “A DISASTER DRILL is being conducted”,
followed by the name of the area. When a DISASTER DRILL is in progress, all
stations whether mobile or fixed must standby, except those having MAYDAY,
URGENCY, or DISASTER messages. Tbe difference behveen DISASTER and
DISASTER DRILL must be thoroughly understood.

12.6.4 SAFETY SIGNAL

No. 3 Priority - International Frequencies

Tbis need only be understood by those operating on international circuits or

frequencies. The French pronunciation of SECURITE will be spoken three
times and followed by the station identification. The SAFETY SIGNAL is used
 when a station is going to broadcast a message concerning the safety of
navigation OTgiving important m&orological warnings.

12.6.5 PRIORlTY TRAFFIC

Repairs to facilities involved in disasters should be classified as PRIORITY

TRAFFIC.

12.6.6 ROUTINE

All messages except those classified above should be ROUTINE.

12.7 Distress Messages

(Fomns and Examples)

12.7.1 MAYDAY

1 Distress Signal

The distress signal is MAYDAY, MAYDAY, MAYDAY followed

by the name of station or station call letters repeated three times.

Give location, first.

Give the nahlre of the distress, second.

Give the kind of assistance required.

Complete message with any other information which can be of

assistance to racue operations.

2 Stations Receiving Message

From the location given. the receiving stations can determine if they
are in the immediate vicinity. AU stations shall cease transmission.
The station in the immediate vicinity shall acknowledge receipt by
transmitting the following message: “(Give name of station in
distress; repeat three. times) - This is the (name of station), Roger,
your Mayday Message. ”

This station assumes the full responsibility of a control station for all
futher radio transmissions and all other stations remain off the air
urdes directed to transmit by the control station.

By virtue of acknowledging the MAYDAY message, the receiving

station assumes control and becomes fully responsible. It may use
my means at its disposal to carry out the rescue operation.

Phlwy 1993 - 12.0 Radio c0mmunicatic.M Page 13

 3 End of Mayday Diitres

When the distress traffic has cased or when silence is no longer

necessary on a circuit or frequency which has bea used for distress
traffic, the control station shall transmit the following message:

“To all stations, to all stations, to all stations - This is (control

station identification, repeated three times) distress traffic has ended
with (station in distress identification). All stations resume. normal
traffic. ”

The message should be. repeated at intervals in order to assure.that all

stations standing by receive the message.

IMPORTANT: The transmission of MAYDAY messages for the

purpose of training is not permitted under any circumstances.

12.7.2 Urgency Signal

This signal indicates that the calling station has a very urgent message to transmit
concerning the safety of a person, ship, or aircraft.

1 Signal

Radio operators, operating on international circuits or frequencies,

shall be alert for the urgency signal which is PAN, repeated three
times followed by the station call letter or identification. The
Company equivalent to urgency signal is DISASTER.

2 RCTpOIW

All stations shall cease transmitting and listen to the message that
follows. If the stations receiving the message can be of any
assistance, they shall acknowledge and render all assistance possible;
otherwise, they shall case. transmission until the urgency traffic has
been cleared.

3 Procedum

All persons operating Company communications equipment shall be

familiar with the word DISASTER. When it is heard, they shall
cease transmitting until the DISASTER is over. The procedures are
outlined in the General Instruction Manual, under Disaster
Procedure, Abqaiq, Dhahmn, Ras Tanura.

4 Return to Normal

when the disaster has ended, the responsible parties outlined in the
General Instruction shall clear the radio circuits for nom14 traffic.

Fcbmsry 1993 - 12.0 RadioCommunications Page74

12.7.3 Priority Tmtlic

Repairs to facilities involved in disasters would be classified as priority traffic

and the priority would depend on the situation.
13.0 TRANSPORTATION

This section outlines tbe procedures and responsibilities for preventing motor vehicle accidents in
Saudi Aramco’s jurisdiction. In addition, it sets the standards for driver performance, responsibility,
and vehicle maintenance expected of all contractor, service organization and Saudi Aramco drivers.
AI1 drivers are expected to drive in a defensive manner and maintain control of their vehicles et all
times.

INSTRUCTIONS AND STANDARDS

Saudi Ammco General Instructions:

GI 1183.215 Transporting Explosives in Company GwnedkasedlRented Motor Transport

VdliCleS

GI 150.002 First Aid I CPR Training and First Aid Kits - Remote Areas

GI 6.025 Control of Remote Area Travel and Search/Rescue Procedures

GI 6.029 Reporting and Recording Of Motor Vehicle Accidents

GI 6.030 Traffic and Vehicle Safety

GI 1321.015 Request for Air Medical Evacuation

Driving in Saudi Arabia: A Saudi Ammu, guide to safer driving and desert travel.

Schedule ‘D’:

Saudi Aramco Safety, Health and Environmental Requirements - Transpatation.

13.1 Driver Requirements

AI1 contractors must employ only qualified personnel as drivers of motor vehicles. It is
the responsibility of the. driver’s supervisor, foreman, or superintendent to verify tbe
driver’s credentials prior to his employment. It is Saudi Arab Government law and a
Company rule, that each person driving a motor vehicle must possess and have on bis
person e valid Saudi Arab Government driver’s license.

13.2 Driver’s Responsibilities

13.2.1

It is tbe responsibility of tbe driver to ensure that his vehicle is safe to operate..

x3.2.2

It is tbe responsibility of each driver to take bis vehicle to the proper facility for
serviciog and repairs when tbey are required or scheduled.
 13.2.3

Tt.; driver of the vehicle is fully responsible and accountable for the mechanical
and physical condition of the vehicle. He must report any damage, beyond
normal wear and tear, immediately.

13.2.4

Tbe driver is responsible for transporting materials properly and ensuring that B
load does not exceed the manufacturer’s design load capacity. All loads must be
properly secured and tied down. Materials should not extend over the sides of
the truck. Loads extending beyond the front or rear shall be marked with a red
&. Also such loads must be. equipped with visible brake and tail lights at tb~
rear end points.

13.2.5

Tires which have breaks in the casing, or with exposed fabric, shall not be used.

13.2.6

Sand tires present a hazard if used on vehicles which are operated at excessive
speed especially when they are not properly inflated. It is the driver’s
responsibility to ensure that Saudi Aramco Transportation Department tire
inflation standards are maintained. Proper inflation pressures are posted at the
Department’s tire shops.

13.2.7

Drivers shall not transport unauthorized persons in Company v&i&s. The

driver’s supervisor shall authorize all passengers in the vehicle.

13.2.8

The driver and all passengers of a Company vehicle shall wear seat belts at all
times while the vehicle is in motion.

13.2.9

Drivers have full authority to refuse to transport any passenger who refuses to
use seat belts. Conversely, passengers may refuse to ride with a driver who
refuses to wear his seat belt.

13.2.10

Passengers shall not be tnuxpotted in the rear of pickups or on truck beds.

13.2.11

Drivers should not transport more passengers than the number of sat belts
provided io tbe vehicle.

Fclinury 1993 - 13.0 TnnspolUtion Page 77

 l3.2.12
All drivers shall be familiar with what the Company considers unsafe driving
practices and avoid them at all times.

The driver must not exceed the posted speed limit. This is the maximum speed
allowed in a certain area.. Every driver is expected to reduce his vehicle’s speed
under hazardous weather or mad conditions. (See GI 6.030.)

13.3 Motor VehicleRegulations: Saudi Arab Government and Saudi

Aramco
Each driver shall become familiar with, and abide by, the Saudi Arab Government Traffic
Regulations. An English translation of these regulations is available from the Loss
Prevention Department.

13.3.1

Where there is no sign post indicating the maximum sped limit, no vehicle may
be driven at a speed greater than the following:

1. 100 kilometers per hour for light motor vehicles outside city limits.
(See GI 6.030.)

2. 70 km/hr for vehicles with sand tires.

To drive safely, sped must be reduced below the allowable speed limit at night,
or during fog, rain or sand storm.

13.3.2

Drivers shall comply with all Saudi Arab Government and Saudi Aramco
traffic signs.

13.3.3

All vehicles shall be parked correctly and/or in designated parking areas.

Parked vehicles shall not obstruct other vehicles, roadways, accessways or fire
hydrants.

13.4 Vehicle Condition

It is the responsibility of the driver to ensure his vehicle is safe to operate. It is the
responsibility of the driver to bring the vehicle in for scheduled maintenance. The driver
is responsible for inspecting a vehicle before operating it to determine if the following
items have been provided and are. in satisfactory condition:

Vehicle Inspection Checklist:

1. The vehicle number, company name, current inspection stickers and license plate
(front and back) must be. in place.
 2. seat ha.5 are mandatory for all vehicle occupants.

3. Two reflective warning triangles should be in each vehicle.

4. Windows and windshield must be clean and free of cracks or damage. The glass
must he in good condition. The windows must open and close properly.

5. All lights (high and low beam headlights, tail lights, dash lights, stop lights, turn
signal lights, and the rear license plate. light) must be in working order. When fog
lights (front & rear) and clearsnce lights have been provided, they must be also be in
good working order.

6. All brakes (foot and hand brakes) must be in good working order. Check the foot
and hand brake mechanism for correct operation.

7. The automatic transmission must be in good operating condition and should shift into
the parking position correctly.

8. Springs and shock absorbers must be in good condition with no alignment or control
problems.

9. There should be no excessive movement of the steering wheel and no signs of

damage. Steering knobs and loose coverings are prohibited.

10. Tires should have no breaks in the tire casing or exposed fabric and must be inflated
to correct au pressure. as specified by the Transportation Department.

If the treads show any signs of wear like bare patches, this uxdd indicate defective.
steering, springs and/or shock absorbers.

11. Check the wheels for rim damage. Make sure the wheels are not buckled or out of
alignment and wheel lug nuts are. in place and secure.on the rim.

12. If the vehicle is fitted with a trailer, the coupling must be intact and working
correctly. The trailer should have safety coupling chains, rear brake lights, turn
signals, tail lights and rear license plate lights.

13. Make sure that the inside and outside rear view mirrors are clean, adjusted, secured
and undamaged.

14. Check that the windshield wiper blades are in good condition, and operate properly.
Inspect the rear window wiper, if fitted.

The windshield washer should work pmpwly and there should be water in the washer
container.

IS. The speedometer should be in good working order.

16. Test the exhaust system by starting up the engine of the vehicle, listening for sounds
and spotting any leaks associated with it. Check to see if the tail pipe extends at least
three inches from the body of the vehicle. The tail pipe emissions should be r&ased

Febwty 1993 - 13.0 Trmqmtatioa hge 19

 from a point where they do not directly come into contact with the driver of the
vehicle or its occupants, thereby causing any adverse health affects to any of them.

17. A properly inflated spare tire with a jack and tire wrench most be provided. The tire
wrench should be. the correct size to fit the wheel nuts of the vehicle.

18. Check the following fluids for leaks and proper levels, especially in hot weather.

l Radiator coolant
l Oil
l Brake fluid
l Transmission oil (checked with engine running)
l Distilled water for the battery

NOTE: The driver should check the radiator coolant level only when the engine is cool.
Fluid should be added to the level mark oo the overflow expansion tank only if
provided.

19. The vehicle’s horn must be operational.

20. Note all damage on the vehicle, process the proper reports and have ths damage
repaired. You could be charged with a bit and run accident unless you have a police
vehicle release for major damage, and back up repats for minor parking lot “dings
and scratches”.

Each driver must conduct a vehicle inspection whenever taking charge of a vehicle
and periodically thereafter (at least once a month) to ensure that all systems are
operating properly and there is no damage.

Passengers will be carried only in the passenger compartment of a vehicle. All

vehicle occupants must wear seat belts. Driven shall insist that all passengers wear
Seat belts before starting the vehicle. Drivers cao receive a moving violation for not
adhering to this regulation.

Loose materials are to be kept out of the driving compartment. Do not place
materials (bard hats, etc.) on rear window shelf.

13.5 Driver Training

The Company conducts driver training course.s for Saudi Aramco employees. Details
about the courses are available from the On-the-Job Training Unit.

13.6 Enforcement of Safe Driving Practices

Tbe Industrial Security Organization issues “Unsafe Driving Practice Warning” notices.

13.6.1

Saudi Ammco drivers who commit traffic offenses are given penalty points.
Repeat offenders may receive disciplinary action. (See GI 6.030.)
 13.6.2

Contractors driving on Saudi Ammco facilities or in the communities are

required to abide by all Saudi Ammco and Saudi Arab Government traffic
regulations. Offenders will be referred to proponent organizations for
appropriate action, including counseling and revocation of driving privileges
within Saudi Aramw. For repeat offenders, contract may be. reviewed for
cancellation.

13.7 Action Taken After a Saudi Aramco Motor Vehicle Accident

All motor vehicle accidents (MVAs) shall be reported to the closest main gate or security
control center. This must be done by telephone, radio, or by sending a message with a
passing driver. Other procedures in GI 6.029 must then be followed.

The Main Gate/Security Control Center telephone numbers are:

Dhahran: 874-2055
Ras Tanura: 673-5231
Abqaiq: 572-5291
Udhailiyah: 577-8114
Yanbu: 3214284
Mubarraz: 577-2344
Abu Ali: 678-2228
Beti: 678-7226

Other procedures as detailed in GI 6.029 must then be followed.

13.7.1 Emergencies

In the event of serious injury, fire or hazardous road block caused by an accident
on Saudi Aramco facilities, the emergency telephone number 110 should be
used. For emergencies occurring off Saudi Aramco facilities, a Main
Gate/Security Control Center telephone number can be used (see above). This
will allow both the Main Gate&.curity Control Center and Medical Controller to
be informed and they will ensure that the proper unit will respond to assist.
When reporting any accident, make sure the message is understood before
hanging up.

13.7.2 Remain at Scene

A driver shall not leave the scene of an accident or move his vehicle after an
accident unless he needs to take an injured person to a hospital. This is a Saudi
Arab Government law and the Traffic Department investigating officer is the
only one delegated the authority to release vehicles involved. The Saudi Ammco
Government Affairs Representative will advise you of this release. If a damaged
vehicle is blocking traffic or is stopped on the highway, reflective triangles must
be used to warn approaching traffic of the vehicle’s presence.
13.8 Passenger Seating and Seat Belts

Passengers shall be transported only in passenger compartments of cars, trucks and buses.
The number of passengers being transported in the passenger compartment of a vehicle
must not exceed the manufachrrer’s specifications.

Seat belts shall be worn by the driver and passagers in all vehicles except buses with more
than 14 seats, where seat belts are only required for drivers.

13.9 Desert Driving

AI1 persons who drive in the desert should study “Driving In Saudi Arabia,” the Saudi
Aramco guide on safe driving tips and desert travel. It is recommended that the driver
have a copy with him in the vehicle. Copies may be obtained from any Loss Prevention
area office.

In particular, any person who drives in the desert shall ensure that:

1. His immediate supervisor knows his destination and route.

2. His vehicle is in good condition with adequate fuel, oil, and water.
3. His vehicle has tools, equipment, and spares for emergency use.
4. He has sufficient food and drinking water to sustain him until rescue, should he be
stranded.
5. He is familiar with survival and rescue techniques and procedures.
6. Driver shall pass the off-the-road vehicle test conducted by Saudi Aramco Driver
Training Unit before being permitted the use of 4-wheel drive vehicles.

13.9.1 Stay With Vehicle

A person lost or stranded in the desert must stay with the vehicle as it provides
shelter and to make it easier for searchers to locate him.

13.9.2 Sand Tires

Sand tires are hazardous to use when they are not properly inflated, when they
are driven at high speeds OT when the roads are wet. It is the driver’s
responsibility to ensure. the following requirements are met for sand tires:

VEHICLE TYPE TIRE SIZE RECOMMENDED

TIRE PRESSURE
Mm MAX
Carryall, 4x4 9.00~16 15 35
Pickup, 4~4,112 Ton 9.00x15 15 35
Pickup, 4x4.314 Ton 9.00~16 15 35
Pickup, Crewcab, 4x4, 1 Ton 11.00~16 15 35
Utility, 4x4,3/4 Ton 9.00~16 15 35
Utility, Crewcab, 4x4, 1 Ton 11.00~16 15 35
Stake. Truck. 4x4, 1 Too ll.GUx16 15 35
WPldPl’C l-m& d.d 1 Ton 11 Mrlh 15 15

F&-my 1993 - 13.0 Tnmportakm P*gt 82

 Maximum speed for sand tires (on hard dty road):

. 70 KPH at maximum sand tire pressure

. 20 KF’H at minimum sand tire pressure

Since sand tires have a larger diameter than standard tires, speedometer readings
will not he accurate. Unless the vehicle speedometer has been corrected to
account for the oversize tires, the driver should remember that he is traveling
approximately lo-1596 faster than the speedometer reading.

13.10 Vehicle Admittance to Restricted Areas

Vehicles requiring admittance to a restricted area (e.g. hydrocarbon facilities, refinery and
terminal areas) shall be inspected by the Saudi Ammco Transportation Department. Upon
successti~l completion of the inspectioo, a window sticker is issued for the vehicle. This
sticker is valid for three months after which the vehicle must be inspected again. If the
vehicle fails inspection, it will not be. permitted entry into any restricted area until all
deficiencies have been corrected. File form 7575 (Restricted Area Access Sticker
Request).

13.11 Operation of Motor VehiclesWithin Saudi Aramco Communities

All contractor, service organization and company operated vehicles must be. constructed to
comply with the Saudi Arabian Traffic Regulations, Saudi Arabian Standards Organization
(SASO) and Saudi Aramco rules for the safe operation of motor vehicles while driving
within any Saudi Aramco community.

13.11.1 seat R&s

All vehicles shall be equipped with seat belts for each passenger seat in
accordance with Saudi Arabian Standards Organization (SASO).

13.112 Traffic Regulations

All posted speed limits shall never be exceeded and all local traffic signs shall be
Obeyed.

February 1993 - 13.0 Tmmporution Fagc 83

14.0 AIRCRAFl'OPERATION
Tbis section will deal with both passenger and cargo transportation for which Saudi Ammco aircraft
areused.

Although some of the safety standards imposed will seem to restrict use, these regulations were
designed not only with the safety of the passengers and aircraft cargo in mind, but also for the safety of
the aircraft and the crew.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 1310.00 Transportation of Dangerous Articles Onboard Saudi Aramco Aircraft

Aircraft Guidelines For Crew Managers And Aviation Remote Airfield Operations Personnel
(February 1988)

IATA Dangerous Goods Regulations (33Rd Edition, 1992)

US Code of Federal Regulations (CFR) 49 Part 175 - “Carriage By Aircraft”

14.1 General Operating Responsibilities

14.1.1 Captain/Pilot
The Captain/Pilot is in command of the aircraft at all times and is responsible for
the safety of his passengers and cargo. He is the sole judge and will make all
decisions in determining if the weather is acceptable for flight or if landing and
take off conditions are within Company minimum standards.

No one is allowed to “pressure” the pilot into carrying more weight than the
pilot states is acceptable.

The Captain/Pilot is authorized to follow any course of action which he judges

requires immediate decision or action in the interests of safety.

14.1.2 Camp Supervisars

AI1 camp supervisors in remote weas will familiarize themselves with all the
relevant instructions on the movement of aircraft to and from their areas as
detailed in the “Saudi Aramco Aviation Department Policy and Guidelines for
Camp Managers”.

It is to the mutual advantage of the user department and the pilots of the Aviation
Department that rules of Aviation Safety be reviewed and applied to all
operations in remote areas. Complete. cooperation and understanding between
pilots and camp supervisors is essential for the safe and efficient operation of all
inbound and outbound aircrat?.
14.2 PassengerBriefmghstruction, General (All AiratI Types)
14.2.1

The pilot shall either orally brief his passengers or direct their attention to the
aircraft safety instructions.

14.2.2

Passengers should never approach fixed-wing aircraft for boarding from the
front, and they must keep well clear of props and engina at all times.

14.2.3

A flight crew member or designated safety observer should monitor passenger

movement while they are boarding or leaving an aircraft.

14.2.4

Smoking is prohibited on all Saudi Aramco aircraft and on all ramp and apron
BTeBs.

14.2.5

Seat belts must be fastened during all flights. Do not unfasten the seat belt until
the aircraft has come to a complete stop and you are instructed to do so.

14.2.6

Passengers will comply with all flight crew or flight attendant instructions.

14.2.7

Far protection is supplied by Saudi Aramco where appropriate.

14.2.8

All Saudi Ammco aircraft carry US registration. The Company complies with
US DOT, FAA, ICAO and KSA President of Civil Aviation (PCA) regulations.
Failure to comply with these regulations and instructions could endanger the
lives and property of others and could be refused future use of the Saudi Amoco
aircraft, termination of service, or prosecution.

14.2.9

Other ams of briefing may include the use and haadling of special material or
equipment which must be declared and will be shipped only at the Captain’s
discretion.
 142.10

In the event of forced landing, the pilot and passengers will stay with the
aircrafi. The Captain will direct rescue/survival activities. The Aviation
Department will conduct a day and night search for the disabled aircraft.

14.3 Transportation of Dangerous Goods

Saudi Aramco complies with the provisions of ICAO regulations as published in the IATA
Dangerous Goods Regulations. AI1 shippers and passengers intending to transport
dangerous goods on Saudi Amman aircraft are required to he familiar with and comply
with the IATA Regulations. Further requirements are contained in GI 1310.00.

Any questions on Dangerous Goods Transport should be. addressed to Central Area Loss
Prevention Department, Aviation Safety Officers, or the Terminal Supervisor of the
nearest Saudi Ammco airfield terminal.

14.4 Hours of Operation for Single-EngineHelicopters

Normal hours of single-engine helicopter operations are from sunrise to 30 minutes before
sunset. A helicopter is required to be at its final destination no later than 30 minutes
before sunset.

By permission from the area supervisor, a helicopter may fly overland up to 30 minutes
after sunset if warranted by extenuating circumstances. Operations may also authorize
short flights to continue until sunset if rescue facilities are immediately available.

14.5 General Precautionsfor Helicopter5

No loose. clothing should be worn which may entangle on any aircraft surface or impede.
egress or flotation in any way.

All persons shall approach the helicopter from the front in full view of the pilot. Never
walk around the rear of the helicopter. Hold onto your headgear when approaching
aircraft. Carry long objects below waist level.

When visibility is reduced by dust or other conditions, persame shall exercise special
caution to keep clear of the main and stabilizing rotors.

14.5.1 Life Vest.9

In the event of a forced landing at sea, the float gear is capable of supporting the
helicopter. Life vest must be worn on all over-water flights. only the vests
provided in the helicopter should be used.

Fcbnmy 1993 - 14.0 Aimaft Opmion

II. General And Civil
1.0 WORK PERMIT SYSTEM
The Work Permit System incorpomtes procedures commonly used in industrial facilities to emwe that
II-ssry communication takes place and hazards are controlled.

Saudi Ammco’s restricted areas are. potentially hazardous. However, knowledgeable people using
proper procedures can perform work tasks efficiently and safely. The Saudi Ammco work permit
procedure is important in maintaining a safe work environment and is a requirement for all Saudi
Aramco jobs in restricted areas.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 2.100 Work Permit System

GI 2.708 Gas Testing Procedures

GI 2.711 Fire & Safety Watch

GI 6.012 Isolation, Lockout And Use Of Hold Tags

Power Distribution Instruction:

No. 3.0 Definitions of Terms and Approved Abbreviations

No. 10.0 Power Distribution Operations

No. 11.0 Hold Orders, Clearances and Permission to Test

1.1 Definitions
1.1.1 Restricted Areas

Restricted areas are. those areas or activities which have been designated by
department managers as requiring the work petit system. These include (but
are not limited to) all areas where hydrocarbons, flammable liquids or gases, or
oxidizing agents are handled, stored, piped, or processed in significant
quantities; and critical non-hydrocarbon operations.

The following are examples of restricted was: petroleum processing plants;

pump stations; tank farms; loading piers; hydrocarbon pipelines; oil wells; gas
plants; specified locations on marine vessels; gasoline service. stations; areas
where explosives and industrial X-my or radioactive materials are used or stored;
work areas under or near power Lies; contined space entry; and material supply
storage mYas.
 1.1.2 lsw?r (Opmtion supervisors)
Operation supervisors are those supavisors who are certified by then divismn or
department bead to issue and approve work permits in restricted areas under their
supervision.

1.1.3 Receiver (Authorized Craftsmen)

Authorized crattsme.n are the craft supervisors, craftsmen or otben who have
been certified by their division or department bead to sign and receive work
permits in the case of Company employees and by sponsoring organization beads
in the case of contractors.

1.1.4 Work Permit

Release of Hazardous Liquids or Gaws, Folm 924-l (yellow) -

This form is required when opening lines ca vessels that may release
hazardous or toxic materials.

Hot Work, Form 924-2 (red) -

Tbis form is required when using spark or flame producing equipment and
for vehicle entry into a restricted area.

Cold Work, Form 924-3 (blue) -

This form is for work that will not produce. sufficient energ; to ignite
flammable atmospheres/materials.

Confined Space Entry, Form 924-I (green) -

This form is required for tank cleaning, tank inspection. work in sewers
or excavations of 4 feet or deeper.

All work in restricted areas must have at least one of tbe listed work permits.
Work must be performed according to tbe instructions and precautions specified
in the work petit.

1.2 Issuanceand Approval

The authorized receiver (nutbowed craftsman) must request a work permit from a certified
issuer (operation supet+sor) before doing any work in B restricted area.

The issuer will grant ;be work permit after be has visited the site with the receiver,
reviewed tbe bawds applicable to the particular job, aad is satisfied that tbe work can be.
done safely. If tbe work contemplated involves any change, addition, or deletion in the
facility, the work should be reviewed by an engineer and appropriate. authorization is
~ecessary~
 Both the issuer nod the receiver must hold valid work permit certificates issued by Saudi
Ammw.

1.2.1 Power Distribution Department Cl-

Power Distribution Department (PDD), issues clearances to enable work to be
accomplished on high voltage electrical apparatus that has been de-energized aad
isolated from the power system in an approved manner. These clearares are
issued by PDD dispatchers in addition to any work permits that are required.

Usually clearance receivers are. PDD employees. Non-PDD employees and

contractors should request PDD Electric System operators for assistance.

The following instructions apply to PDD clearances:

PDD 3.0: Definitions of Terms and Approved Abbreviations

PDD 10.0: Power Distribution Operations
PDD 11.0: Hold Orders. Clearances and Permission to Test

1.3 Precautions
1.3.1 Cheeklit

Each permit contains a checklist of precautions against common hazards. Such a

list cannot include precautions against all hazards. It is the duty of both the
issuer and the receiver to review tbe job, anticipate. what hazards might arise,
check for flammable gases in the area and see that proper precautions have been
specified on the permit before. it is signed.

1.3.2 Clear Area

One specific precaution applying to all work is to clear the area of people not
required for the job to avoid their being exposed to unnecessary hazards. If
people enter an area where they could be exposed to undue danger, the work
should be stopped until they are cleared from the area.

1.3.3 Work Stoppage

If conditions change or become unsafe during the course of work, the issuer or
local supervisor may stop the work and cancel the Permit.

The receiver has the responsibility to stop the work and advise the issuer or
supervisor any time he feels the safety of the job does not meet the conditions of
the work permit.

1.4 Handling of IssuedWork Permit

A work permit is valid for only one shift, but it may be extended for one additional shift
with proper approval. Exceptions in excess of 16 hours may be granted io special cases,
provided certain precautions are taken. (See GI 2.100 for details.)
 The. receiver of the work pennit must keep the pernut posted at the job location at all
tlme.9

The receiver OFa work pennit must keep a copy in his possession or within view of the job
site for the duration of the job, so that it may be presented upon request. If the receiver
leaves the job site, he shall give the permit to a responsible senior crew member to keep
until he rehwns. The issuer, receiver and the senior crew member must sign the work
pernut transferring the work pennit to the senior crew member.

15 Closing Out and Filing the Permit

When the job is completed or at the end of the &A, each work permit must be closed out
by both issuer and receiver. The only exception shall be when the distance. and remoteness
make sqning impractical, and it is so stated when the work petit is issued The work
pernut will be filed and kept by the issuing department for three months.

1.6 Certification
In order for a person to be a certified renewer of work pennits, he must attend the work
perrmt Receivers Course conducted by the Loss Prevention Department and pass a test on
work pemnt System (GI 2.100) given at the end of the course.

The superintendent of the construction organization will assure. Saudi Aramco by his
signature that his employee knows both the general instruction and his job. Contact the
local Loss Prevention office for work permit certification information.

Records of current certificate holders, with their names and the dates issued, must be kept
by each superintendent or organization head.

1.7 12 Rules on Work Permit Procedure

(seebelow)

1.8 Hold Tags and Multiple Lockouts

1.8.1 Instructions contained in Cl 6.012 outline the use of tagging and lockout for
controllers which are to be held inoperative or for work clearance.

1.8.2 The purpose for the Lockout System is to render controllers inoperative, i.e.,
cucult breakers, disconnect switches, valves, etc. on any systems (electrical,
steam, hydrocarbon, water, acid, etc.), where the operation of the control device
could be. hazardous to personnel working on the system.

1.8.3 Hold tags and locks are primarily intended to protect the individual doing the work
from being injured by an inadvertent start-up.

1.8.4 Work permit issuers and operations supervisors shall ensure that hold tags and lock
outs are used and so noted on the work permit. The use of hold tags/lock oats
shall be strictly enforced.

Febmwy 1993 - 1.0 Wc,t Permit System Fag691

TWELVE RULES ON WORK PERMIT PROCEDURE

1) Issuer and receiver must inspect job site together before signing the work permit.

2) Issue the correct permits for the job - hot, cold, vessel or contined space entry, and/or gas
rhase. Two or more permits may be required for the job.

3) Issuer and receiver must bath have in their possession a valid work permit certification card
(issuer and receiver respectively).

4) J-W Sniffer gas test and/or H2S gas test and/or oxygen analysis teat must be made before
issuing work permit.

5) Job description and equipment used must be clearly stated on the work permit. Be specific,
issue permits for a single pump, drum, etc.

-5) All tick boxes must be. correctly tilled in and gas readings indicated.

7) Proper lockouts, hold tags, and blinds must be used where applicable (multiple clips with lock,
and/or chains with padlocks).

8) Work permits should be issued for the specific period of time required to complete the job.

9) To extend time work permit beyond one shift, the oncoming shift issuer must inspect job site,
write in extended time and sign permit.

10) Special precautions such as requirements for tire watch, Scott air packs, life lines, barricades,
etc. must be written on the permit.

11) The work permit must remain on the job site in a conspicuously visible place while work is
going on. If an emergency develops, the permit must be withdrawn immediately and all work
stopped without questions.

12) The work permit must be closed out after a job is completed. Issuer and receiver must inspect
the job site and sign off the work permit.

February1993 I .O Work Pem,i,Sydcm Page92

LOCK OUT ANTI TAG

Workers may be insured while working on equipment when the controls have not been locked and
tagged in the off position. People do make mistakes and start equipment on which maintenance men
are working; vibrations and ineffective mechanisms can cause. controls to move or valves to open.
Protection is simple: lock the control in the off position and prevent an accident.

Saudi Ammco has special rules requiting the use of locks on switches and controls when it would be
unsafe to work on an energi,zed or operating system. Each supewisor of operations and maintenance
should know the rules in GI 6.012 - Isolation, Lock Out and Use of Hold Tags.

When more than one man is going to work on a system or on a number of pieces of equipment within
the system, the multlple lockout clip enables each man to lock out the circuit or machine control. If
your man can’t get his lock on the clip, work should not prweed until a suitable clip is found. Clips
may be ordered under stock number 21-350-487; locks under stock number 08-323-261; tags under
stock number 39-378419. Locks belonging to contractor personnel must have one key only and
should be compatible with the Saudi Ammca system. Contractors will establish their own lock issuing
procedure complete with logging and a numbering system.

Note: Contractors are required to establish a lock out and TAG system compatible with the Saudi
Aramco system as part of the contractor Loss Prevention Program plan requirements of
Schedule ‘D’.

Tags are useful to tell who is working on the equipment and who authorized the shutdown. Teach
your men the lockout procedure and insist they follow it.
FIGURE ll.1: HOLD TAG

Front View

DO NOT OPERATE I
EQUIPMENT
OR
REMOVE TAG
i3Li+u& &I
SEE OTHER SIDE

DATE REMOVED: :ilAJliJj~fi~V ,

\
FIGURE 11.2: LOCKOUT CLIP (TYPICAL)
2.0 EXCAVATIONS, TRENCHING AND SHORING

Accidents due to cave-in can occur for excavations which are not shored or otherwise supported. Even
rock that looks solid from a cursory inspection can collapse without warning. The sides of an
excavation may need to be suitably shored, benched or sloped back to a safe angle of repose, depth,
and soil composition.

Other types of excavation accidents are. caused by contact with underground pipes and cables, by falls
of equipment and persons, by Persons b&g struck by excavating equipment, and by hazardous
atmospheres.

INSTRUCTIONS AND STANDARDS

Saudi Ammco General Instructions:

GI 1021.ooa Street and Road Closure, Excavation Reinstatement and Traffic Controls
(See Appendix D)

GI 2.100 Work Pennit System

Saudi Aramco Engineering Standard:

SAES-A-111 Borrow Pit Requirements

OSHA Safety And Health Standards:

29 CFTt 1926
Subpart P Excavations

DEFlNIl’IONS:

1. Excavation

Any man-made cavity or depression in the earth’s surface, including its sides,
walls, or faces, formed by earth removal and producing unsupported earth
conditions by reason of the excavation.

2. Trench Excavation

A narrow excavation made below the surface of the gromd. In general, the
depth is greater than the width, but the widt,h of a trench is not greater than 4.5
meters (15 feet).

3. Accepted Engineering and Construction Practices

Plans for excavations and protective system methods shall be submitted to Loss
Prevention before work start up.

Febnmry 1993 - Comtmction Safety Manual - Excavalions, Trenching And Shoring Page 96
4. Protective systems

Methods used to protect employees from cave-ins, from materials that could fall
or roll into the excavation onto the workers or from collapse of adjacent
struchwes. Protective systems include suppats, sloping and benching, shields
and other means to protect workers.

5. Shoring

Hydraulic, timber or mechanical systems that support the sides of an excavation,

designed to prevent cave-ins.

6. Hydraulic Shoring

A pre-engineered support system of aluminum hydraulic cylinders (cross-braces)

used with vertical rods (uprights) or horizontal rods designed specitically to
support side walls of an excavation to prevent cave-in.

I. Benching

A method of protecting employees from cave-ins by excava!ing the sides of an

excavation to form one or a series of horizontal steps, with a vertical rise
between steps.

8. Sloping

A method of excavating in which the sides of an excavation are laid back to a

safe angle to prevent cave-ins. (The safe angle required varies with different
types of soil, exposure to the elements and superimposed loads. There is no
single angle of repose. Soil classification must be’identified to select safe
sloping and benching methods.)

9. Soil Classification System

A method of categorizing soil and rock deposits as types A, B, and C in

decreasing order of stability. Soil type is determined by analysis of the soil’s
properties and how it performs under exposure to the elements and superimposed
loads.

Type A:

Cohesive soils with an unconfined compressive strength of 1.5 ton per square.
foot (tc) (144kPa) or greater are classified as Type A. Examples of cohesive
soils are: clay, silty clay, sandy clay, clay loam and in some. cases, silty clay
loam and sandy clay loam. Cemented soils such as caliche and hardpan are also
considered Type A. However, no soil is Type A if one or more of the following
conditions are true:

(i) The soil is fissured.

(ii) The soil is subject to vibration from heavy traffic, pde driving, or similar
effects.
(iii) The soil has been previously disturbed.
 (iv) The soil is part of a sloped, layered system where the layers dip into the
excavation on a slope of four horizontal to one vertical (4H: 1V) or
greater.
(v) The material is subject to other factors that would require it to be
classified as a less stable material.

Type B:

Soils classified as Type B are.:

(9 Cohesive soils with an unconfined compressive strength greater than 0.5
tsf (48 kPa) but less than I.5 tsf (144 kPa).
(ii) Granular cohesionless soils including angular gravel (similar to crushed
rock), silt, silt loam, sandy loam and, in some cases, silty clay loam and
sandy loam clay.
(iii) Previously disturbed soils except those which would otherwise be classed
as Type C soil.
(iv) Soil that meets the uncontined compressive strength or cementation
requirements for Type A, but is fissured or subject to vibration.
Dry rock that is not stable.
::I, Mat&d that is part of a sloped, layered system where the layers dip into
the excavation on a slope less steep than four horizontal to one vertical
(4H: IV) but only if the material would otherwise be classified as Type B.

Type C:

Soils classified as Type C are:

(9 Cohesive soils with an unconfined compressive strength of 0.5 tsf (48
kPa) or less.
(ii) Granular soils including gravel, and loamy sand.
(iii) Submerged soil or soil from which water is freely seeping.
(iv) Submerged rock that is not stable.
(v) Material in a sloped layered system where the layers dip into the
excavation or a slope of four horizontal to one vertical (4H: IV).

10. Trench Boxes:

A structure that is able to withstand the forces imposed on it by cave-ins, and in

the process, protects employees inside the structure. (Plans for trench boxes are
to be submitted to Loss Prevention.)
2.1 Before Work Starts
In order to begin excavation work with minimum risk to men, plant and equipment and to
enable the work to proceed without interruption, the following factors must be considered
well before the job starts:

1.) Size and purpose of the excavation.

2.) Nature of the ground including the proximity of made-up ground.
3.) Stability of adjacent StructLIres.
4.) Position of underground obstructions such as pipes, electric cables, and
utilities.
5.1 Weather and soil moisture conditions, especially high water table.
6.) Sources of soil vibrations (highway traffic, railroads, machinery, etc.).
7.) Adjacent roads and footpaths.
8.) Method of excavation.
9.) Excavation plan submitted to Loss Prevention.

Consideration of these factors will indicate the safety measures which must be implemented
to proceed with the job and whether the sides of the excavation can be sloped and benched
to a safe angle or whether other protective systems will be required. It is important to
prowde adequate and suitable protective systems for use whenever excavation work is to be
camed out to a depth of 1.5 meters (5 feet) or more. Excavation work to a depth of less
than I.5 meters (5 feet) may also require protective systems.

2.2 Work Permit

Work permits must k obtained from the appropriate operations supervisor before
excavation work is started in any Saudi Aramco facility, including residential areas and
roadways, and in any place where the presence of und&ound/utility obstructions is
known or suspected. Outside of clearly defined responsibility areas, work permits shall be
obtamed from the Superintendent, Utilities and the Communications Foreman, Oil and Gas
Dispatch Unit or their delegated representatives. A Confined Space Entry Work Permit IS
a second work permit and is required for trenches deeper than 1.2 meters (4 feet). (See GI
2.100 for work petit requirements.)

All protective shoring systems and configurations, such as timber shoring, hydraulic and
pneumatic systems, sloping, benching, shielding, sheet piling and freezing must be
designed in accordance with Saudi Aramco Loss Prevention requirements. Excavation
plans must be submitted to Loss Prevention before work start up.

2.2.1 Excavation near Saudi Telephone Cables

To avoid disruptions of service and unnecessary costs which result from the
accidental cutting of Government telephone cables by contractors working on
Saudi Aramco projects, proponents should urge their contracton to inquire about
the location of such cables prior to excavation. Contractors may contact the
Saudi Telephone Cable Locator Division on telephone no. 843-3247 during
normal Government working hours or telephone no. 906 at any hour.
Subsequently, they may be required to submit a written application to the Saudi
Telephone Cable Locator Division providing a site plan of the proposed
excavation and stating when it will be done. Contractor letters may be addressed
 to the Director, Dammam Area Communications, Ministry of Telegraph Post
and Telephone, Dammam.

Saudi Ammco proponent inquiries may be addressed to the Contractor Liaison

Division of Government Affairs, telephone 874-1461 (Corporate Advisor,
Contractor Liaison/GAO).

2.3 Underground Obstructions

Whenever the presence of underground pipes, cables, vessels, or structures is known or
suspected, mechanical excavators shall not be used until all such obstructions have been
exposed by hand digging. Mechanical excavators shall not be used within 3 meters (10
feet) of any such obstruction. Pneumatic breakers shall only be used where necessary to
break concrete or other hard surfaces.

2.4 General Precautions

2.4.1 Shoring Protective Systems

As soon as an excavation reaches a depth of 1.2 meters (4 feet) or soil banks are
greater than 1.5 meters (5 feet), suitable shoring shall be. installed or the sides
sloped back to a safe angle. Shoring may be of timber or any other suitable
material, such as steel sheet piling.

The determination of the angle of slopes, benches, (See.Figure 11.3) or the choice
and design of other protective systems shall be based on evaluation of pertinent
factors such as: type of soil (Type A, B, or C), depth of cut; possible variations
in water content of the material while the excavation is open; anticipated changes
in materials from exposure to air, sun, or water; loading imposed by stmchlres,
equipment, overlying material, or stored material; and vibrations from
equipment, blasting, traffic, or other sources.

Excavations shall not be sloped at an angle greater than one and one-half
horizontal to one vertical (34’ measured from the horizontal). Plans for sloping
and benching systems shall be sent to Loss Prevention for review. (See Figures
11.3, 11.4, 11.5.)

Shoring systems shall be designed by a qualified person and meet accepted

engineering requirements. Materials used shall be in good serviceable condition,
and timbers shall be sound, free from large or loose knots, and of proper
dimensions.

2.4.2 Personnel Protection

Poxtable trench boxes or sliding trench shields may be used for the protection of
personnel in lieu of a shoring system or sloping. Where such trench boxes are
used, the design shall be approved by Saudi Aramco Consulting Services
Department.

Trench boxes shall be designed, constructed and maintained to provide

protection equal to or greater than the sheeting or shoring required.
 Shields shall be installed in a manner to restrict lateral or other movement of the
shield and be capable of withstandiig any sudden application of lateral loads.

Shields shall be extended above the excavation to protect employees working

inside the shields and when entering or exiting the areas protected by shields.

Employeea shall not be. allowed inside the shielded areas whenever shields are.
being installed, removed or moved (see Figure 11.7).

2.4.3 Iqection

All parts of an excavation, including the shoring, shall be inspected every day by
a competent person to ensure that there is no danger of collapse and all
observations shall be noted in the site safety log book.

2.4.4 ClWlX”Ct?

In order to provide a safe footing at the edge, and to prevent spoil falling into an
excavation, a clear space at least 0.6 meter (2 feet) wide shall be maintained on
all sides. (See Figure 11.8: Guide to Safe Distance Back From Top Of Slope For
Storage of Materials I Equipment Placing.)

2.4.5 Mechanical Excavator

Men shall not be permitted to work underneath loads or in places where they
could be struck by any part of a mechanical excavator.

2.4.6 Walkways

Where employees, equipment, or members of the public are required or

permitted to cross over an excavation, a close planked bridge or walkway with
standard guard rails shall be provided and kept clear of excavated materials or
other tripping hazards. No sidewalk shall be. undermined unless properly
shored.

2.5 Accessand Egress

Safe means of getting into and out of an excavation shall be provided at intervals not
exceeding 7.5 meters (25 feet). Ladders shall conform to the requirements set out in
Section 9.2, be placed at an angle of 7S’, and extend at least 0.9 meter (3 feet) above the
steppingdff point. Ladders shall be securely fixed.

2.6 Hazardous Atmospheresand Materials

2.6.1 V.MiMiO”

Where there is reason to suspect oxygen deficiency or the presence of a

hazardous atmosphere in an excavation, gas tests must be carried out by a
qualified person. Where necessary, mechanical ventilation shall be used, or
other appropriate precautions shall be taken before men enter.
 Note: Toxic, oxygen and flammable gas tests are. to be conducted before entering
hazardous excavations in Restricted Areas (as mentioned in GI 2.100).

2.6.1.1 Hazardous Atmospheres

Prior to entry into excavations greater than four feet deep, or

confmd spaces, a work petit shall be issued. Gas tests shall verify
that the oxygen level is 20-21’3, combustible gases 0.0 LEL, and
H2S is 0 ppm. For elevated levels of gases tested follow
requirements of GI 2.100. Corrective measurers may include use of
air movers, identification and isolation of sources from fuel lines,
sewers, open tanks or other measures to return the breathing
atmosphere to normal readings. Subsequent testing is required to
monitor the area during the work so appropriate precautions can be
taken a.3necessary.

l Precautions shall be taken to prevent employee exposure to an

atmosphere containing a concentration of any flammable gas
above its lower explosive limit (LEL).

l For an atmosphere with a concentration of any flammable gas

below its lower explosive limit (LEL), use the guidelines given
in GI 2.100 (Work Permit System) as shown below:

. Above 0.0 LEL - No hot work permitted

. 0.05 LEL to 0.5 LEL - Breathing apparahls must be used
. Above 0.5 LEL - No entry permitted

. When controls are used that are intended to reduce the level of
atmospheric contaminants to acceptable levels, testing shall be
conducted as often as necessary to ensure that the atmosphere
remains safe.

2.6.1.2 Emergency Rescue Equipment

(i) Emergency rescue equipment, such as breathing apparatus, a

safety harness and line, or a basket stretcher, shall be readily
available where hazardous atmospheric conditions exist or may
develop during work in an excavation. This equipment shall be
attended by a standby man outside the trench when in use.

(ii) Employees entering bell-bottom pier holes, or other similar deep

and confmed footing excavations, shall wear a harness with a lifeline
attached to it. The lifeline shall be separate from any line used to
handle materials, and shall be individually attended at all times while
the employee wearing the lifeline is in the excavation. Mechanical
devices shall be available to lift incapacitated employees from
excavations.

Febmmy 1993 - 2.0 Excavations, Trenching Ad Shoring Page LO2

 2.6.2 Exhaust Gases

Where an internal combustion engine is used in an excavation, special

precautions must be taken to ensure that exhaust gases are discharged so as not to
be a hazard to men working in the excavation.

2.6.3 Organic Lead

Where the presence of buried organic lad (TEL) sludge, asbestos or any other
hazardous chemical is known or suspected, whether in a Restricted Area or not,
excavation work shall not be started (or continued) until the Industrial Hygiene
Service and Loss Prevention Departments have identified the hazard and
specitied the precautions to be taken and a new work permit has been issued.

2.7 Edge Protection, Markers and Fixed Lighting

Whenever it is necessary to place or operate power shovels, derricks, trucks, materials,

soil banks or other heavy objects on a level above and near 80 excavation, the side of the
excavation shall be sheet-piled, shored, and braced as necessary to resist the extra pressure
due to such superimposed loads. When mobile equipment is utilized or allowed adjacent to
excavations, substantial stop logs or barricades shall be installed. If possible, the grade
should be away from the excavation. If men or vehicles are in the vicinity after dark,
fixed warning lights shall be used to mark the limits of the work.

2.8 Roads, Streets, and Sidewalks

Excavation work in roads, streets, and sidewalks shall not be undertaken without the prior
approval of the relevant authorities (See Section 11.1, Work Pennit System). Excavation
work on public highways will have to be cleared in advance with Government Affairs and
any special measures that they might specify must be implement&l (See Section 11.8,
Roadworks).

2.9 Backfilling
Backfilling and removal of trench supports shall be accomplished first by backfilling up to
a level allowing for the removal of the lower braces. Another layer of backfill shall be
positioned in the trench to the next layer of braces to be removed. Removal of trench
supports shall progress together with the backfill from the bottom of the trench. In
unstable soil, ropes shall be used to pull out the jacks or braces from above after
employees have cleared the trench. All excavations shall be backfilled and consolidated,
and the surface shall be left in good condition as soon as is practicable.

2.10 Borrow Pits

Location of borrow pit boundaries (i.e., residential, industrial plants, sub-stations,
highways, etc.) shall be located at the distance noted in SAES-A-111.

2.10.1 A separate traffic flow plan is required to keep pedestrian traffic away from
vehicle traffic areas. Traffic is strictly prohibited in borrow pit areas. Signs in
 Arabic and English shall be posted in mpedaff areas, warning personnel to stay
out of borrow pits.

2.10.2 Dust concentration, noise levels, and security fencing associated with borrow
pit operations shall be in accordance with Saudi Ammco Safe Operating
PIocedUreS.

2.10.3 Hydraulic Shoring For Trenches

Hydraulic shoring is provided as a method of protection against cave-ins in

trenches that do not exceed 20 feet (6.1 m) in depth. Trench depths exceeding
20 feet (6.1 m) require Loss Prevention review.

It is not intended that the aluminum hydraulic specifications apply to every

situation that may be experienced in the field. These. data were developed to
apply to the sihlations that are most commonly experienced io current trenching
practice. Sihlations that are not covered require specific designs for specific
applications and will be subject to Loss Prevention review. (See Figures 11.9,
11.10, 11.11, and11.12.)

2.10.4 Timber Shoring For Trenches

Timber shoring is provided as a method of protection from cave-ins in trenches

that do not exceed 20 feet (6.lm) in depth. Loss Prevention requirements must
be used when timber shoring protective systems are. designed. (See. Figures
11.13,11.14,11.15and11.16.)
SOIL OR ROCK TYPE MAXIMUM ALLOWABLE SLOPES
(H:V) [l] FOR EXCAVATIONS LESS
THAN 20 FEET DEEP [3]

STABLE ROCK VERTICAL (900)

TYPE A [2] 3/4: 1 (539
TYPE B 1:l (459
TYPE C l-112 : 1 (349

NOTES.
A

1. Numbers shown in parentheses next to maximum allowable

slopes are angles expressed in degrees from the horizontal.
Angles have been rounded off.

2. A short term maximum allowable slope of 1/2H : 1V (63O) is

allowed in excavations in Type A soil that are 12 feet (3.67 m)
or less in depth. Short-term maximum allowable slopes for
excavations greater than 12 feet (3.67 m) in depth shall be 3/4
H : 1V (53”).

3. Sloping or benching for excavations greater than 20 feet deep

shall be reviewed by Loss Prevention.

Slope Configurations

(All slopes stated below are in the horizontal to vertical ratio)

FIGURE Il.3: EXCAVATIONS MADE IN TYPEA SOIL

1. All simpleslopeexcavation20 feetor lessin depthshallhavea maximumallowableslopeof

314: 1.

SIMPLE SLOPE--GENERAL
Exception:Simpleslopeexcavationswhichareopen24 hoursor less(shortterm)and
whichare12feetor lessin depthshallhavea maximumallowableslopeof l/2 : 1.

SIMPLE SLOPE--SHORTTERM
2. AU benchedexcavations20 feetor lessin depthshallhavea maximumallowableslope
of 3/4to 1 andmaximumbenchdimensionsasfollows:
FIGUREIL3A

SIMPLE BENCH
:

MULTIF’LE BENCH
All excavations
8 feetor lessin depthwhichhaveunsupported
verticallysidedlower
portionsshallhavea maximumverticalsideof 3-W feet.

IJNSUPFORTEDVERTICALLY SIDEDLOWERPORTION--MAXIMUM 8 FEET IN DEFI’H

All excavationsmorethan8 feetbut notmorethan12feetin depthwhichunsupported
verticallysidedlowerportionsshallhavea maximumallowableslopeof 1:l anda maximum
verticalsideof 3-112feet.

3-W Max.

Febmmy 1993 - 2.0 Excavalions, Trenching And Shoring hgc 107

FIGURE II.3B

UNSUPF’ORTEDVERTICALLY SIDEDLOWERPORTION--MAXIMUM 12FEET IN DFPTH

All excavations
20 feetor lessin depthwhichhavewtically sidedlowerportionsthatare
supportedor shieldedshallhavea maximumallowableslopeof 3/4:1. The supportor shield
systemmastextendat least18inchesabovethetop of theveticalside.

SUPPORTEDOR SHIELDEDVETICALLY SIDEDLOWERPORTION

All othersimpleslope,compoundslope,andverticallysidedlowerportionexcavations
shall be in axcmiance with the other optionspermittedby LossF’revention.
FIGURE 11.4: EXCAVATIONS MADE IN TYPE B SOIL

ExcavationsMa& in TypeB soil

1. All simpleslopeexcavations20 feetor lessin depthshallhavea maximumsllowable
slopeof 1:l.

SIMPLE SLOPE
All benchedexcavations
20 feetor lessin depthshallhavea maximumallowableslope.
of 1:l aadmaximumbenchdimensionsasfollows:

‘IhiS benchallowedin cohesivesoil only

FIGURE 11.4A

SINGLEBENCH
.
This benchallowedin cohesivesoil only

MULTIPLE BENCH
All excavations20 feetor lossin depthwhichhaveverticallysidedlowerportionshall
be shieldedor suppatedto a heightat least18inchesabovetbetopof theveticalslope. All
beachexcavations shallhavea maximumallowableslopeof 1:l.

Totalheightof verticalside.

VERTICALLY SIDEDLOWERPORTION
All otherslopedexcavationsshallbein acccudance
with theotheroptionspermitted
by LassPrevention.
FIGURE11.5: EXCAVATIONS
MADEIN TYPEC SOILS

ExcavationsMadein TypeC soil

All simpleslopeexcavations20 feetor lessin depthshallhavea maximumallowable
slopeof l-lizI.

SIMPLE
SIMPLE SLOPE
SLOPE
All excavations20feetor lessin depthwhichhaveverticallysidelowerportionsshall
be shieldedor supportedto a heightat least18inchesabovethetop of thk verticalside. All
suchexcavationsshallhavea maxjmomallowableslope.of l-l/2:1.

VERTICAL SIDED LOWER PORTION

All otherslopedexcavationsshallbein accordance

with theotheroptionspermitted
by LossPrevention.

Fcbnuq1993 - 2.0 Excav&ms, Trenching And Shoriq hgc 111

FIGURE 11.6: EXCAVATIONS MADE IN LAYERED SOILS

All excavations 20 feet or less io depth made in layered soils shall have a maximum
allowable slope for each layer as set forth below.

B OVWA
FIGURE 11.6A: EXCAVATICPNS MADE IN LAYERED SOILS

AOVERB

February 1993 - 2.0 Excw&mr, Trmching And Shoring Faga 113

Flcum II.7: EXAMPLES OF TRENCII SIIIELDS

EXAMPLES OF TRENCH SHIELDS

FIGWW KS: GUIDE To SAFX DISTANCE BACK FROM TOP OF SLOPE FOR STORAGE OF MATERIALS
OR PLACING EQUIPMENT

Cut excavation slope

:
7 Equivalent weight
;: of block on new
.’ : soil

Distaace back =
Sftx3/4=4ft *

Note: If outriggas are used

theysimaldlx.placed
tb) backofthe4ftline.
 Flcm II.9: EXIU~PLES OF SCREW TRENC~I JACKS

HARD COMPACTGftO”ND\Y
FIGURE 11.10: ALIJMIN~HYDRAULICSIIORINCTYPICAL
INSTALLATIONS
FIGURE II.11: ALUMINUM HYDRAULIC SHORING

Vertical Shores for Soil Type A

Hydraulic Cylinders
Width Of Trench

I I
Depth of MnXiIIlUIll M&IIOlII Upto Over8upto overl2upto
Twnch Feet HorimntaJ Vdd 12 15
spacing Spacing
over 5 8 4 2 inch 2 inch 3 inch
upto 10 diameter diameter diameter
over 10 8 4 2 inch 2 inch 3 inch
up to 15 diameter diameter diameter
over 15 1 4 2 inch 2 inch 3 inch
up to 20 diameter diameter diameter

over 20 Loss Prevention Review

Vertical Shores for Soil Type B

Hydraulic Cylinders
Width Of Trench

I I I
Depth of Maximum Upto Over 8 up to Over 12 up to
Trench Feet Vertical 12 15
Spacing
over5 4 2 inch 2 inch 3 inch
up to 10 diameter diameter diameter
over 10 4 2 inch 2 inch 3 inch
up to 15 diameter diameter diameter
over 15 5.5 4 2 inch 2 inch 3 inch
up to 20 diameter diameter diameter

over 20 Loss Prevention Review

FIGURE II.12: ALUMINUM HYDRAULIC SIIORING WALER SYSTEMSFOR SOIL TYPE B
FIGURE 11.13: EXAMPLE OF TlhlnER SIIORINC PROTECTIVE SYSTEMS

CLEAR 2’ MINIMUM

ES
MINIMUM
2ECIFICATIONS

FebNary 1993 - 2.0 Excwalions, Trenebing And Shoring Page I20

FIGURE Il. 14: TIMBER TRENCII SIIORING - MINIMUM TIMBER REQUIREMENTS*
FIGURE Il.15: TIMBER TRENCH SIIORINC - MINIMUM TIMBER REQUIREMENTS*
FIGURE ll.16: TIMDER TRENCH SHORING - MINIMUM TIMIIER REQUIREMENTS*
(SOlLTYFl3B)P,=45XHt72psf(2hSurd1~ge)

(SOlLTYPEC)P, -gOXH+72psf(ZftSmcharge)
3.0 DEMOLITION

Numemus factors must be taken into account before the method of demolition is decided. Of prime
importance are the age of the structure, the method of construction, the state. of preservation, its
previous use, and the surrounding environment. These factors must be. known before any planning can
begin.

Many problems are peculiar to the demolition of tanks, vessels, and ancillary pipe work associated
with the oil industry. For instance, many serious accidents have resulted when due consideration was
not given to the cleaning and gas-freeing of this equipment before work began.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 2.100 Work Permit System

GI 2.711 Fire and Safety Watch

GI 6.012 Isolation, Lockout And Use Of Hold Tags

GI 8.001 Safety Requirements For Scaffolds

GI 150.001 Asbestos Regulation

GI 402.001 Operational Chemical Cleaning of Boilers

Refinery Instruction Manual:

No. 10.185 Precautions for Working in Leaded Product Tanks

American National Standards Institute:

ANSI A 10.6-83

Safety Requirements for Demolition

ANSI Z 88.2-80

Standard Practice for Respiratory Protection

ANSI Z 117.1-89

Safety Requirements for Working in Tanks and Confined Spaces

American Petroleum Institute:

API 2217434 Guidelines for Confined Space Work in Petroleum Industry

API 2015-91 Safe Entry And Cleaning Of Petroleum Storage Tanks

3.1 Before Work Starts
The contractor shall submit a Hazard Identification Plan as a part of his loss prevention
program to the Company Representative. All such programs must be reviewed and
concurred with by the Loss Prevention Department before start-up. (See. Chapter I,
Section 1.3.2.)

3.1.1 Responsible Supervisor

Before any demolition work is started, a competent supervisor must be appointed

in writing as the person responsible for all work on site. The man appointed
should be experienced in demolition operations. His duties will include the
direct supervision of the work force, ensuring that work pennit requirements are.
met, and liaison with other contractors working in the general area and with
operators and construction or maintenance engineers.

3.1.2 Original Drawings

The original drawings of the structure to be demolished should be obtained. An

examination of them should be made. to ascertain whether any major changes
from the original construction have been made and where utility connections may
be found.

3.1.3 Disconnections

All utility services such as electricity, gas, and water must be shut off and the
main supplies disconnected outside the line of the demolition work. Tanks,
vessels, and papework must be completely disconnected from inlet, outlet, and
overflow points.

3.1.4 Adjacent Structures and Public Areas

Adjacent structures, public buildings, pedestrian walkways, parking lots, etc.

shall be protected from demolition debris that can likely cause hazards to the
general public. Also, bracing must be installed to insure stability of adjacent
structures.

3.1.5 Barricades/Signs

Barricade% must be erected around the work area. Signs baring the words
“Danger - Demolition in Progress” in Arabic and English must be erected at each
approach to the barricade.

3.2 Method of Demolition

The method of demolition to be used should be decided upon in consultation with the
Saudi Aramco representative, Lass Prevention and all contractors involved. The reuse of
salvage materials should be. considered prior to this decision. It should be remembered
that the safest and most efficient method is to start at the top and dismantle in the reverse
order of construction. There are, however, cases where such a method is impractical or
uneconomical and where other methods have to be considered. Any portion of the job
 which contains a.sbestos insulation should be cleared under the general procedures (See
Section 11.4), and Industrial Hygiex Services, Preventive Medicine Services Division,
shall be contacted.

3.2.1 Demolition of Equipment Containing PCB: Polychlorinated Biphenyl

(ASKAREL)

Before quipment containing or suspected of containing PCB(s) is removed in

demolition work, the Loss Prevention Department and the Industrial Hygiene
Unit shall be notified to ensure safe procedures are used. Proper personnel
protection equipment and disposal systems must be utilized. (See GI 355.004.)

3.2.2 Demolition Of Buildings With Asbetas I lnwlation Materials

Before demolition of buildings with asbestos and insulation, notify Loss

Prevention and Industrial Hygiene Services to ensure safe procedures are
followed. Proper personnel protective equipment and disposal systems must be
utilized. (See Chapter 4 and GI 150.001.)

3.3 Stability During Demolition

As work progresses, continuing inspections must be made to detect hazards arising through
weakened or overloaded floors, unsupported walls, or loose material. Immediate steps
shall be taken by bracing or by other means to prevent the premature collapse of the whole
or any part of the structure.

3.3.1

Lateral support should not be removed from more than one story of wall at any
time before starting to demolish it. when a wall from which support has been
removed must be left standing at anytime, including overnight and off-shift work
hours, adequate bracing (guying) must be provided to prevent collapse and to
guard against wind pressures.

3.4 Working PlaceClearance

3.4.1 Access
A safe means of access to and egress from all working places must be provided.
Work places and the areas around ladders and stairways must be kept clear of
material and debris.

3.4.2 Glass Removal

Nails in timber must be removed or bent over, or the timber must be stacked
where it will not be a source of danger. All glass in windows, doors, partitions,
etc. should be completely removed prior to structural demolition.
3.5 Structural SteelRemoval
All steel construction should be demolished column length by column length and tier by
tier. A stmchunl member b&g removed must not be under any stress other than its own
weight. Members b&g cut or dismantled should be cbaiied or lashed in place to prevent
uncontmlled swinging or dropping.

3.6 Tanks, Vesselsand Pipe Work (Explosion Prevention)

3.6.1 Welding and Hot Cutting

No tank, vessel, or pipe work which has contained explosive or flammable

material shall be subjected to welding or hot cutting operation until all steps have
been taken to remove the substance and any vapors. when hot cutting is
planned, the advice. of tbe area Fire Chief and tbe Loss Prevention Department
should be sought.

3.6.2 Cold Cutting

Tbe use. of cold cutting techniques for the dismantling of tanks, vessels, and pipe
work, can substantially reduce tbe risk of explosion. Although this is often more
costly and laborious, there are times when it is the only safe method which can
bewed.

3.6.3 Steaming and Ventilation

In the case of vessels and tanks up to about 22,712 liters (6000 gallons) capacity,
both vapors and residues CM usually be removed by steaming out; however, with
larger tanks tbe problems are somewhat different. Because of tbe high capacity
of a large tank, steaming cannot be relied on to volatilize. all residues uolessiwy
large quantities of steam are. available. It is, however, relatively easy to
eliminate explosive concentrations of vapor witbin tbe tank by forced ventilation
using a blower or eductor system approved for bazwdous locations.

3.6.4 Residue Cleaning

With volatile materials, use of such methods as in 3.6.3 above will rapidly
reduce vapor concentrations. With materials less volatile, the main danger lies
in the hot cutting setting fire to any residues in the tank. It is, therefore,
essential tbat any residues are removed before work starts.

3.7 Protective Clothing and Equipment

All demolition workers should be provided witb and make. use of tbe following protective
equipment:

1 Safety helmet
2 Goggles
3 Heavy duty gloves

February 1993 - 3.0 Lkmdition Page 121

 4 Appropriate respiratory equipment (whenever mxe.ssary to prevent inhalation of dust
and fiunes)
5 Safety boots with steel toe caps and preferably with pen&ant resistant soles.

Safety belts or harnesses (with lifelines where required) shall be used by men working in
isolated or dangerous locations where there. is the possibility of them falling and where
other preventive measures are impractical.

3.8 Mechanical Equipment Guards

Mechanical equipment such as cranes and bulldozers should be equipped with wire. mesb
guards over windows and with solid protection over the driving position so that there is no
danger of the operator being struck by flying debris.
4.0 ASBESTOSANDOTHERF'IBERS
Asbestos is the generic name given to a number of naturally occwring inorganic fibrous silicate
minerals. Asbestos materials have been widely wed in the construction industry and may be present in
a number of manufactured products such as cement sheeting, molded insulation, gaskets, ropes,
blocks, fire resistant boards, etc. For the purpose of these regulations, asbestos is defmed as any of
the minenls crocidolite, amosite, chrysotile, fibrous nnthophyllite or any mixture containing any of
these minerals.

The use of asbestos is restricted. At present, the Saudi Ammu, Industrial Hygiene Unit must approve
the we of asbestos materials, under GI 150.001.

INSTRUCTIONS AND STANDARDS

Saudi Ammco General Instructions:

GI 2.108 Work Permit System

GI 8.883 Breathing Appaxtus

GI 150.881 Asbestos Regulations

American National Standards:

ASTM C468-88

Standard Definitions of Terms Relating to Asbestos - Cement

4.1 Types of Asbestos

These exist in two main rock-forming mineral groups: 1) Serpentine group, which
includes chrysotile (white asbestos); and, 2) Amphibole group, which includes crocidolite
(blue asbestos) and amosite @rown asbestos). These hvo main groups were the most
widely used asbestos minerals. However, fibrous anthophyllite has also been used in
industry in a few applications. Chrysotile was commonly used as the reinforcing material
in asbestos-cement products. Because cmcidolite has high resistance to acids, it has been
extensively used in chemical plants. Due to the superior beat resistance of amosite it has
been used principally for the manufacture of fire-resistant insulation boards. The majority
of asbestos products has been made of white asbestos, but some products contain blue
asbestos (crccidolite). Of the asbestos products manufactured blue asbestos has the higher
health risk. Blue asbestos can usually be recognized by its dark lavender blue color;
however, its presence could be masked by other materials. Since prolonged exposure to
heat, as would be the case with boiler or hot-pipe lagging, may change the characteristic
blue. color of crocidolite to a white or fawn color.

4.2 Health Risks

Over a period of time, breathing asbestos dust can cause asbestosis (scarring of the lung),
which may go undetected for years after exposure. All forms of asbestos are capable of
causing asbestosis. The most important factors in the development of the disease are the
 amount of dust to which the individual is exposed, duration of exposure, and the personal
susceptibility of the individual to the asbestos fiber. In addition, asbestos fibers can
penetrate the skin, causing small tumors, warts, or corns. These asbestos tumors are
usually found on the palms CITfingers. They may not be cured unless every minute. fiber is
removed.

The maximum allowable concentration of airborne asbestos dust shall not exceed 0.2
asbestos fibers longer than five microns in length per cc of air on a time-weighted average
(TWA) exposure for an eight-hour work day.

4.3 Before Work Starts

The contractor shall submit a Hazard Identification Plan to Loss Prevention Department
and to the Industrial Hygiene Service, Preventive Medicine Services Division for review
and concurrence prior to job start-up, when removing or using asbestos materials. (See
Administration I, Section 1.3.4.) Unless approved of in advance by the Industrial Hygiene
Unit. asbestos products shall not be. used in new construction.

4.3.1 Air Sampling

Where the contractor knows that some part of an operation requires the use or
removal of asbestos materials, he must notify, in writing, the Industrial Hygiene
Services, Preventive Medicine Services Division. When informed, the Industrial
Hygiene Services will take random samples of air at the paint of operation
during the working period. Bulk samples may be sent for the analysis and
identification of asbestos to either Industrial Hygiene Services or to the
Laboratories Department.

4.3.2 Job Details

Tbe contractor shall then inform the Industrial Hygiene Services of details of the
work involved, the number of persons employed, the anticipated duration of the
operation, the type of asbestos being used, and the type of equipment being used
to work the asbestos material.

4.3.3 Chest X-rays

It is the contractor’s duty to ensure that each man employed on asbestos work be
given a chest X-ray prior to commencement of the job and thereafter at hvo-year
intervals. Detailed records shall be kept by the contractor of all persons
employed in the process. These records shall be available to Saudi Aramco upon
request.

4.4 Storage and Transportation

All asbestos materials removed from or used on a job shall be stored in an approved
container at all times. For new construction, only that amount of asbestos material that is
immediately required for the operation shall be moved to the work area.

Pebnury 1993 - 4.0 Asbcdaa Ad Other Fikn Page 130

 Approved containers shall during the transportation
be wed of asbestos materials. All
such containers that contain asbestos shall be clearly marked in English and Arabic:
“Caution: Health Hazard - Contains Asbestos”.

4.5 Work Area

The work area shall be clearly detined and where feasible mped off and notices displayed
warning persons of the presence of asbestos dust. Signs shall be posted at all approaches
to the work area. These. signs shall be posted at readily visible locations near work areas
and these notices shall read in both English and Arabic:

Caution:
ASBESTOS HEALTH HAZARD
Respirator and protective overalls must he worn when entering this area.

Only persons directly concerned with the operation shall be permitted inside the area.

4.6 Handling and Use

4.6.1 Wetting/Vetttilation

The handling, mixing, applying, removing, cutting, and spraying of asbestos

materials shall be done in a wet state so as to prevent the emission of harmful
fibers in excess of allowable concentration.

Before removing asbestos cement mortar, coating, grouting, plaster, or similaf

material containing asbestos from bags, cartons, or shipping containers, the
material shall be wetted or enclosed, or the operation shall be. carried out under
total exhaust ventilation.

Work practices for using or removing asbestos are given in Section 4, GI

150.001.

4.6.2 Cutting

Shearing or punching shall be used in preference to sawing or drilling of

r~~bestos. Where it is necessary to cut or saw materials containing asbestos using
hand or power tools, it shall be done in a separate cordoned off area with an
approved exhaust and dust collection system.

4.6.3 Protective Equipment

Protective equipment shall be required for all instances where asbestos is wed
regardless of ventilation, wetting, etc.
4.7 Protective Clothing
4.7.1 Types

Tbe contractor shall provide approved disposable overalls, head covering, foot
protection, and gloves to prevent any airborne asbestos fibers from coming into
contact with the body.

The contractor shall provide a sufficient amount of clothing to each employee

working with asbestos to ensure that a complete change of clean protective
clothing is available for the start of each shift.

4.7.2 Contamination

At the end of each shift, contaminated personal protective equipment shall be

collected and disposed of in accordance to GI 150.001. Under no conditions
shall contaminated clothing be worn from the work site. Employees shall be
careful to prevent contamination of street clothes from work clothes.

Asbestos-contaminated clothes shall be packed and carried in sealed impermeable

bags or containers and disposed of in accordance to Section 6, GI 150.001.

4.7.3 Review

The Loss Prevention Department and Industrial Hygiene Setvices shall review
the types and applications of contractor’s protective clothing for its’ acceptability
to Saudi Aramco.

4.8 Respiratory Equipment

Where there is an unavoidable emission of asbestos dust, the contractor shall supply a
respirator approved by Industrial Hygiene Services and Loss Prevention Department to
each employee.

4.8.1 Type

In nonnal circumstances, an approved filter type dust respirator will be adequate

protection; however, dusty jobs (e.g. stripping, delogging, demolition, etc.)
involving asbestos materials require air-supplied Positive pressure respiratory
equipment.

4.8.2 Use

All employees shall be properly trained in the use of respiratory equipment

before being engaged in any work with asbestos. Also, it is the contractor’s
responsibility to make sure that each worker be supplied with equipment that
provides the level of protection required and of the proper fit.

February1993 4.0 AsberaosAnd OtherFibers Page132

 4.8.3 care

All respiratory equipment shall be thoroughly checked, cleaned, disinfected and

stored at the end of each work period and before use by other persons.

4.9 Washing and Changing Facilities

The contractor shall provide showering/washing facilities for all employees engaged in
a.sbe.stoswork.

The. contractor must ensure that employees use these facilities before leaving the job site at
the end of each shift.

The contractor shall provide suitable changing accommodations, disposal facilities for
protective clothing worn during asbestos work and &par&e accommcdations for street
clothing not worn during working hours.

4.10 Disposal of Waste AsbestosMaterials/Clothing

All waste asbestos materials and disposal clothing shall be disposed of in sealed
impermeable bags or containers.

All bags and containers shall be marked in both English and Arabic: “Caution: Health
Hazard - Contains Asbestos”. The bags and containers shall be handled and disposed of in
accordance to Section 6. GI 150.001.

4.11 Cleanlinessof Work Areas and Equipment

The contractor shall ensure that all machinery, equipment, work areas, and adjacent areas
are. kept free. from asbestos dust and waste as provided in Section 5, GI 150.001.

Febmary 1993 - 4.0 Asbc~os And Other Fibers Fapc 133

5.0 WELDING, CUTTING, AND BRAZING
This section outlines the principles involved and the precautions to be taken in gas welding, cutting,
and brazing and electric arc welding operations.

Welding/cutting are. safe operations if carried out in the correct manner. Where equipment is defective
or there is no well-arranged, well-lit, or properly ventilated working place, hazards can arise..

INSTRUCTIONS AND STANDARDS

Saudi Aramco General lnstnwtions:

GI 2.100 Work Petit System

GI 355.020 Control of Compressed Gas Cylinders

GI 481.081 Performance Qualifying Tests Of Welders And Welding Operations

Saudi Aramca Engineering Standards:

SAES W-4 Welding Alloy Steels

SAES W-5 Field Stress Relieving

Saudi Aramco Bottled Gas Manual:

Section 6 Safe Handling of Compressed Gases

Schedule ‘D’:

Saudi Aramco Safety, Health and Environmental Requirements - Oxygen and

Acetylene Equipment and Electric Arc Welding Equipment

American National Standards:

ANSI 249.1 Safety In Welding and Cutting

ANSI 287.1 Practice For Occupational And Educational Eye And Face Protection

NFPA 70 National Electrical Code

5.1 Gas Welding: Oxy-AcetyleneEquipment and Use

Perscnmel working with welding equipment shall be trained, competent, and provided with
personal protection equipment. Welding goggles, helmets, screens, forced ventilation and
similar equipment shall be provided to all workers and to trainees in the immediate area.

5.1.1 Gases

Oxygen (02) is odorless. It can promote rapid combustion, therefore, grease

and oil must never be used near oxygen as this could cause fire.
 Oxygen cylinders or apparahu shall not be. handled with oily hands or gloves. A
jet of oxygen must never be permitted to strike a0 oily surface, greasy clothes or
enter fuel, oil or other storage tanks.

Acetylene (C2H2) has a distinct odor often likened to that of garlic or sour
apples. It is combustible when mixed with air over a wide range. (2.5% - 81 W).
Acetylene burned with oxygen can produce a higher flame temperatire than any
other commercial gas.

Acetylene becomes unstable at pressures above 103 kPa (15 psig) which means it
may explode. Under no conditions shall acetylene be generated, piped (except in
approved cylinder manifolds) or utilized at a pressure in excess of 15 psi gauge
pressure. Inside the cylinder, acetylene is dissolved in acetone to prevent
internal explosion; therefore, it is essential that acetylene cylinders be stored,
handled, and used in the vertical position to prevent the liquid acetone from
escaping and damaging the valves and other equipment.

Warning: Regulated Acetylene pressures must never be allowed to exceed 103

kPa (15 psig) or it may explode.

5.1.2 Color Coding of Cylinders

Color coding can be of great help but also a potential source of danger as there
is no internationally recognized standard color code. Refer to GI 355.0204,
Control of Compressed Gas Cylinders, for Saudi Aramco color ccding
requirements.

51.3 Storage Of Cylinders

5.1.3.1

Cylinders should be stored in a safe, dry, well-ventilated place

prepared and reserved for that purpose. Flammable substances such
as oil and volatile liquids or corrosive substances should not be
stored in the same area. Oxygen cylinders and flammable gas
cylinders shall be stored separately, at least 6.6 meters (20 feet) apart
or separated by a tire proof, 1.6 meters (5 feet) high partition.

All storage areas shall have Arabic and English “No Smoking
Permitted” signs prominently displayed.

All cylinders should be chained or otherwise secured in an upright

position. To prevent rusting, cylinders stored in the open should be
protected from ground contact, extremes of weather, or contact with
water. Valve caps shall be kept in place when cylinders are not in
use. Flammable substances shall not be stored within 50 feet of
cylinder storage areas. (See GI 355.020.)

5.1.3.2

Cylinders shall not be. stored at tempemhlres exceeding 54OC

(13O’=F). Accordingly, they should not be stored near sources of
 heat such as radiators, furnaces, or near highly flammable substances
like gasoline. Cylinders shall be. stored out of the direct rays of the
sun, in protective enclosures or sun shelters.

5.1.3.3

Cylinder storage should be planned so that cylinders will be used in

the order in which they are received from the supplier. Empty and
full cylinders must be stored separately with empty cylinders plainly
marked as such, to avoid confusion. Empty cylinders should be.
segregated according to the type of gas they have held.

5.1.3.4

All cylinder storage rooms shall be ventilated sufficiently so that

explosive concentrations of gas cannot accumulate. Smoking or any
other source of ignition shall be prohibited near storage areas, and
appropriately marked “No Smoking’ as in Section 5.1.3.1 above.
All wiring shall be in conduit and electric switches shall be located
outside the room. All electrical installations shall meet the National
Electrical Code (NFPA 70) for hazardous areas.

5.1.4 Handling of Cylinders

Serious accidents may result from the misuse, abuse, or mishandling of

cylinders.

5.1.4.1

Cylinders should never be lifted by their valves since the valves are
not designed to take such stress. When the cylinder is not in use, the
valve shall be protected with the valve cap.

5.1.4.2

All valves must be fully closed before a cylinder is moved. Unless a

trolley or special carrier is used, regulators and hoses should be
detached from the cylinders, for moving.
 5.1.4.3

If cylinders are to be lifted by a crane, specially designed bottle

holders with lifting eyes should be. used. Chain and wire rope slings
can allow cylinders to slip. Where. a trolley is to be used for
slinging, its base should be strong enough to take the weight of the
cylinders. Do not lift a cylinder with an electromagnet.

5.1.4.4

Cylinders in transit on vehicles shall have valve caps in place and be

fimdy secured to prevent movement. Cylinders shall be secured to
avoid any violent contact. Loading and unloading shall take. place
carefully. Cylinders shall not be dropped, thrown, dragged, wed as
rollers, or as a support. No damaged or defective cylinder shall be
used.

5.1.4.5

When in doubt as to the proper handling of a compressed gas

cylinder or its contents, the supplier of the gas, the Bottled Gas
Coordinator (Central Area Storehouse Department), or Loss
Prevention Department should be consulted. Depleted cylinders
shall be. returned to the supplier with the valves closed and the valve
protection caps in place. Cylinders, even those marked empty,
should be treated as a possible hazard and handled with great care as
they still contain some gas.

5.1.5 Inspecting Equipment

All equipment should be examined immediately before use and regularly

maintained. All welding operations shall be conducted in well ventilated areas.

5.1.5.1

Only soapy water should be used to check for leaks. Presence of a

leak is often indicated by a hissing sound or unusual changes in the
torch flame. Cylinders and valves should be. kept clean. Valve
sockets shall be kept free of grit, dirt, grease. or oil.
 5.1.5.2

Hoses should be used for one type of gas only and color coded for
identification. They should be examined before. use for any signs of
splitting which might give rise to leakage. All connections should
be made by clips or crimps. The hoses used for acetylene and for
oxygen shall not be interchangeable.

5.1.5.3

Connections and check valve-s should be regularly examined.

Equipment should be fitted with the correct pressure regulators and a
regular check should be made to ensure. that the regulator is working
properly. The torch nozzle should be. kept closed.

An acetylene cylinder valve wrench shall be available at all times for

the cylinder in use.

5.1.5.4

Means of torch ignition should be readily available. A friction

lighter shall be used for this purpose.

5.1.5.5

Acetylene can form explosive compounds in contact with certain

metals or alloys, particularly unalloyed copper or silver. Joint
fittings or lines made of copper should not be used and acetylene
should not be allowed to come into contact with copper pipe work or
tubing. Only approved materials shall be used for acetylene systems.

5.1.5.6

It is dangerous to let the torch flame come into contact with gas
cylinders or for the lighted torch itself to be. left unattended.
Torches shall never be sat down while lit. It is equally dangerous to
rest blowpipes, even extinguished ones, on old drums. “Empty”
drums which have contained low flash point liquids are known to
have become lethal bombs when a hot welding torch was laid down
on them.

5.1.5.7

Cylinders in use should be kept upright on a custom-built stand fitted

with a bracket to accommodate the hoses and equipment or otherwise
secured. The metal cap should be. kept in place to protect the valve
when the cylinder is not connected for use.

FCbnUry1993- 5.0 Welding, Cuning, And Brazing Fage138

 51.6 FCWltS

It is not uncammo~~ for minor ‘explosions” to occur during weldmg or cutting.

Most are more frightening than harmful, but some can lead to very dangerous
conditions.

There we four general groupings of these faults:

1 Snapout can occur during we when:

. Both regulators are set at an incorrect pressure

l Torch nozzle obstructed
l Nozzle held too close to the work

Corrective action:

. Completely shut both torch valves

l Check regulator setting

. Check cylinder pressures

l Checknozzles

. Relight
l Ensure adequate gas flow

2 Backfire can occur on lighting up when:

. Regulators not set to correct pressure

. Light applied before flow of gas mixture pmperly established

Corrective action:

. Close both torch valves, oxygen first

. Check cylinder pressures
. Check and adjust regulator settings
. Cool torch and check nozzle orifice for obstruction
l Re-light

3 A flashback is very dangerous. Flashback is caused by gases being mixed

in the bosf+). Usually tbis mixing of gases occurs when tbe hoses have
been disconnected from regulators or torches or when a new hose is being
wed for tbe first time. Sometimes it is due to loose connections. Usually
one of tbe hoses will have burst and possibly ignited.

Preventive action:

. Use flashback flame arrestors for regulator and torch

. Ensure all connections are tight
. Ensure cylinder valves are open end torch valves closed
l Set regulators to the required pressure.3
l Purge each hose. separately and consecutively by opening tbe
torch valve end allowing gas to flow for sufficient time to ensure
only pure gas remains in tbe hoses
. Close the valve for each gas as tbe purge is completed

Febnury 1993 - 5.0 Welding, cUnir& Ad Bmzin, Page 139

 . This purge should be carried out only in the. open or in
extremely well-ventilated areas

Corrective action:

. Close both torch valve.3

. Close both cylinder valves
. Extinguish hose if alight
. Repair equipment and hoses

5.1.7 Fuel Gas and Oxygen Manifolds

Fuel gas and oxygen manifolds shall bear the name of the substance they contain
in English and Arabic letters at least l-inch high which shall be either painted on
the manifold or on a sign permanently attached to it.

Fuel gas and oxygen manifolds shall be placed in safe, well ventilated, and
accessible locations. They shall not be located within enclosed spaces.

Manifold hose connections, including both ends of the supply hose that lead to
the manifold, shall be such that the hose cannot be interchanged between fuel gas
and oxygen manifolds and supply header connections. Adapters shall not be
used to petit the interchange of hose. Hose connections shall be kept free of
grease and oil.

When not in use, manifold and header hose conwctions shall be capped.

Nothing shall be placed on top of a manifold, when in use, which will damage
the manifold or interfere with the quick closing of the valves.

5.2 Electric Arc Welding

Arc welding is a process for joining metals by heating with an electric arc. For arc
weldiig, hvo welding leads, the electrode lead and the work lead, are required.

52.1 VOltage

The voltage across the welding arc is normally within the range 20-4OV. The
voltage supplied, however, needs to be somewhat higher so that means of
stabilizing and regulating the arc current can be introduced into the circuit.
Using DC, a 60-80V supply will usually suffice. Using AC, an 80-8% supply
will suffice although some of the latest techniques need an open circuit voltage of
up to IOOV behveen electrode and work. It should be remembered that a
nominal 1OOVsupply has, in fact, a peak voltage of 141V.

For these reasons, DC should be used for welding operations in any sihurtion
where the effect of electric shock is likely to be extreme, such as in damp and
confined spaces (tanks, boilers, etc.).
 5.2.2 welding connoetio”s

In each welding circuit there am three main connections:

1) the welding lead;

2) the welding return;
3) the welding ground.

5.2.2.1

The weldinn lead is the conductor carrying the welding current from
the point of supply to the electrode holder.

5.2.2.2

The weldine return is the conductor carryying the current back from
the work to the point of supply. Its conductivity should at least
equal that of the welding lead. The welding return should be used to
gmund the metal case of the welding machine. This high current
capacity is essential, because all the current fed to the arc has to be
conducted back to the supply point. The current involved could be
as high as 300 amtnxes on a hand welding operation.

5.2.2.3

A continuous welding ground is essential and indispensable for

conductors since electric currents as low as 50 milliamperes can be
fatal. The ground should be. of low impedance so that there can be
no rise in the potential of the work and so that sufficient fault current
passes quickly enough to cut off the supply if necessary. It is
recommended that the welding ground be bonded to the ground of
the main supply system by a separate substantial conductor.

The frames of all fixed arc welding and cutting machines shall be
grounded either through a third wire in the cable containing the
circuit conductor “T through a separate wire. which is grounded at the
so”rce of the current.

Welding grounds and returns should be securely attached to the work

by cable lugs, by clamps in the case.of stranded conductors, or by
bolts for strip conductors. Bolts are ““satisfactory for stranded
conductors, since the strands can lcwen under the bolt head and
become detached (see Manufachuers Grounding Specifications for
Electrically Powered Equipment and Engine Powered Equipment).

February 1993 5.0 Welding, Cutting, And Brazing Page 141

 5.2.2.4

Welding cable insulation needs to be abrasion resistant to withstand

normal treatment over rough ground and the wear inflicted by foot
and vehicular traffic. Where feasible, cables should be additionally
protected by stringing overhead or by using cable covers. They
should be regularly examined for cuts or abrasions to the insulation;
damaged cable shall not be used. If joints become necessary,
standard plug and socket coupling shall be used. Holders should be
unplugged when not in use. If joints become necessary, standard
plug and socket couplings shall be used Splices are not allowed in
welding cables.

5.2.2.5

Electrode holders shall be constructed to accommodate all sizes of

electrodes and with an ejector for hot, spent stubs.

5.2.2.6

A shield should be fitted between electrode holder and handle to

prevent live elements from being touched. The handle. itself shall be.
made of non-flammable insulating material and be free from joints or
holes.

5.2.2.1 Auxiliary Power Outlets

Most welding machines are furnished with an alternator which

produces 3 KVA of 115 and 230 volts. As a safety factor, all power
hand tools which are not double insulated should be grounded to the
welder frame. Ground Fault Interrupters are required, where power
output exceeds 5 KV. Placards must be placed on the welding
machine.

5.3 Protective Measures

5.3.1
The need for the operator to take safety precautions and preventive measures
during the operation of welding machiies to ensure that no safety-related
incident occurs cannot be overemphasized. The following is a list of precautions
and operating considerations to take into account when operating a 400 amp arc
welding machine, for example. All users are strongly encouraged to read the
equipment’s operating manual to ensure reliable and safe operation.

1. Keep all doors, covers and panels in ulace when otwatine the machine:
the arc weldiig machine is designed to operate with all its doors, covers
and panels in place. They ensure the optimum flow of cooling air, and
removal of these CLWXSand panels will reduce the cooling of the engine
and generator, resulting in overheating and premature failure of the unit.
 2. Ensure that the ennine or&&m oush button ‘DODSout’ when the em&e
is switched off. Under normal circumstances, this button will ‘pop out’
once the engine is switched off. However, if the unit becomes clogged
with dirt, dust or sand, it may not r&urn to its ‘off position without
assistance. If the button remains depressed, it will quickly drain the unit’s
battery. The resulting failure to start will delay your work while a new
battery is fitted, a ‘jump start’ arranged, or a recharge cycle is completed.

3. Maintain weldinn and mound cables and connections in nood condition.

A major source of safety hazards, poor and inconsistent weldiig
performance, and loss of point-of-use welder capacity is a set of welder
leads in poor condition, or of the wrong size for the length of cable b&g
run. Other sources of safety hazards related to cables and connections are.:

. cracked insulation is an obvious source of hazard producing shorts to

ground eventually leadiog to iocrease of conductor resistance. With no-
load voltages approaching lOO+ volts, significant hazard of electrocution
to personnel exists, especially in wet areas or when working on metal
stlllChlreS.
. combinine sets of low caoacitv cables to reach a distant welding site. can
greatly reduce the effective welding power available to the weldiig
machine. Largerxapacity cables must be used to reach distant sites,
because of the buildup of resistance from the extra length of the leads.
Inadequate or weak cable connections can also introduce sparking hazards,
potential shorts to ground, and extra resistance which reduces effective
welding machine capacity. Cable sizes and lengths must be as
recommended by the manufachuer, as follows (for 400 amp machine):

4. When welding is in progress, the full lennth of cable must be stretched out
on the wound. Leaving the cable coiled on the machine alters the current
flow and disrupts the welding proce.ss.

5. Do not adjust the ‘current control’ while welding is in progress. This can
damage. the control.

5.3.2

Sparks and molten or hot metal coming from the work area can easily set tire. to
combustible materials near or below the working area. wherever possible, all
combustible material should be removed from the work area. If it cannot be
removed, it should be covered with fireproof material. Gas cylinders should be
protected from falling sparks.
 5.3.3

Operators of arc welding equipment must always switch off the current to the
electrode holder and remove. the electrode whenever it is to be set down and is
not actually in use.

5.3.4

When welding or cutting material that is supported by a crane, a shield or an

effective screen should be provided to protect the suspension ropes or chains.
Grounding cables shall only be connected to the work, not to the crane or
rigging.

53.5

Forced ventilation shall be arranged wherever work is to be carried out in a

confined area. Suitable metal bins shall be provided for spent electrode stubs as
they are usually hot when discarded and can easily cause. a fire. Dry chemical
tire extinguishers should be kept available while work is in progress. All
completed work should be marked “HOT”.

5.4 Welding and Cutting: Tanks, Vesselsand Drums

Careful tests should be made to establish that the tank, vessel or drum is free from
explosive. flammable vapors or substances. The responsible supervisor should make. a
check before permitting any work to begin. It is essential that past contents of the tank,
vessel or drum be identified. If there is any doubt or if the tank is known to have had any
kind of flammable or explosive content, it should be cleaned and purged thoroughly prior
to welding or cutting. Extreme care should be taken in considering methods of tank
welding and cutting as these jobs are hazardous operations unless correct safety measures
are taken. (See General And Civil II. 1, Work Petit System.) Welding and cutting on
drums is strictly controlled and, in most cases, prohibited. Contact area Loss Prevention
for guidance and information.

Note: The use of oxygen for blowing out containers and small tanks is forbidden.

5.5 Confined Spaces

It is vital that forced ventilation be maintained in confined spaces at all times. Air line
respirators may be needed for men working inside such places. No gas cylinders should
ever be allowed into such an area. The hoses and equipment used inside must be in
excellent condition.

Where work in confined spaces has to take place over several days, the hoses and
equipment shall be. taken outside overnight in case of any leakage that could occur,
resulting in a build up of gas. (See General And Civil 11.1, Work Petit System. )
5.6 PersonnelProtection
5.6.1

Helmets, welding hoods, and goggles are necessary to protect eyes and face
against heat and the effect of the intense light emitted by welding operations.

5.6.2

Goggles are required to protect the eyes of the welder from pieces of flying slag
chips during electric arc welding. They should be fitted with opaque side pieces.
These goggles should also be worn under the regular welding hwds.

5.6.3

Electric welding operations must be effectively screened to prevent nearby

personnel from being affected by harmful radiation. Screens should be made
from tire. resistant materials or should be suitably treated with a fire resistant
compound. Screens should be designed and placed so as not to restrict the flow
of air for ventilation purposes.

5.6.4

Gloves are necessary protection to the hands against heat, sparks. molten metal,
and radiation. Leather, suitably reinforced at Points of maximum wear, is the
material most generally wm. Gloves should be. long enough to protect wrists
and forearms. When gloves are not long enough, protective sleeves of similar
materials should be worn.

5.6.5

Safety boots and leggings are essential to provide effective protection against
heat, flying sparks, and falling metal. Pant cuffs shall never be worn inside of
the safety boot.

5.7 Health Hazards

Apart from the obvious hazards of physical bums, health hazards in welding operations fall
into hvo classes: hazards from radiant energy and hazards from dusts and fumes.

5.1.1 Radiant Energy

The pnxxss of welding produces radiant energy in the form of visible light,
ultra-violet rays, and infrared rays. The risk of this energy harming the operator
or other personnel can be minimized by the proper use of protective clothing and
shielding. Exposure of the skin to infrared and ultraviolet rays can result in
irritation and burning. The risk of exposure is lessened by wearing protective
clothing, shielding, and distance.
 Am-eye or flash bum is a well known condition in welding operations end is due
ta the eyes beiig exposed to ultraviolet rays. This condition is a sup&i&l bum
on the outer layer of the eye.

The effects normally wear off within two days, and generally no permanent
damage is caused. The condition is, however, extremely painful and can easily
be avoided by the we of eye protective lens or shields.

Welding protective lens shall be tempered glass. Lens shall be. distinctively
marked to identify approved lens shade.

Lens Shade Guide:

I. Am Welding- 10 to 14
2. Torch Brazing- 3to 6
3. Gas Welding- 410 8

5.7.2 Respiratory Effds

The risk of b&g gassed in normal welding operations is slight; however, when
working in confined areas, a forced ventilation system should be in operation to
remove any build up of hazardous gases.

5.7.2.1

Oxy-acetylene welding operations cm cause the oxygen and nitrogen

of the air to unite to form nitrogen oxides. In well ventilated area
this does not cause any problems; however, in confined areas or
where. the welder is working very close. to the job, the amount of
nitrogen oxides breathed can rapidly reach toxic levels. The main
problem with this gas is that the welder does not appear to be
affected at tbe time; the real effects take place some 6 to 24 hours
after exposure.

5.7.2.2

All welding operations produce quantities of ozone, a highly toxic

gas. In ony-acetylene and electric arc welding, the amount produced
is small and providing adequate. ventilation is wed, the risk is
negligible. Significant and sometimes dangerous amounts of ozone
can be formed when inert gas shielded welding is beiig carried out.

There are. may other dangers which can arise when welding or
cutting under specific conditions or on particular metals. Hazardous
operations include: welding on manganese steel, galvanized
material, material which has been degreased or on material which
has bee41painted with lead, copper-bearing, or chmmate+ontaining
paint. These problems must be recognized before the job starts, and
safe practices for dealing with them must be established.

Although welding cannot be regarded in general as an extremely

hazardous occupation, exposure to concentrated fumes may be
irritating and in some cases dangerous. It is essential that each
operation be analyzed before work starts and that the control
measure.3are correctly applied.
6.0 EXPLOSIVE MATERIALS

The use of explosive materials within construction is extensive and, whether large or small quantities
are handled, the respons~bd~tes falling upon supervisory staff are considerable. Those responsible
must consider the acquisition, storage, transporting, handling and use of explosive materials, as well as
the emergency procedures to be adopted in the case of misfire, accident, fire, etc. The acquisition and
use of explosive materials in Saudi Arabia are strictly controlled by the Saudi Arab Government,
whose requirements must be adhered to at all times. All blasting operations in Saudi Ammco are
strictly controlled and the use of explosive materials by contractors is prohibited without prior written
approval by Company representatives. For contractor In-Kingdom blasting operations, contact the
Resources Planning Department, Project Support Services Division, Blasting Services Unit for all
blasting requirements.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 2.100 Work Petit System

GI 355.015 Requisitioning, Receiving, Storing and Issuing Explosives

GI 475.001 Blasting Near Existing Facilities

GI 475.002 Use. Of Explosives In Construction

GI 610.001 Special Regulations for the Use of Explosives in Seismic Operations

GI 1183.215 Transporting Explosives on Company Owned&eased/Rented Motor Trampott

V&iCl~

GI 1310.00 Transportation Of Dangerous Articles Aboard Saudi Ammco AircraFt

Schedule ‘D’:

Saudi Aramco Safety, Health and Environmental Requirements

American National Standards:

ANSI A10.7-89 Safety Requirements for Transportation, Storage, Handling, and Use. of Commercial
Explosives and Blasting Agents in Construction and Demolition

NFPA 495-90 Explosive Materials Code

National Safety Council Industrial Data Sheets:

I-644-90 Treatment Of Extraneous Electricity In ElcxztricBlasting

I-730-86 Ammonium Nitrate. ! Fuel Oil Mixtures As Blasting Agents

7.0 PILINGOPERATIONS
Piling operations attract many of the pmblems associated with other types of construction work:
access, unguarded machinery, housekeeping, etc. Heavy equipment and the stress and vibration
imposed upon that equipment give rise to hazards peculiar to piling operations. The standard of
supervision should be high, as well as the standard and maintenance of equipment.

Piling operations fall into hvo categories: driving load-bearing piles, which may be. driven vertically
or raked; and, driving sheet piles. Piles may be of steel, concrete, timber or any combination of the
three. Piling equipment can vary from a simple air-operated hand-held hammer to a large complex rig.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 2.100. Work Permit System

GI 7.025. Mobile Heavy Equipment Operator Testing and Certification

GI 7.026. Crane and Heavy Equipment Accident Reporting Procedures

GI 7.029. Inspection, Testing and Maintenance of Wire Rope Slings

GI 7.030. Inspection And Testing Requirements Of Elevating I Lifting Equipment

Schedule ‘D’:

Saudi Aramco Safety, Health and Environmental Requirements - Excavations

Crane Safety Handbook (Page 99)

National Safety Council Data Sheet:

Special Hazard Bulletin X128. Property Damage from Blasting, Pile Driving, and
Similar Sources

ASME Standard:

Section I Power Boilers

Section VII Pressure Vessels

7.1 Before Work Starts

In order that piling operations may be. undertaken with the minimum risk to men and
equipment, the following factors should be considered before work starts.

l The nature. and purpose of the operation.

l Soil investigation reports of tbe *rea.

l Location and nature of any underground services in the area, which should be checked
with the various departments through the Saudi Aramco Construction Engineer; then,
precisely located by careful hand digging, under competent supervision.

Where piling operations are within a restricted area, the proper Work Petits should be
obtained before. any work is undertaken.

Competent supervision, experienced in piling operations, is essential for piling work.

Equipment of adequate capacity to perform the operation should be assembled. All

equipment must be carefully inspected before being used with particular attention to the
following. (See GI 7.030.)

7.1.1

Cranes used for both lifting and piling operations should be of an adequate size
and capacity to perform the work safely. Where cranes are to be. used for
driving raking piles with a drop hammer or driving piles below the level of the
crane using extended leaders, the hammer will be suspended from the crane at a
greater radius than the boom angle indicator will show. In all such cases, the
distance of the hammer from the center point of the crane must be calculated and
this distance used to ascertain the safe working load.

Outriggers, counterbalances, etc., shall be. provided to maintain stability of the

pile driver rig.

7.12 Pile Gates

Sufficient timber or steel must be available for the construction of pile gates.
Proper ladder access must be provided to the pile gates, and where they are over
I.8 meters (6 feet) high, handrails or rigger’s belts must be provided.

7.1.3 Inspection

Air compressors or steam boilers must be carefully examined and all hoses and
couplings checked both for leaks and general condition. All steam and air hoses
should be fitted with a regulator valve and a quick acting shut-off valve for
emergency.

7.1.4 WdgeS

An adequate supply of hardwood wedges should be obtained for adjusting piles

while pitching. Sofhvood wedges are likely to split and must not be used.

7.1.5 Timber Block

Stop blocks shall be. provided for the leads to prevent the hammer from being
raised against the head block.

Guards shall be provided across the top of the head block to prevent the cable
from jumping out of the sheaves.
 Fixed leads shall be provided with ladder and adequate attachment points so that
the lot? worker may engage his safety belt lanyard to the leads. If loft platforms
are provided, they shall be protected with standard guardrails.

Steam/air hose leading to the hammer or jet pipe. and all hoses shall be securely
attached with l/4” chain or cable to prevent whip lash.

7.1.6 Ground Support

The ground upon which the crane or rig will stand should be firm and level.
Digger mats or a hard-core standing should be provided if the ground is likely to
subside under the high ground loading imposed by driving or extracting piles.

7.2 Driving Piles

72.1 Pitching

Piles should only be lifted and positioned in the pile gate or onto the leaders or
rig with sound lifting gear adequate for the purpose. Quick release shackles
should be. examined before each use. Where hollow section or concrete piles are
lifted with chains or wire slings, timber or burlap packing should be placed
behveen the lifting gear and the pile. Adequate wxess, such as a cradle or a
properly secured ladder, must be provided for the topman when pitching sheet
piles. The topman must wear stout gloves when pitching.

7.2.2 Driving

Workmen should stand clear of the operation while driving is in progress. The
emergency shut-off valve and the crane or winch controls must be manned at all
times during driving. The foreman must be present and so positioned that he can
be seen by the crane or winch operator and the man standing by the valve. When
driving raking piles, the pile, leaders, and machine must all be. in the same line.
Under no circumstances should any man touch the hammer until all valves are
closed. A system of signals must be arranged behveen the foreman, the winch or
crane operator, and the valve operator, so that the emergency shutdown does not
depend on verbal communication. Where the head of a pile becomes distorted
through driving, no attempt should be made to clear it from the leaders by lifting
or booming up. The pile head should be cut off and the debris cleared from the
IeadeTS.

7.3 Pile Extraction

No attempt should be made to extract piles which have been hammer-driven by lifting or
booming up with a crane. A steam, air, or electric operated extractor should be. used.
Particular attention should be paid to the extractor wedges and the rendition of the
gripping faces, which should not be smooth. Workmen must not walk under piles that are
suspended from extractors.

February 1993 -7.0 F'iliingOpcntiom F-age I51

7.4 General Precautions

7.4.1

Men handling piles or working on piling operations should always wear safety
helm&, safety shoes, safety glasses, stout gloves, and be equipped with ear
protection, preferably of the muff type.

7.4.2

At the start of each shift, hammers and extractors should be. caretidly checked for
loose bolts, etc.

7.4.3

All other equipment should be inspected daily for defects.

7.4.4

Piling operations should never be undertaken except under competent supervision

and with a crew experienced in this class of work. Crane operators shall have a
valid Saudi Arab Government heavy equipment license and a valid Saudi Aramco
certificate (See GI 7.030).

7.4.5

Piling operations are a construction process with special hazards. In addition to

these special hazards, men are exposed to the hazards commonly associated with
all types of constmction work, and precautions against these general hazards
must not be neglected.

hge 152
8.0 ROADWORK!3

A contractor engaged in roadwork is not only responsible for the safety of his own men, he also has an
obligation to protect the public from potential constmction hazards, during the day, at night and in all
weather conditions. Consequently, the marking of constmction sites and the safe and efficient
diversion and control of traffic must be properly planned and executed. Road closure plans must be
submitted to Loss Prevention before roads are closed.

Failure to do this can have disastrous results.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 1021.ooa Street and Road Construction, Excavation, and Maintenance of Traffic Controls
(Appendix D)

GI 2.100 Work Permit System

8.1 General

8.1.1

Saudi Aramco organizations can obtain barriers, lights, etc. from the
Maintenance Department during nom14 working hours. Contractors shall
provide their own barriers, lights, etc..

8.1.2

To avoid creating a traffic hazard, warning devices must not be put in place until
they are needed. They must be promptly removed when work is complete.

8.1.3

Activities which produce dust shall be kept to a minimum.

8.1.4

Permanent road signs and striping shall be restored before the roadway is
returned to service.

8.1.5

The surface of any highway, street, or sidewalk shall be level and in good
condition before any barriers and markers are removed.

8.1.6

Should there be any doubt as to the type of marking and protection required for
roadwork in any location, the Loss Prevention engineer for the area should be
consulted.
 8.1.7

A flagman, equipped with a safety vest and a red flag, shall be posted at least 50
meters (165 feet) from the work site at the eutnmw barricade and another
flagman at the exit barricade. It shall be the duty of the flagmen to control the
flow of traffic in P safe mamer. Both flagmen shall be in sight of each other. If
conditions do not pzmit this, then a third man shall be positioned where he can
see and be seen by the other two men in order to signal them to start or stop
traffic. Traffic control signals shall be in accordance with GI 1021.000. At
night, flagmen shall wear light-reflecting vests and gloves, and use reflective
signs or flags. Flagmen shall be stationed in an illuminated area.

8.1.8

During darkness, the work area will be marked by lights spaced 10 meters (30
feet) apart. Warning lights used in oil operations, industrial, or company
housing areas shall be w&h& proof and positioned 0.6 meter (2 feet) and 0.9
meter (3 feet) above grade.

8.1.9

In addition to the foregoing, excavation work in residential areas shall be. entirely
enclosed, covered over, or roped-off.

8.1.10

Excavations in sidewalks or areas of expected pedestrian traffic shall be provided

with close-planked walkways or bridges 0.9 meters (3 feet) wide and equipped
with standard guardrails.
8.2 Street and Road Construction, Excavations, and Maintenance Traffic
Controls
See Appendix D (GI 1021.000).

Fehmy 1993 _ 8.0 Radwork. hge I54

9.0 WORKING PLACES, LADDERS, AND SCAFFOLDING
Every contractor and every employer of workmen has P legal and contractual responsibility to ensure
that each place at which his mea work is safe. and that it remains safe so long as men work there.
Similarly, each supervisor is responsible for ensuring that every man working under his direction or
control has a safe working place and a safe means of getting to and from every working place.

Where work cannot safely be done on the ground or from part of a building or permanent struchue,
scaffolds, ladders, or other means of support shall be provided and properly maintained.

INSTRUCTIONS AND STANDARDS

The Standards wed for guidance in this section of the Construction Safety Manual are those of the.
American National Standards Institute, Inc. (ANSI) and US Code of Federal Regulations (CFR)
1910.28. Where scaffold manufacturers products meet other scaffold standards that are equivalent to
or higher than ANSI requirements, thea those products can be used. Scaffold products from different
manufachwers shall not be mixed on a scaffold, unless they are specifically designed to be wed
together.

Saudi Ammco Instructions and Standards:

GI 2.100. Work Permit System

GI 6.020. Personal Flotation Devices for Work Over, On or Near Water

GI 8.001. Safety Requirements For Scaffolding (formerly 1009.006)

SAES-P-123. Lighting Utilization

Schedule ‘D’:
Saudi Ammco Safety, Health and Environmental Requirements - Ladders;
Scaffolding; Personal Flotation Devices for Work Over, 00 or Near Water.

American National Standards Instihtte:

Uniform Building Code

ANSI A10.8 - 1988

Scaffolding-Safety Requirements

ANSI A14.1- 1982JANSI A14.la- 1985

Ladders - Portable Wood Safety Requirements

ANSI A14.2 - 1990

Portable Metal Ladders

ANSI A14.3 -1984

Ladders - Fixed-Safety Requirements
ANSI A92.2 - 1990
Vehicle - Mounted Elevating and Rotating Aerial Devices

US. Code of Federal Regulations, 29. CFR Part 1910.28, Safety Requirements for Scaffolding

National Safety Council Data Sheets:

Data Sheet 568. Job-Made Ladders

NFPA 70 - 90 National Electrical Code (NEC)

9.1 Working Places,General

9.1.1 Falls

Within Saudi Aramco, every working place shall be safe and of adequate
dimensions. Where men, tools, or materials could fall 1.8 meters (6 feet) or
more, a guardrail system (consisting of toprails and midrails) and toeboards
shall be provided. Should the provision of these safeguar& be impracticable,
other means of preventing falls, such as safety belts, etc. shall be used. For
further information, see Personal Protective Equipment, Section 1.9, (9.6.5 and
9.6.6) of this Manual.

9.1.2 Acccs and Egress

A safe means of getting to and from a working place shall be provided and
used. Ladders shall conform to the requirements set out in 9.2.

9.1.3 Lighting

Every working place and every means of getting to and from a working place
shall be provided with adequate lighting which shall be properly maintained.
(See SAES-P-M)

9.1.4 Prevention of Falls

Permanent decking, parts of a struchwe, walkways, footbridges, etc., which

men use in the course of their work or for a permanent or temporary access,
shall be provided with a guardrail system and to&oar& (permanent or
temporary) at all edges from which men, tools, or materials could fall 1.8
meters (6 feet) or more. Holes and gaps shall be guarded or securely covered.
Stairs @ermanent or temporary) shall have all treads properly secured and shall
be fitted with handrails throughout their length and conform to the Uniform
Building Code.

9.1.5 Ramps

Where the slope of a ramp exceeds 1 vertical to 4 horizontal, the ramp shall be
fitted with stepping cleats at 0.3 meter (1 foot) intervals. When a ramp is to be.
used by the general public, its slope. shall not exceed 1 vertical to 4 horizontal.
Handrails shall be provided.
 9.1.6 Falling Material

Where there is danger of men being struck by falling material, protective

coverings shall be. erected or No. 18 gauge wire, 112 inch mesh or equivalent,
shall be securely fixed behveen the toeboard and midrail to prevent falling
objects.

9.1.7 Hot surfaces

Suitable precautions shall be taken to prevent men coming into contact with any
hot surface.

9.1.8 Slipping and Tripping

Contractors are responsible for maintaining good housekeeping to prevent

slipping, tripping, and falling. Oil spills, mud, scrap, and other debris must be
cleared up immediately. Men shall not be permitted to walk or work on steel
work or other surfaces onvhich paint or cement wash is still wet.

9.1.9 Roof Work

Where work is done on or from the roof of a building or structure, or where

men have to cross, work on, or work from fragile roofs or surfaces, adequate
protection in the form of crawling boards, roof ladders, or other suitable
covering must be provided to prevent men and materials falling from or through
the roof. Temporary guardrails shall be placed to prevent workers from falling.
If roof work is accomplished on pitched roofs with a slope greater than 1:4,
workers shall be equipped with safety belts that are securely anchored to the.
stluctwe. During storms or high winds, workers shall not be. working on a
roof or scaffold that is exposed to the weather.

9.1.10 losecure structures

Unstable or weak stnuchlres shall be supported by guys, stays, supports, or

other fixings where necessary. If work being done is likely to reduce the
stability of an existing struchlre or building, bracing or other means of support
shall be used. Unstable structures shall not be left unsupported over night.

No wall sector which is more than one story in height, shall be permitted to
stand alone without lateral bracing, unless such wall was originally designed to
do so and is in a safe condition to be. self-supporting. All walls shall be left in a
stable. condition at tbe end of each shift by bracing support jacks, timbers
and/or guy-wired, taking wind force and storm conditions into consideration.

February 1993 - 9.0 Working Places, Lddcn, and Scaffolding k-age 157
 9.1.11 Work over water

9.1.11.1

where men work on, over or near water, a guardrail system and
toeboards, fencing or other suitable barriers shall be provided for the
protection of the worker.

9.1.11.2

Wherever tbe provision of a guardrail system and toeboards, fencing

or other suitable barriers is impracticable, or if for any reawn men
are outside the protection of these. safeguards, suitable life vests shall
be worn and a safety belt or harness securely fixed to a dropline.

9.1.11.3

Approved rescue equipment that meets the requirements of GI 6.020

in the form of life rings with life lines, etc.; where necessary, a
suitably equipped rescue boat shall be readily available, and properly
maintained. Men shall be thoroughly trained in the use of all
protective and rescue equipment, first aid and cardiopulmonary
resuscitation (CPR).

9.2 Ladders and Stepladders

The safety of a ladder depends on four important factors: selection, condition, position
and use. Ladders shall comply with the referenced ANSI or equivalent codes.

9.2.1 S&XtiOtl

9.2.1.1

A ladder must be. of the proper length for tbe job to be. done. If it is
to be used for access or as a working place, it shall rise to B height of
36 inches to 42 inches above the landing place or above the highest
rung to be reached by the feet of the man using the ladder.

9.2.1.2

Metal ladders, ladders with metal reinforced side rails, and ladders
which are wet shall not be used near electrical equipment with
exposed live conductors. Such ladders shall have a warning notice
attached to guard against use near electrical equipment.

9.2.1.3

Aluminum ladders shall not be used where there is a likelihood of

contact with materials harmful to aluminum, such as caustic liquids,
damp lime, wet cement, etc.
9.2.2 Condition

9.2.2.1

Each ladder shall be. examined before use. Those. with split or
broken side rails, missing, broken, loose, decayed or damaged rungs
or cleats, or with other faulty equipment shall be. tagged and
removed from service.

9.2.2.2

Rungs shall be properly mortised into side. rails. Cleats shall be

inset by 2.25 centimeters (7/8 inch), or tiller blocks used on the side
rails between the cleats. Cleats shall be uniformly spaced 30.5
centimeters (1 foot) between centers.

9.2.3 Position

9.2.3.1

The side rails of a ladder shall be equally supported on a firm level

surface. Boxes, blocks, barrels, etc. shall not be used as a means of
support. The area at the base of a ladder must be kept clear.
Ladders shall not be wed in a horizontal position as platforms,
runways or scaffolds.

9.2.3.2

Ladders shall not be supported on their rungs or cleats. Rungs or

cleats shall not be used to support planks.

9.2.3.3

Whenever possible, ladders shall be set at an angle of 75“ to

horizontal ground (i.e., one meter out to four meters up).

9.2.3.4

Metal reinforcing shall be on the underside of the lungs and where

reinforcing is on only one side of the side rails, that too shall be on
the underside.

9.2.3.5

Both side rails of a ladder shall be evenly supported at the upper

resting place. Side rails must be securely tied off to prevent
movement. Where secure fixing is impracticable, other maswes
must be taken to prevent movement by securing at the base, using
side guys, or stationing a man at the base. It must be understood,
however, that a man stationed at the base will be. unable to control a
ladder more than 6 meters (20 feet) in length.
 9.2.3.6

Where there is a possibility of a ladder being struck by moving

vehicles or equipment, a man should be placed on guard or a space at
the base should be. securely fenced off. If a ladder is erected close to
a dcxxway, the door should either be locked, shut, or be secured in
the open position with a man on guard or properly barricaded.

9.2.3.1

Ladder landing places shall be provided at least every 9 meters (30

feet) of height and shall be fitted with a guardrail system and
toeboards. Holes in decking through which ladders pass shall only
be enough to petit passage of the man using the ladder.

9.2.3.8

A ladder should always be placed so that there is space behind each

rung or cleat for a proper foothold. There should be no obstruction
in the way of a man’s foot, particularly at the landing platform.
Here the rung or cleat should be level with the platform.

9.2.3.9

Where ladders have to be suspended, bath side rails shall be lashed

top and bottom so as to provide equal support. Where long ladders
are used, they shall also be lashed at the center to prevent lateral
movement.

9.2.4 USI?

9.2.4.1

Where an extension ladder is used fully extended, the minimum

overlap depends on the extension ladder length, and overlap should
be a.9follows (examples):

9.75 to 10.97 meters (32 to 36 feet) = 1.22 meters (4 feet) overlap

10.97 to 14.63 meters (36 to 48 feet) = 1.52 meters (5 feet) overlap

Splicing or lashing ladders together shall not be permitted.

9.2.4.2

Before mounting a ladder, personnel shall check their shoes for

freedom from grease, oil or mud. They shall always step through,
not around, the rail extensions at the top of the ladder.
 9.2.4.3
0 Single rung and single cleat ladder should be used by only one man
at a time. When ascending or descending personnel shall face the
ladder and keep both hands on the ladder. Personnel shall not run
up or down or slide down a ladder at any time. The width of single
cleat ladders shall be at least 38.1 centimeters (15 inches) but not
more than 50.8 centimeters (20 inches) behveen rails at the top.

9.2.4.4

Men ascending or descending ladders shall not carry tools and

materials in their hands. Tools may be carried in pockets or on
special belts provided there is no risk of injury and movement is not
impaired. Materials shall be raised or lowered using a handline after
being securely tied or placed in a basket.

9.2.4.5

A man working on or from a ladder must always have a secured

handhold and both feet on the same rung or cleat. If the work to be
done requires the use of both hands, a safety belt is required,
securely fixed to a dropline (life line). Only one person shall be on a
ladder at a time.

9.2.4.6

Job-made ladders shall be constructed for intended use. If a ladder is

to provide the only means of access or exit from a working area for
25 or more employees, or if simultaneous hvo-way traffic is
expected, a double cleat ladder shall be installed.

Double cleat ladders on Saudi Aramco construction sites shall not

exceed 4.5 meters (15 feet) in length.

Single cleat ladders shall not exceed 4.5 meters (IS feet) in length
between supports (base and top landing). If ladders are to connect
different landings. or if the length required exceeds this maximum
length, hvo or more separate ladders shall be used, offset with a
platform between each ladder. A guardrail system and toeboards
shall be erected on the exposed sides of the platforms.

5.08 by 10.16 centimeters (2 by 4 inches) lumber shall be. used for

side rails of single cleat ladders up to 4.5 meters (15 feet) long.

5.08 by IO.16 centimeters (2 by 4 inches) lumber shall be used for

side and middle rails of double cleat ladders up to 3.6 meters (I2
feet) in length; 5.08 by 15.24 centimeters (2 by 6 inches) lumber for
double cleat ladders from 3.6 by 4.5 meters (12 to 15 feet) in length.

Wood cleats shall have the following minimum dimensions when

made of weeds that meet ANSI requirements for ladders:
 LENGTH OF CLEAT THICKNESS WIDTH
Up to and includiig 1.9 cm (.75 in) 7.62 cm (3 in)
50.8 cm (20 inches)
Over 50.8 cm (20 in.) and up 1.9 cm (.75 in.) 9.52 cm (3.75 in.)
to
and including 76.20 cm (30
ill.)

Cleats may be made of species of any other group of wood provided

equal or greater strength is maintained.

Cleats shall be inset into the edges of the side rails one&If inch, or
tiller blocks shall be used on the rails behveen the cleats. The cleats
shall be secured to each rail with three 1Od common wire nails or
other fasteners of equivalent strength. Cleats shall be uniformly
spaced, 30.48 centimeters (12 inches) behveen centers.

9.2.4.1

Metal ladders shall not be used for work on electrical systems unless
the ladders are speitically designed for that application.

9.2.5 Stepladders

Generally, the foregoing remarks on selection, condition and use of ladders

apply equally to stepladders. The following requirements also apply:

9.2.5.1

To ensure. stability, stepladders shall be spread to their fullest extent

limited by manufacturer’s braces when in use. Whenever possible,
they should be placed at right angles to the work with either the front
or back facing the work.

9.2.5.2

Do not stand, climb or sit on the stepladder top, pail shelf, braces or
back section.

9.2.6 General

9.2.6.1

Ladders and stepladders shall be maintained in good condition at all

times. Joiots shall be tight, all hardware and fittings shall be
securely attached, and movable parts shall operate. freely without
bindiig or undue. play.

9.2.6.2

Ladders and stepladders must not be painted.

 9.2.6.3

Where a ladder is carried by one man, the front end should be kept
high enough to clear mea’s heads and special care shall be taken at
corners and blind spots.

9.3 Scaffolding Components

9.3.1

All scaffold struchwea shall be erected with metal components approved per
ANSI requirements or equivalent. Scaffolds shall be. stored to prevent damage
and to permit easy access for we. Scaffold erection plans (drawings) shall be
submitted to Loss Prevention Department for review prior to men being allowed
to work on the scaffold.

9.3.2 Tubing

Ordinary scaffold tubing is 4.8 centimeters (l-29132 inches) in diameter and

nominal wall thickness 0.4 centimeter (5132 inch) and is referred to as hvo-inch
nominal diameter tubing. It is mild steel and normally supplied in lengths of
6.4 meters (21 feet). Tubes must meet ANSI or equivalent requirements and
must be free from cracks and surface flaws, laminations, excessive rust and
other defects. The ends shall be cut square and cleanly. A tube shall not
deviate from a straight line by more than 11600 of its length measured at the
center of the tube length.

9.3.3 Aluminum Tubing

9.3.3.1

Although the aluminum tubing is dimensionally interchangeable with

steel hlbing, it must not be used in the same struchwe; the difference
in the elastic modulus of the two materials results in greater
deflection in aluminum tubing for the same loading conditions.

9.3.3.2

Aluminum tubing shall not be wed where there is likelihood of

contact with materials harmful to aluminum such as caustic liquids,
damp lime, wet cement and sea water.

9.3.4 Fittings

AI1 fittings (couplers, clamps, etc.) shall be of a metal type approved to ANSI
or equivalent requirements. They shall be examined regularly and care must be
taken to enswe that moving parts are sound and well lubricated and that threads
are. not stripped.
 9.3.5 Typical ScatTold Fittings

(Figures II.17 - U.22)

RosePlate: A 15 centimeter (6 inch) by 15 centimeter (6 inch) steel plate

greater than 0.64 centimeters (l/4 inch) thick providing a flat bearing surface for
load distribution from posts. It has an integral spigot and fixing holes for use
with sills.

Screwjacks: Used for compensating variations in ground levels.

Standard Coupler: Also known as a Right Angle or 90° Coupler. A load

bearing coupler used for connecting hvo h&es together at right angles.

Ar@stahle Coupler: Used for connecting two h~bes together at any angle
through 3600. Not to be used where a load bearing standard coupler is
required.

End-to-End Coupler: Also known as a Sleeve Coupler. Used for connecting

hvo hlbe.s end-to-end.

Reveal Pin: Inserted into the end of a tube and adjusted to form a rigid
horizontal or vertical member behveen hvo opposing surfaces. It forms a solid
anchorage to which a scaffold can be tied.

9.3.6 Planks

9.3.6.1

Planks shall be of rough timber and graded as scaffold planks

without defects (2” x 9”). 5 centimeters (2 inches) thick by 23
centimeters (9 inches) wide, and shall conform to the following
specifications:

1 All planking shall be Scaffold Grade to ANSI requirements

2 00 the face of the plank, the ends shall not be split up more than
30.5 centimeters (1 foot), without fixed banding or the end
bolted through.

3 On the face. of the plank, not more than one third the width in
any one place shall be knot wood.

4 On the edge of the plank, not more than half the depth shall be
knot wood.

5 On the edge of tbe plank, the grain shall not cross from face-to-
face.within a distance of less than 30.5 centimeters (1 foot).

6 From end-to-end, the plank must not be h&ted by more than

1.3 centimeters (l/2 inch).

Pcbmary 1993 - 9.0 Working Ptaces, Ladden, and kaflolding Page 164
 7 Scaffold planks shall meet the loading requirements of Table
11.2.

9.3.6.2

Planks shall not be painted or treated in any way that would conceal
defects.

9.3.6.3

Planks which are split, decayed or warped shall not be used, but the
part.9 affected may be cut off to produce shorter planks with the ends
banded or bolted through.

9.3.6.4

Planks should be stacked on a suitable foundation. where. the height

of B stack exceeds 20 planks, measures should be taken to tie or bond
suc4%ding layers.

9.3.6.5

Planks should not be stood on end unattended.

9.3.6.6

Scaffold planks shall not be used for shuttering for concrete, shoring
for trenches, or as sills for scaffolding. Planks shall be inspected for
defects, including decay, prior to each use.

9.3.6.7

The design working load of each platform unit (i.e., plank) shall be
capable of supporting without failure one or more 91 kg (200 lb)
person with 22.7 kg (50 lb.) of equipment.

9.3.6.8

PI&foam units rated for one. person capacity shall be de-signed and
constructed to carry 113.6 kg (250 lb.) at the center of the span.

9.3.6.9

Platform units rated for two persons shall be designed and

constructed to carry a working load of 227 kg (500 lb.) : 113.6 kg
(250 lb.) placed at 0.46 meters (18 inches) to the left and right of the
center of the span.

February 1993 - 9.0 Work&~ Phccs, Lddcn. ,nd k,ffoldi Page 165
 9.3.6.10

Platform units rated for three persons shall designed and constructed
to carry a working load of 341 kg (750 lb.) : 113.6 kg (250 lb.)
placed at 0.46 meters (18 inches) to the left and right of the center of
the span, and at the center of the span.

9.3.6.11

The design loads in sections 9.3.6.7 to 9.3.6.10 are not to be added

to uniformly distributed loads for light, medium and heavy duty
scaffold (i.e., 25, 50 and 75 Ib./ft2 respectively), but are shown as
alternates.

9.3.6.12

Each platform, where applicable, shall be designed and constructed

to carry B uniformly distributed load as an alternate to the person
loading of 9.3.6.7 to 9.3.6.10. Uniformly distributed loads and
person loading are not cumulative and the most restrictive loading
shall be used for platform design.

9.3.6.13

Light, medium and heavy duty uniformly distributed load

requirements shall be 25, 50 and 75 pounds per square foot
respectively. Greater uniformly distributed loads shall be specially
designed.

TABLE lL2: WOOD SCAFFOLD PLANK LOADING CHART

Pemissihle Span (ft)

I Douglas Fir or
I
SpIW
I
Southern Pine Rough Sam

2inx loin l-718 in x 9-718 in

I Nominal or I

Loading Condition 1 I-1/2inx9-1/4inAchul 1 2inx9in I

One worker or medium-duty IO ft I 8ft I
Two workers or heavy-duty 8ft 7ft

Three workers sft 5ft

REFERENCE: ANSI AlO.%1988

FIGURE 11.17: STANDARD COUPLER FIGURE Il.18: ADJUTABLE COUPLER
(Bearers, Runners) (Brace6 Only)

FIGURE 11.19: TYPICAL END To END COUPLER ~CURE U.20: SCREWJACK

FIGURE II.21 TYPICAL REVEAL PIN FIGURE II.22 TYPICAL BASE PLATE
9.4 Requirements Common to All Scaffolding
9.4.1 Foundations

9.4.1.1

A sound base is essential; therefore, the ground or floor on which a

scaffold is going to stand must be carefully examined. Sand or
made-up ground may need compacting to ensure there are no
cavities. Such bases as floors, roofs, etc. may need shoring from
underneath.

Scaffolds, including components, shall be. capable of supporting

without failure at least 4 times the maximum intended load.

9.4.1.2

Timber sills at least 23 centimeters (9 inches) wide by 3.8

centimeters (l-1/2 inches) thick (not scaffold planks) will be required
to spread the load on sand, made up ground, asphalt pavement,
wooden floors, and slippery surfaces. A sill shall extend under at
least hvo posts.

9.4.1.3

Where scaffolding is erected on a solid bearing such as rock or

concrete, small timber pads may be used in place of sills and nailed
to prevent the base plates sliding off.

9.4.1.4

Concrete blocks, barrels, and other loose or unsuitable material shall

not be used for the construction or support of scaffolding.

9.4.1.5

If used to compensate for variations in ground level, the screwjack

shall not be adjusted to more than two-thirds of the total length of
the thread. The base plate shall be. of a type approved for supporting
scaffolding posts. (See manufacturer’s specifications.)

9.4.2 Post.5

9.4.2.1

Posts shall be pitched on 15 centimeters (6 inches) by 15

centimeters (6 inch) steel base. plates and at least 0.64 centimeter (l/4
inch) thick. Join!s in posts should be staggered, i.e., joints in
adjacent posts should not occur in the same lift. All posts shall be
vertical.

February 1993 - 9.0 Working P&cs, Ladders, and Scaffolding Page 168
 9.4.2.2

The inner row of posts shall be placed as close as possible to the Face
of the building or struchwe. To avoid projections, the posts may be
up to 41 centimeters (16 inches) away From the wall or structure as
wxssary, provided that, where. there is room to do so, the gap
between the wall or stluchwe and the inner posts shall be closed with
planks on extended board bearers. The outer row of posts shall be
positioned From the inner row of posts depending on tbe load
requirements of tbe scaffold, and the working platform shall be Fully
decked out.

9.4.3 RlUUlW

9.4.3.1

Runners shall te securely fixed to posts with standard couplers and

shall be horizontal. Joints in runners should be staggered, i.e.,
joints in adjacent runners should not occur in the same bay. Runners
should be secured end-to-end by sleeve couplers, not by joint pins.

9.4.3.2

Runners shall be vertically spaced no more than 2.0 meters (6 Feet, 6

inches) to give adequate headroom along the platforms.

9.4.4 Bearers

Bearers should be installed behveen posts and securely f&d to the posts
bearing on tbe runner coupler and secured with standard couplers. When
coupled directly to the runners, the coupler must be kept as close to the posts as
possible. These bearers must remain in position as they are a structural part of
the scaffold.

9.4.5 Board Bearers

Board bearers shall be installed between bearers to accommodate differences in

plank lengths.

Board bearers shall be secured to the runners behveen bearers where necessary
to support platform units (planks). These may be removed when no longer
required to support platform units.
9.4.6 Braeiltg

9.4.6.1

Cross bracing shall be installed across the width of the scaffold at

least every third set of posts horizontally and every fourth runner
vertically. Such bracing shall extend diagonally from the inner and
outer runners upward to the next outer and inner runners. These.
braces should be fixed to the nmne.rs with standard couplers as close
to the posts as possible. Where such a fixing is impracticable,
adjustable couplers may be used to fix the braces to the posts. (See
Figures II.23 and 11.24.)

9.4.6.2

Longitudinal diagonal bracing shall be installed at approximately 45

degree angle from near the base of the first outer past upward to the
extreme top of the scaffold. Where possible, such bracing shall be
duplicated at every fifth past. On short but high runs, diagonal
bracing shall he installed at an angle of 45 degrees from the base of
the first outer post to the last outer post and shall alternate directions
to the top of the scaffold. When bracing cannot be attached to the
posts, this bracing may be attached to the runners, as close as
possible to the posts. Only standard couplers or adjustable couplers
may be used. Joints in braces shall he made with end-to-end or
parallel couplers.

9.4.6.3

Temporary rakers (inclined load-bearing tube supports) brace the

scaffold against the ground when setting out. These rakers are
replaced by permanent braces when the scaffold has been plumbed,
leveled and tied. Rakers must be secured with proper couplers at the
scaffold and coupled to a ground stake.

9.4.1 Ties

9.4.7.1

It is essential that all scaffolds, with the exception of certain tower

and mobile scaffolds (See 9.7 and 9.8), be securely tied to the
building or structure throughout their length and height to prevent
movement of the scaffold either towards or away from the building
or struchw.. This should be done by connecting a tie tube to both
runners or posts and coupling this to a hvo-way tie or column box tie
assembly. (See Figures 11.25 and 11.26.)

9.4.7.2

Where the foregoing is impracticable, tubes may be securely wedged

behveen opposing surfaces on the building or structure by the use of
reveal pins and coupled to the tie h&s (Figure 11.27). Where. reveal
 ties are. used, they shall not exceed 50% of the total number of ties.
Two-way ties or column box ties shall be evenly distributed over the
scaffold area. To ensue the security of reveal ties, it is necessary to
check frequently for tightness.

9.4.7.3

Ties shall occur at tbe top of the scaffold and at least every 7.9
meters (26 feet) vertically and 9.1 meters (30 feet) horizontally and
at each end of the scaffold. All tie assembly connections shall be
made with standard couplers.

9.4.8 Platform unit.5

9.4.8.1

All platform units (i.e., planks, fabricated decks, etc.) shall be

closed planked with, whenever practicable, each plank resting on at
least three supports. Planks shall extend over their end supports by
not less than 15 centimeters (6 inches) and not more than 30.5
centimeters (12 inches).

9.4.8.2

Supports for scaffold planks shall be spaced with due regard to the
nature of the platform and the load it will bear. (See Table 11.2.)

9.4.8.3

Except on platform units adjacent to the surface df a cylindrical or

spherical structure, planks shall be laid flush.

9.4.8.4

Planks shall be. secured in position to prevent displacement by high

winds.

9.4.8.5

Adequate space for men to pass in safety shall be provided and

maintained wherever materials are. placed on platform units or if any
higher platform is erected thereon.

9.4.8.6

Platform units shall be kept free of unnecessay obstructions,

materials. and projecting nails.

9.4.8.1

Platform units which have become slippery with oil or any other
substance shall be cleaned, or otbenvise removed and replaced.
 9.4.8.8

Slopes in platform units shall not exceed 1 vertical to 4 horizontal

and stepping cleats at 0.3 meter (1 foot) intervals shall be provided.

9.4.8.9

All platform units shall be closed planked for the full width of the
scaffold structure.

9.4.9 Guardrail Systems and To&oards

9.4.9.1

Guardrail systems (consisting of toprails and midrails) and to&cards

shall be installed at all open sides and ends of all scaffolds and
supports oo no nwre than 3-m&r (lo-foot) centers from which men
or materials could fall a distance of more than 1.8 meters (6 feet).
Toprails shall be no less than 0.91 meter (36 inches) and no more
than 1.14 meters (45 inches) above the working surface; midrails
shall be installed equidistant behveen the working surface and the
toprail. Toeboards shall not be less than 10 centimeters (4 inches) in
height by 2.5 centimeters (1 inch) thick. Guardrail systems and
toeboards shall be. securely fixed to the inside of posts to withstand a
lateral thrust of 200 pounds.

9.4.9.2

Landings: Safe landings shall be provided at the top of all ladders.

Rings shall be eliminated above the landing level, and side rails shall
extend 36 to 42 inches above the landing for mounting and
dismounting. Where multiple ladders are required, solidly decked
platforms shall be provided. Guardrails, intermediate rails and
toeboards shall be erected on the outside edges and exposed sides of
the platform.

9.4.10 Awes

Access to a working platform is best achieved by providing a separate ladder

tower or a cantilevered access platform so as not to obstruct the working
platform and to minimize the risk of persons falling through gaps in the
guardrail system or platform units. Access must be provided to working
platforms.

9.4.11 Scaffold Ladders

Scaffold ladders provide the means of access and egress for scaffolds. They can
genemlly be classified as follows:

Fcbnury 1993 - 9.0 Working Places, Ladden, md Scaffolding hge 177.

9.4.11.1 Portable Straight and Extension Ladders
(Figure II.24)

A straight ladder is a portable ladder that only consists of one section

which determines its overall length. It cannot support itself or be
adjusted in length.

An extension ladder is a portable ladder that cannot support itself but

cm be adjusted in length. It consists of hvo or more. sections which
are arranged to permit length adjustment. Its overall length is the
sum of the length of all its sections measured along the side rails.

Portable straight and extension ladders shall have a firm base and be.
positioned with a slope of 1:4.

9.4.11.2 Vertical Ladder

A vertical ladder is a type of fixed ladder which is permanently

attached to the horizontal or vertical components of a scaffolding.

The main criteria to consider in the use of a vertical ladder is

clearance. The following clearance guidelines shall be used.

l Gene-d:

Safe clearances shall be maintained to prevent workers from

bumping into, or snagging onto, projecting objects while
ascending or descending the ladder.

l Climbing Side:

Ladders shall have a minimum clear perpendicular distance of 30

inches from the rungs to the nearest projecting object on the
climbing side. When unavoidable obstructions are encountered,
the minimum clearance distance may be reduced to 24 inches if
deflector plates are provided.

l Back Side Of Ladder:

The perpendicular distance from the face of the rung on the

climbing side to the nearest fixed object on the back side of the
ladder shall not be less than 10 inches. When unavoidable.,
horizontal obstructions (e.g. beams, pipes, etc.) are
encountered, the vertical toe. clearances specified in the
following sections, shall apply.

. Side Clearance:

The minimum clear distance to the nearest fixed object shall be

15 inches on each side of the centerline of single rung ladders.
 . Vertical Clearance:

The minimum vertical toe clearance from horizontal obstructions

shall be 1 l/2 inches below and 4 112 inches above the top edge
of the rung.

l Multiple Ladders:

When hvo or more separate ladders are used with a landing

platform, the side-step distance. shall be a minimum of I5 inches
from the centerline of tbe upper ladder to the near side of the
lower ladder.

9.4.12 worlmlanship

9.4.12.1

Scaffolding shall be erected, altered, and dismantled by experienced

men working under tbe direction of a competent supervisor.

9.4.12.2

Posts shall be set accurately in place and checked vertically by using

a spirit level or by using vertical lines on the building or stmchue.

9.4.12.3

Scaffolding couplers should be tightened with proper scaffolding

spanners. The use of an ordinary spanner or tool giving greater
leverage could damage the screw threads and render the coupler
unserviceable.

9.4.12.4

Scaffolding materials shall not be thrown or dropped from heights.

9.4.13 Insp&ions

All scaffolds shall be. inspected regularly by a competent Supervisor and after
adjustments, modifications, adverse. weather conditions, etc. Erected scaffolds
and platforms should also be inspected continuously, by those using the
scaffold, to insure. that the scaffold has not been altered and is in a safe working
condition.

9.5 Fabricated Tubular Frame and SystemScaffolding

Fabricated hlbular frame and system scaffolding are composed wholly or partly of
prefabricated sections. There are many types of fabricated tubular frame and system
scaffolding available which vary in design and methods of erection; however, the same
basic principles set out in 9.4 apply and the following matters warrant particular
attention. All scaffolds must be erected as per manufacturer’s direction and limitations.
A scaffold plan needs to be submitted to Loss Prevention Department for review. (See
Figures 11.28 to 11.31)

9.5.1

To be. erected, altered and dismantled by experienced men, under the direction of
* competent Supervisor.

9.5.2

Periodic inspections shall be made. of all pats and accessories. Broken, bent,
altered, excessively rusted or othewise structurally damaged frame.5 or
accessories shall not be used.

9.5.3

All fabricated tubular frame and system scaffolding shall be constructed and
erected to support four times the maximum intended loads.

9.5.4

Scaffold posts shall be pitched on steel base plates and on timber sills or pads as
WXS=Iy. Screwjacks shall be used to compensate for variations in ground
level.

9.5.5

Scaffolds shall be properly braced by cross braces and longitudinal diagonal

braces for securing vertical members together. Tbe cross braces shall be of such
length as will automatically square and align vertical members so that the erected
scaffold is always plumb, square, and rigid. All brace connections shall be made
secure.

9.5.6

The frames or posts shall be placed one on top of the other with coupling or
stacking pins to ensure proper vertical alignment of the legs.

9.5.7

The frames and posts shall be locked together vertically by pins or other
equivalent suitable means.

9.5.8

Fabricated tubular frame and system scaffolding over 38 meters (12.5 feet) in
height shall be specially designed by a Professional Engineer. In Saudi Aramco,
scaffold heights are limited to a maximum height of 12.2 meters (40 feet), unless
a scaffold plan has been reviewed by the Area Loss Prevention Division
representative prior to construction. Scaffolds above 12.2 meters (40 feet)
should be constructed using scaffold contractors; however no scaffolds shall
exceed 38.1 meters (125 feet) unless the design has been reviewed by an Area
 Loss Prevention Division representative, Consulting Services Department and
approved by a qualified engineer. (See.also GI 8.001, section 6.1.1.)

9.6 Tube and Coupler Scaffolds

(Tube and Coupler Construction - Figure 11.23)

9.6.1 Independent Tied Scaffold

An independent tied scaffold (also commonly known as a double pole scaffold)

consists of a double row of posts connected together longitudinally with runners
and with bearers at tight angles to the runners. Braces and ties are essential for
stability. Independent tied scaffold is the most common form of tube and
coupler scaffolding and is divided into three groups.

In Saudi Aramco the height limitation of the hlbe and coupler scaffold shall not
exceed 12.2 meters (40 feet) unless a scaffold plan proposing to use such a
scaffold at a greater height has been reviewed by the Loss Prevention
Department per the provisions of Section 9.5.8.

I Light Duty: for painting, cleaning, etc.

2 Medium Duty: when materials are deposited on the platfonnr.
3 Heavy Duty: where the deposited material is of a more substantial
nature.

9.6.2 Light Duty Tube and Coupler Scaffolds

(For general requirements, see 9.4 and 9.5)

9.6.2.1 Design, Loading and Dimensions

A light duty tube and coupler scaffold can have up to three working
platforms in use at any one time, and the maximum distributed load
on the platform shall be 1.2 kPa (25 Ib./sq. ft) with pasts 3.05
meters (IO feet) ‘apart longitudinally and 1.83 meters (6 feet)
transversely.
TABLE 11.3: TUBE AND COUPLER SCAFFOLDS--LIGHT DUTY

Uniformly distributed load Not to exceed 25 p.s.f.

Post Spacing. (longitudinal) 10 ft. 0 in.
Post Spacing (transverse) 6 ft. 0 in.

Working Levels Additional Planked Maximum Height

Level.9

1 8 125 ft.
2 4 125 ft.
3 0 91 ft. 0 in.

Reference: CFR 1910.28

 9.6.2.2 Platform

The platform between posts should be decked out with 23

centimeters (9 inches) wide by 5.1 centimeters (2 inches) thick
planks. Bearers may be cantilevered for use as brackets to carry not
more than hvo planks between the building and inner post.

9.6.2.3 Limitations

Light duty tube and coupler scaffolds erected in accordance with

these directions may be used up to a maximum height of 38.1
meters (125 feet) and limited to a uniformly distributed load of 25
Ib./ft2. Light duty tube and coupler scaffolds departing from these
directions shall be. specially designed or designed to a higher rating
such as medium or heavy duty.

9.6.3. Medium Duty Tube and Coupler Scaffold

(For general requirements, see 9.4)

9.6.3.1 Design, Loading, and Dimensions

A medium duty hrbe and coupler scaffold may have up to hvo

working platforms in use at any one time. The maximum distributed
load on each platform shall not exceed 2.39 kPa (50 Ib./sq. ft) with
posts not more than 2.4 meters (8 feet) apart longitudinally and 1.83
meters (6 feet) transversely.
TABLE II.4 TUBE AND COUPLER SCAFFOLDS--MEDIUM DUTY

Uniformly distributed load Not to exceed 50 p.s.f.

Post Spacing: (longitudinal) 8 h. 0 in.
Post Spacing (transverse) 6 A. 0 in.

Working Levels Additional Planked Maximum Height

Levels

1 6 125 h
2 0 78 h. 0 in.

Reference: CFR 1910.28

9.6.3.2 Platform

The platform between posts should be decked out with 23

centimeters (9 inches) wide by 5.1 centimeten (2 inches) thick
planks. Bearers may be cantilevered for use as brackets to carry not
more than hvo planks behveen the building and inner post.
 9.6.3.3 Liiitations

Medium duty tube and coupler scaffolds erected in accordance with

these directions may be used up to a maximum height of 38.1 meters
(125 feet) and limited to a uniformly distributed load of 50 lb./ft2.
Medium duty tube and coupler scaffolds departing from these
directions shall be specially designed or designed to a higher rating
such as heavy duty.

9.6.3.4 Bearers

Bearers on medium duty hlbe. and coupler scaffolds shall be 6.35

centimeters (2.5 inches) outside diameter steel tube and of nominal
wall thickness of 0.4 centimeter (S/32 inch).

9.6.4 Heavy Duty Tube and Coupler Scaffolds

(For general requirements, see 9.5)

9.6.4.1 Design, Loading and Dimensions

A heavy duty tube and coupler scaffold has one working platform
with a maximum distributed load of 3.6 kPa (75 lb./sq ft) on the
platform. The posts shall be no more. than 2.0 meters (6 feet, 6
inches) apart longitudinally and 1.8 meters (6 feet transversely).
TABLE H.5: TUBE AND COUPLER SCAFFOLDS--HEAVY DUTY

Uniformly distributed load Not to exceed 75 p.s.f.

Post Spa&a (longitudinal) 6 ft. 6 in.
Post Spa&a (transverse) 6 ft. 0 in.

Working Levels Additional F’lanked Levels Maximum Height

1 6 125 ft.

Reference: CFR 1910.28

9.6.4.2 PldfOllll

The platform behveen the posts shall be decked out with 23

centimeters (9 inches) wide by 5.1 centimeters (2 inches) thick
ph&.

9.6.4.3 Limitatiolls

Heavy duty tube and coupler scaffolds erected in accordance with

these directions may be wed up to a maximum height of 38.1 meters
(125 feet). Heavy duty tube and coupler scaffolds departing from
these directions shall be specially designed.

Febnmy 1993 - 9.0 Working Flaccs, hiden, md kHdding F-age 178

 9.6.4.4 Beam?

Bearers on heavy duty tube and coupler scaffolds shall be 6.35

centimeters (2.5 inches) outside diameter steel tube and be of
nominal wall thickness 0.4 centimeter (S/32 inch).

9.7 Free-StandingTower Scaffolds

A free-standing tower scaffold consists of four or more posts connected together
longihldinally with numers and bearers at right angles to tbe runners, forming a square or
rectangular tower (see Figure 11.32). AItematively, a free-standing tower scaffold may he
constructed of a fabricated tubular frame or system scaffolding (see 9.5). A free-standing
tower scaffold has a single working platform and is a common form of access scaffolding
for painters and others who do work of a light nahlre and of short duration.

9.7.1 General Requirements

For general requirements, see 9.4 and where a fabricated tubular frame or
system scaffolding is to he used, see 9.5.

9.7.2 Design, Loading and Dimensions

A free-standing tower scaffold shall have only one working platform and the
maximum distributed load shall not exceed the load rating which is detetined
by the platform unit type and the scaffold duty.

The height from the base to working platform of a free-standing tower scaffold
shall not exceed four times the minimum base. dimension. In no case. shall the
minimum base dimension be less than 1.2 meters (4 feet).

9.7.3 Runners and Beaws

The vertical spacing of runners and bearers shall be 2.0 meters (6 feet, 6
inches). The lowest nmners and bearers shall he as near to the base as possible.
Runners and bearers shall be secured to the pasts with standard couplers.

9.7.4 BlWilIg

Sway bracing is necessary on all four elevations to the full height of the
scaffold. Plan bracing is also required at the base, at the top, and at every third
lift to prevent racking.

9.7.5 Ties

Free-standing tower scaffolds more. than 9.8 meters (32 feet) in height shall be
adequately tied to a building or struchue. Where tying to a building or
structllre is impracticable, one of the following methods of ensuring stability
shall be used (see Figures II.33 to 11.35):
 1 Guy wires at a slope of approximately 45” connected to the working
platform level of the tower.
2 Bottom corners of the tower securely anchored.
3 Outriggers extending to the ground.

The strength of the guy wires or of the anchorage wed shall be calculated,
having due regard to the horizontal wind forces and other known forces which
may be applied to the tower. These calculations shall be reviewed by Loss
Prevention Department.

9.7.6 lwfoml

The single working platform of a free-standing tower scaffold shall not project
beyond the base area and the platform unit(s) shall be securely fixed in position.

9.7.7 ACCSS

Where the means of access to the working platform is outside the tower
structure, due consideration must be given to the effect of such means of access
on the stability of the scaffold. Where a sloping ladder would cause instability,
a securely fixed vertical ladder may be used.

9.1.8 Limitations

Free-standing tower scaffolds erected and used in accordance with these

directions and with one working platform may be used up to a maximum height
of 12 meters (40 feet) to the work platform. Free-standing tower scaffolds
departing from these directions shall be specially designed.

9.8 Mobile Tower Scaffolds

(Figure 11.31)

The requirements for free-standing tower scaffolds in 9.7 also apply to mobile tower
scaffolds with the exception that wheels are used in place of base plates and sills.

9.8.1 Foundations

Wheels or casters, not less than 12.7 centimeters (5 inches) in diameter, and
fitted with brakes, which cannot be released accidentally, shall be securely fixed
to the bases of the posts by lock pins or dowels.

A mobile tower scaffold shall only be used and moved on surfaces sufficiently
firm and level to ensure stability. where the scaffold is to be used on a
suspended floor, it shall be designed to apply loads no greater than the bearing
capacity of the floor.

Temporary foundations or track laid on soft or uneven ground to facilitate the

erection and movement of the tower shall be constructed and anchored so that
its bearing capacity is not exceeded due to imposed loading from the tower.
The track shall be level and properly secured.
 9.8.2 Operation

A mobile tower scaffold shall be moved only by pushing or pulling at the base.
Force. must not be applied at a height greater than 1.4 meters (4 feet, 6 inches)
above the base. No men, equipment or materials shall be on the working
platform or elsewhere on the structure while it is in motion. Wheel brakes shall
be applied at all times when men are on the stationary mobile tower scaffold.

9.8.3 Liiitations

Mobile tower scaffolds, erected and used in accordance with these directions,
supported on four wheels and with one working platform, may be used up to a
maximum height of 12 meters (40 feet). Mobile tower scaffolds departing from
these directions shall be specially designed and properly secured (See 9.7.5).

9.9 Scaffolds for Tanks and Vessels

Tube and coupler scaffolds for tanks and vessels shall be erected in accordance with 9.6.
Secure tying to the structure is essential for stability.

9.9.1 Bracket Scaffolds

9.9.1.1

Brackets and bracket straps shall be constructed, fixed and erected in

accordance with the manufacturer’s instructions.

9.9.1.2

It is essential that the brackets, straps and welds are of sufficient

strength to support the weight of the scaffold, men, tools and
materials.

9.9.1.3

The bracket straps shall be welded to the wall of the tank by a

certified welder. The weld shall be a full 5 millimeters (3116 inch)
fillet. Prior to welding on any tank, approval is required from Saudi
Aramco Consulting Services Department.

9.9.1.4

The weld shall be made with the same type of electrode a.. used for
the main tank weld joints. Before the bracket is attached to the
strap, the weld shall be inspected by a competent welding inspector
or welding supervisor who will approve and accept the weld.

9.9.1.5

Brackets shall be inspected prior to each use and damaged or

defective brackets shall be removed from service. Brackets shall be
 vertical and horizontal spacing shall not exceed 2.5 meters (8 feet)
on centers.

9.9.1.6

A rigid guardrail system and toeboards shall be securely fixed to the

uprights of the brackets (see Section 9.4.9). Alternatively, 3/8 inch
diameter wire ropes may be. used in place of toprails and midrails
providing that they are securely fixed and kept taut by the use of turn
buckles.

9.9.1.7

Whenever men are working, the platform shall be fully decked

9.9.1.8

Excessive storage or accumulation of materials or platform units

(planks) shall not be. permitted.

9.9.1.9

The scaffold shall be designed to support a minimum load of 1.2 kPa

(25 Ib./sq. A). No more than hvo persons shall occupy any given
2.5 meters (8 feet) of bracket scaffold at any one time. Tools and
materials shall not exceed 34 kg (75 lb.) in addition to person(s)
occupying the area.

9.10 SpecialScaffolds
Scaffolds to suit special applications and those required for unusual heights or for use. in
abnormal circumstances shall be of a special design, which has been reviewed by the Loss
Prevention Department as per the provisions of se&ion 9.5.8.

Vehicle-mounted elevating and rotating aerial devices shall comply with ANSI A92.2-
1990.

9.11 Scaffold Terminology

Where possible, the scaffold terminology used in this document is based on ANSI AlO.&
1988: Scaffolding - Safety Requirements. A list of common ANSI scaffold tans is
included, and in brackets are equivalent British Standard (BS 5973: 1990 scaffold terms.
where. an equivalent term exists.

(1) Base Plate. A metal plate with a spigot or screwjack for distributing the load from a
post or other load bearing tube.

(2) w (Transom). A horizontal hlbe across runners to form the support for a
platform or to connect the outer posts to the inner posts.
(3) b. A tube placed diagonally with respect to the vertical and horizontal members
of a scaffold and fixed to them to give stability.

(4) B. A device for locking together component parts of tube and coupler
scaffold.

(5) Design Load. The maximum intended load; that is, the total of all loads including
the worker(s), material and the equipment placed on the unit.

(6) DroDline. A vertical line from a fixed anchorage, which is independent of the work
platform and its rigging, and to which the lanyard is affixed.

(7) Fabricated Tubular Frame Scaffold. A system of tubular frames (panels) field
erected with bracing members.

(8) Guardrail &stem. A rail system erected along open sides and ends of platforms.
The rail system consists of a toprail and midrail and their supports.

(9) M. A flexible line to secure the wearer of a body belt or harness to a dropline
or a fixed anchor.

(IO) Load Ratines. Maximum loading for the following categories:

Scaffolding constructed to carry a working load of 75

@) vIb./ft such as for masonry work, with storage of materials on the
platform.
(b) Medi;m Duty: Scaffolding constructed to carry a working load of 50
lb./B such as for bricklayers with the weight of materials in addition to
workers.
(c) Li ht Dut : Scaffolding constructed to carry a working load of 25
_g,r.
Ib./ti and IS Intended for workers only, with no material storage other
than the weight of tools.
(d) Stxcial Duty: Scaffold designed and constructed to carry specific types
of objects.

(I I) Mobile Scaffold. A scaffold assembly supported by casters and moved along

manually.

(12) &&+J. A horizontal rail approximately midway behveen the toprail and platform
of a guardrail system.

(13) plank. A wood board or fabricated component that is a flowing member.

(14) Platform. An elevated work surface composed of one or more platform units.

(15) Platform Unit. Individual wood planks, fabricated planks, fabricated decks, and
fabricated platforms.

(16) Post (Standard). Vertical scaffold tube that bears the weight of the structure.

(17) m (Truss). A fabricated tube upon which the platform rests, the putlog has a
flattened end, to rest in or on part of the brickwork.
(18) Rated Load. The manufacturer’s recommended maximum load.

(19) Runner (Ledger). A horizontal scaffold tube that extends from post to post, that
supports putlogs or bearers and that forms a tie behwen the posts.

(20) Scaffold. A temporary elevated or suspended work unit and its supporting structure
used for supporting worker(s) or materials, or both.

(21) Scaffold Access. A separate, attachable or built-in means of access to and from a
scaffold or work unit.

(22) Scaffold Deck ‘Fabricated’. A work unit equipped with end hooks that engage the
scaffold bearer.

(23) s;ll (Sole Plate). A timber, concrete or metal spreader used to distribute the load
from a post or base plate to the ground.

(24) &. A device used behwen scaffold components and the building or struchtre to
enhance lateral stability.

(25) Toeboard. A barrier secured along the sides and the ends of a platform unit to
guard against the falling of material, tools and other loose objects.

(26) w. The uppermost horizontal rail of a guardrail system.

(27) Tube and Cowler Scaffold. A scaffold system consisting of tubing that serves as
posts, bearers, braces, ties and nmners; a base supporting the posts; and special
couplers that serve to connect the uprights and join the various members.
Cross bracing
FIGURE 11.24: ATYPICALTUBEANDCO~PLERSC~LD

PLANKlNG

GUARD RAIL SYSTEM

RUNNER

BEARER

BTANDARD
COIJPLER

!&I

LONGITUDINAL BRACE
CROSS BASE pLATEfiiioN
BRACING

ADJWSTABLE
COUPLER
FIGURE II.25 PLAN VIEW OF TWO-WAY TIE

TIE TUBES TO SCAFFOLD

, I
FTGURE II.26: PLAY VIEW OF COLUMN Box TIE
COUPLERS
/ \

TIETUBESTO SCAFFOLD [WI

FIC~RE 11.27: PLAN VIEW OF REVEAL TIE

REVEAL PIN

/ WALL WALL
OR
SOLID

Feb~ary 1993- 9.0 Workhg Fkes. hdden, and kai%lding Rge 187
GUARD RAIL SYSTEM FIXED ATTACHMENT LOCATIONS
7

TOESOARD d// WORKING

LEVEL

I
POSTS

f---RUNNERS
STAIR
UNIT
BEARERS

SCREW
JACK

I- DIAGONAL BRACES

VARIOUS INDUSTRY
JOINT CONNECTIONS
FIGURE 11.29: A TYPICAL SYSTEMSCAFFOLD BEING AWMDLED

FIG~E 11.30: A TYPICAL SYSTEMSCAFFOLD BASE IN THE PROCESSOF BEING ASSFMIILED AND
LEVELED
FIGURE n.31: A T~ICAL FABRICATED TUDULAR FRAME MANUALLY PROPELLEDMOBILE
.%AFFOLD

working Phlfom
Access Gate

aster Fastening Pins

FIGURE II.32: A TYPICAL TUBE Am COUPLER MOBILE ACCESSTOWER

Horizontal hinged handrail

(bl Section through

ladder
e
!S1
FIGURE 11.33: Cross TUBE ANCHOR

hGURE 11.34: OUTRIGGERS IN USE RGURE 11.35: DRIVEN TUDE ANCHOR

February 1993 - 9.0 Workiq Places, Laddcn, and .S&%ldilding Rge 192
10.0 HANDTOOLSANDPOWERTOOLS
Hand tools are those. tools for which the hand provides the motive force, e.g., picks, shovels, axes,
crowbars, wrenches, saws, chisels, hammers, screwdrivers, etc. It is tbe contractor’s duty to ensure
that his workmen are properly instructed in the selection and use of tbe correct teal for the job. Tools
constructed of good quality materials should always be used. Poor quality tools increase. the risk of
accidents and also reduce the efficiency of work.

Power tools, however, allow many jobs to be carried out more efficiently and with greater speed and
accuracy. Tbe correct use. of power tools can only be. achieved by the proper training of workmen, by
proper maintenance, and by adequate site supervision. Many accidents have occurred because
unskilled and untrained labor have been allowed to operate power tools in an incorrect manner.

INSTRUCTIONS AND STANDARDS

Saudi Aramco Instructions And Standards:

Schedule ‘D’:

Saudi Aramco Safety, Health and Environmental Requirements - Cartridge Operated

T&S

United States Code of Federal Regulations 29, Part 1910, Subpart “0”. Machinery And Machine
Guarding

American National Standards Institute:

ANSI A10.3-1985

Safety Requirements For Powder Actuated Fastening Systems

ANSI A10.9-1983

Safety Requirements For Concrete Construction and Masonry Work

ANSI B7.1-1988

Safety Code For The Use, Care, And Protection Of Abrasive Wheels

Ah’SI BlS.l-1984

Safety Code For Mechanical Power Transmission Apparatus

NFPA - 70-90

National Electrical Code (NEC)

10.1 Hand Tools, General
10.1.1 Quality

The contractor shall ensure that the finest quality tools shall be provided for all
jobs where hand tools are. used.

10.1.2 Cleanliness

The contractor shall ensure that hand tools are regularly cleaned and, where
necessary, lightly oiled as a protection against corrosion.

10.1.3 Repair and Storage

All hand tools shall be regularly inspected before and after use, and before
storage. If wear or damage is observed, the tool should be withdrawn from use
for repair or disposal. The contractor shall ensure that the storekeeper maintains
a record of all tools issued, repaired, and withdrawn from use. Proper racks and
boxes shall be provided for the storage of hand tools.

10.1.4 Selection

The majority of accidents are caused by using an incorrect tool for the job. It is
essential that the correct type, size, and weight of tool should be decided upon
before. any work is carried out.

10.1.5 Electrical Risks

All uninsulated metal tools are conductors of electricity. Where work takes
place on or near electrical operations, only properly insulated and non-
conductive tools should be used. Insulation should be checked at regular
intervals by a competent electrician.

10.2 Individual Hand Tools, Precautions

10.2.1 Screwdrivers

It is essential that a screwdriver has the correct size of tip to fit the slot of the
screw. If the screwdriver fits the screw correctly, the screw will be drawn into
the correct position without unnecessary force being applied. Over-tightening of
screws can lead to possible hand injury if the screwdriver slips.

Screwdriver shanks are not designed to withstand the hvisting strain applied by a
pair of pliers or more. grips in order to obtain additional leverage. On no
account should screwdriver handles be subjected to blows from a hammer or
similar instrument.

Screwdrivers should never be carried in the pockets of coveralls or other

clothing. A screwdriver can produce a serious wound.
10.2.2 Hammer

It is essential that the right kind of hammer be selected for the job. Hnmmer
handles should be made from smooth timber or be made of au integral head and
shaft of steel. Hammer heads should be secured to wooden handles with proper
wedges.

10.2.3 Chisels

Cutting edges should be. kept sharp at all times, and the original shape and angle
should be maintained. Re-sharpened cold chisels should be suitably hardened
and tempered to maintain them in P safe working condition. The chisel heads
will mushroom in use. As soon as mushrooming is observed, the head should be
reground with a slight taper around the edge to prevent chipping and reduce the
tendency to r-e-mushroom. Eye protection should be worn at all times when B
cold chisel is used.

On jobs where. it is necessary to use a sledge hammer for striking the chisel, the
chisel should be held by a second person using a pair of tongs.

Wood chisels should also be maintained in B sharp condition so that minimum

pressure is exerted when making a cut. If the chisel is to be struck, only a
wooden or soft mallet should be used.

10.2.4 Pi& and Shovels

Picks and shovels shall be maintained in a serviceable condition at all times.

Shovel blades should not be allowed to become blunt, turned, split, or jagged.
Pick head points should be kept sharp and heat-treated so that the metal wears
down in use and does not splinter or chip off. Shafts of picks and shovels should
be kept free. from cracks and splinters.

10.2.5 Spanners and Wrenches

Only spanners and adjustable wrenches of the right size should be used. When
possible, use box-end rather than adjustable wrenches. Tbe jaw should first be
checked for any sign of opening out or splitting. Spanner and wrench lengths
are graded to provide sufficient leverage. on the nuts for which they are designed.
Improvised extension to these tools is an unsafe practice and may cause. the bolt
tread to strip or cause shearing of the bolt. On no account should ordinary
wrenches be struck by a hammer when tightening nuts. For heavy work of this
nature, P properly designed slugging wrench should be used.

10.2.6 Pipe Wrencha

Pipe wrenches must be large enough for the job, the jaw teeth must be kept clean
and sharp, and the knurl, pin, and spring should be. kept free from damage. Pipe
wrenches should never be. struck with a hammer, nor should they be used as a
hammer.
 10.2.7 Pliers

Pliers should onIy be used when there are no other tools for the job. They are
meant only for gripping around objects and should not be used as a wrench.

Care. should be taken when cutting sot? metal with pliers to ensure the scrap
Portion does not fly off and cause injury. If wire is cut under tension, then long
handled pliers should be used. Where pliers are. used for electrical work, they
must be. fitted with insulated handles. All pliers should be kept free from dirt
and grit, and tbe movable parts should be lightly lubricated.

10.2.8 Jtleks

Jacks should be marked with rated capacity and must be heavy enough and strong
enough to raise. and maintain the load. They should be. placed on a firm and
solid support, and the load should be. positioned on the center line of the jack.

Once a load has been raised, it must be. shored or blocked. The jack should
never be relied upon to hold the raised load in position by itself. Extreme. care.
should be taken when working under or near a raised load.

10.2.9 Hacksaws

The correct type of blade should be selected to suit the material to be cut. The
blade should be set in a hacksaw frame so that tbe teeth are pointing in the
forward direction, and sufficient tension should be applied to ensure blade is
maintained rigid.

10.2.10 Hand saws

Many kinds of woodworking hand saws are available, and care should be taken
to select the correct saw. All hand saws shall be regularly examined to ensure
that tbe saw teeth are properly set so as to avoid binding in the timber which can
cause the blade to buckle. Tbe teeth should be kept sharp, clean, and lightly
oiled When the saw is not in use, the blade should be protected by a slotted
piece of timber or a sheath.

Two-man saws should be operated by pulling only. The cut should be kept
straight to avoid the blade buckling. The cut should be wedged open to prevent
the timber from pinching the blade.

10.3 Power Tools, General

10.3.1 Quality

The contractor shall ensure that all portable power tools do not exceed 125 volts
rating, are manufachxed of sound materials, and are free from defects and
properly grounded.
 10.3.2 Repair and Storage

All portable power tools shall be. stored in clean, dry conditions. The contractor
shall provide a schedule of systematic inspection and maintenance for all power
tools. All tools shall be returned to the storekeeper at the completion of each
individual job. Power tools must not be left lying around the job site where they
could be. damaged.

Rotating tools should be switched off and held until rotation has completely
stopped before they are. set down. Tools must be disconnected before changing
bits, blades, cutters, or wheels.

Power for tools can be supplied by compressed air, explosive cartridge, or

electricity. All poxtable power tools must be. equipped with properly functioning
“dead man” switches.

10.4 Pneumatic Tools

10.4.1 General

10.4.1.1

An air compressor shall always be under the supervision of a

competent person. It should always be sited in such a place so as to
have adequate ventilation. Compressors shall not be permitted to
operate in confined spaces without the provision of adequate exhaust
ventilation.

10.4.1.2

All compressed air hoses shall be of the correct size to tit the tool
being used. Any joint in the hoses shall be made. with a proper
coupler and secured by safety wire. The hose length shall be kept as
short as possible and placed so as not to be subjected to damage.

10.4.1.3

Pneumatic tools require clean air to operate efficiently. In every line

feeding a power tool, there shall be an adequate filter and lubricator.

10.4.1.4

During operation all air tools should be held firmly to prevent them
spinning and jumping. This pressure should be. maintained during
the stopping pmcas to prevent injury to the operator’s feet and
hands.

Fcbnury 1993- 10.0 HandTo& Ad PowerTools Page197

10.4.2 Individual Tools, Rwautions

10.4.2.1 Jack Hammer and Concrete Breakers

The tool bit retaining spring shall always be securely in position to

prevent the bit from dropping out. The bit must be kept sharp.

Ear, eye and foot protection shall be required when working with
this type of equipment. See I.9 for other personal protective
equipment requirements.

10.4.2.2 Rock Drill

It is extremely important that the operator maintains a firm grip

with both hands and stands in a balanced position. Any other
method of using the tool can cause serious bodily injury.

10.4.2.3 Grinding Machine

This tool is probably the most misused of all the power tools. Care
should always be taken to ensure that the grinding wheel is free from
defect before mounting. Any defect may cause the wheel to
disintegrate as it gains momentum.

Only persons who have been instructed in the proper selection and
fitting of grinding wheels should be allowed to install wheels on
to&.

The proper size and type of wheel should be fitted to the tool so that
the maximum permissible running speed of the spindle does not
exceed the maximum periphery sped displayed on the grinding
wheel. No grinding machine shall be used unless the maximum
speed is clearly marked on the case. All wheels shall be fitted with
adequate guards in conformance with ANSI B7-l-1988. (See Figure
11.36.)

Floor stand and bench mounted abrasive wheels, used for external
grinding, shall be. provided with safety guards (protection hoods).
The maximum angular exposure of the grinding wheel periphery and
sides shall be not more than 90”. except that when work requires
contact with the wheel below the horizontal plane of the spindle, the
angular exposure shall not exceed 12P. In either case, the exposure
shall begin not more than 65’-’ above the horizontal plane of the
spindle. Safety guards shall be strong enough to withstand the effect
of a bursting wheel. (See.Figures II.37 and 11.38.)

Floor and bench-mounted grinden shall be provided with work rests

which are rigidly supported and readily adjustable. Such work rests
shall be kept at a distance not to exceed one-eighth inch from the
surface of the wheel. (See Figure. 11.37.)
Cut type wheels used for external grinding shall be protected by
either a revolving cup guard or a band type guard in accordance with
the provisions of the American National Standards Institute, B7.1-
1988 Safety Code for the Use, Care, and Protection of Abrasive
Wheels. All other portable abrasive wheels used for external
grinding, shall be provided with safety guards @rot&ion hoods)
meeting the requirements of this paragraph, except as follows:

l When the work locstion makes it possible, a wheel equipped

with safety flanges shall be wed.

l When wheels 2 inches or less in diameter which are. securely

mounted on the end of a steel mandrel are used.

Portable abrasive wheels used for internal grinding shall be. provided
with safety flanges @rot&ion flanges) except as follows:

. If the wheels are entirely within the work being ground while in
use.

l When wheels 2 inches or less in diameter which are securely

mounted on the end of a steel mandrel are wed.

When safety guards are required, they shall be so mounted as to

maintain proper alignment with the wheel, and the guard and its
fastenings shall be of sufficient strength to retain fragments of the
wheel in case of accidental breakage. The maximum angular
exposure of the grinding wheel periphery and sides shall not exceed
1800.

When safety flanges are required, they shall be used only with
wheels designed to fit the flanges. Only safety flanges of a type and
design and properly assembled so as to ensure. that the pieces of the
wheel will be retained in case of accidental breakage, shall be. used.

All abrasive wheels shall be closely inspected and ring-tested before

mounting to ensure that they are free from cracks or defects. (See
Figure 11.39.)

Grinding wheels shall tit freely on the spindle and shall not be forced
on. The spindle nut shall be tightened only enough to hold the
wheel in place. (See Figure 11.40.)

All employees using abrasive wheels shall be protected by eye

protection equipment.

Materials that require grinding shall be. placed on the tool rest with
moderate head-on pressure applied. Materials should not be forced
or jammed into the wheel. Grinding the materials on the sides of the
wheel is an unsafe practice which can damage. the wheel. A grooved
or damaged wheel must be replaced.
FIGURE II.36: ABRASIVE/GRINDING WHEEL

1 Dimensions

2 Nature of the Abrasive

3 Abrasive Grain Size

4 Grade

5 Structure

6 Bond

I Maximum Speed

8 Color Stripe = Speed

February 1993 10.0 Hand Tools And Power Taols Page 200
Elcum II.37: GRINDER GUARDS

1. Work rests shall be kept adjusted to the wheel with a maximum gap of l/8 inch.

2. Tongue guards shall be kept adjusted closely to the wheel with a maximum opening
of l/4 inch.

3. The maximum angular exposure of the grinding wheel periphery should not exceed
90”. This exposure shall begin at a point not more than 65O above the horizontal
ph.%

4. Whenever the nature of the work requires contact with the wheel below the horizontal
plane, the exposure shall not exceed 125“.

TONGUE GUARD

WORK REST
RCURE 11.38: BENCII GRINDER - MACIIINE GUARDING

Fixed Screen
Toughened Glass
\

Motor

February 1993 - 10.0 Hand Tools And hwcr Tools Page 202
10.5 Cartridge Operated Tools
10.5.1 General

Cartridge operated tools have a great advantage in that they can be used in almost
any sihlation without the inconvenience of trailing leads or hoses. However, it is
essential that these. tools be operated only by properly trained personnel who are
over 18 years of age. The contractor shall ensure. that each man required to
operate such a tool will undergo a thorough training period and be certified by
the tool vendor. Use of cartridge operated tools will be in accordance with Saudi
Ammco GI 2.100, ANSI A10.3-1985 and the manufacturer’s specifications and
shall be subject to review and concurrence by the Loss Prevention Department.

10.5.2 storage

Safe and secure storage for cartridges and tools must be provided on the job site.
Storage must be. fire proof, dry, must be capable of being locked and should be
sited in a clear, but easily accessible location where constant supervision can be
maintained.

Cartridges and tools must not be stored together. A storage unit providing
positive physical separation of cartridges and tools (i.e., a wall or partition) is
required.

Warning to be posted where cartridges are stored: “DANGER - NO SMOKING

Cartridge Storage”.

Ventilation must be provided in the store. Cartons of cartridges must not be

stacked against the wall and ventilation spaces must be left around the cartons.
Only one carton of each strength cartridge shall be open at any one time. All
empty cartons, and intermediate packing, must be removed at once.

Tools must be stored in their carrying cases. No loose cartridges must be in the
carrying cases; all cartridges must be in their color coded boxes.

Only authorized pasonnel must be allowed access to the store.

10.5.3 Selection and Training of Personnel

No person may operate, clean, maintain, or repair any cartridge tool without
possessing a certificate of competency, issued by an accredited tool vendor or
manufacturer’s representative, which identities the particular model that the
person is qualified to handle.

Personnel for training must be selected with the following points in mind:

1 Must be over 18 years of age.

2 Must be physically fit and have full use of both hands and both eyes.
3 Should ideally be a tradesman, e.g. plumber, mason, electrician,
joiner/carpenter, etc.
4 Storemen may also need to be trained if they are required to clean and
maintain the tools.
 Training, both theoretical and practical, must be. given by a competent instructor.

The training must follow the manufacturer’s instructions as contained in the

handbook of each particular model.

10.5.4 Personal Rote&se Equipment

Eye Protection shall be worn by the operator and his assistutt whenever usiag
the tools. Goggles must be of a satisfactory standard designed to withstand high
sp+xd impacts and/or, penetrations.

Ear muffs will be available for we at any time and &aJI be wed in confined
spaces.

Safety belts msy be required in certain situations where the recoil from the tool
could cause a” operator to loose his balance.

10.5.5 Issue and Returns

Contractors will ensure that a full register of the serial numbers of each tool is
made and kept up to date.

A log inventory system of issuing and rehlming cartridges and tools against
signatures must be initiated and maintained. See Figure 11.47: Cartridge/Tool
Issuance Control.

Only personnel in possession of a user certificate will be allowed to withdraw

tools or cartridges from the store.

Only the minimum number of cartridges required for that particular shift’s
operation should be issued at any one time.

Cartridge and tools must not be left on the job site at lunch break or at end of
shift but must be returned to the store for safekeeping.

Any loss, either of tools or cartridges, must be reported, at once, to Saudi

Aramco project proponent.

10.5.6 Work Pennits

Work Petits will not nomxdly te required for use on job sites.

Where tools will be used in restricted areas (as defmed in GI 2.100 Work
Permits), a Hot Work Petit must be obtained before work commences.

10.5.7

No person may operate, clean, maintain or repair any cartridge tool without
possessing a certificate of competency which identifies the particular model that
person is qualified to handle.

The manufacturer’s operating instructions must be followed at all times.

February 1993 - 10.0 Hand Tools And her Tmls F-age204

Cartridges are mnnufachred in different calibers and strengths. There are three
sizes: 25 short, .27 short, and .27 long; and, four strengths, as follows:

POWER LEVEL NUMBER COLOR CODE LETTER CODE

Low 3 GIkX” L
Low/Medium 4 YdOW LM
Medium/High 5 Red MH
Extra High 6 Purple/Black EX

It is, therefore, imperative that the correct size and strength of cartridge required
for the tool. the fixing, and the material to be fixed onto be properly determined.
A wrongly sized cartridge will cause a stoppage or misfire.

Using a cartridge which is too powerful could cause a ricochet or a spalling or

fmhlre of the material.

Tbe following General Safety and Operating Rules are common to all types of
tools:

1 As soon as the tool is removed from its carrying case, check to make sure
that a cartridge is NOT LOADED.

2 Inspect the tool before use each day to ensure that it is complete, in good
condition (e.g., clean), and that the safety devices are in proper working
condition.

3 Any tool that is not in proper working order or that develops a defect
during use., shall be immediately withdrawn from service and not used
until properly repaired.

4 Tools shall not be loaded with a cartridge until just prior to the intended
firing time. when loading a tool, point it away from you and anyone
else. Never walk around with a loaded tool; load it where you are
working. Never leave the tool loaded when not in use. Loaded tools shall
not be let? unattended.

5 Never try to operate the tool without the end of the barrel hard against the
fixing surface.

6 All tools shall be used with the correct shield, guard, or attachment
recommended by the manufacturer.

7 Fasteners shall not be driven into very hard or brittle materials including,
but not limited to, cast iron, glazed tile, surface hardened steel, glass
blocks, hollow tile, terra cotta, marble, granite, slate, etc.

8 Driving into soft or easily penetrable materials shall be avoided unless

materials are backed by another material that will prevent the pin from
passing completely through and creating a flying missile hazard on the
other side. Car&l inspection of all materials should be made before.
deciding on the use of a cartridge tool.
 9 No pins shall be driven into a spalled area caused by an unsatisfactory
shot, or into any existing hole in the material. Care should be taken to
ensure that the new fixing is at least hvo inches away from any previous
hole, and a similar distance from any welded joint.

10 Pins must not be tired into corner bricks, mortar joints, and must be at
least four (4) inches (100 mm) away from the edge of concrete or brick
work and one-half inch (12 mm) from the edge of steel.

11 Ensure that the correct strength cartridge is used for the pin, fixing and
material involved. For the first, or test firing use the weakest cartridge.
Too strong a cartridge may result in over penetration, or the fastener may
rebound or ricochet.

12 The tool must be held at right angles to the job when tiring.

13 In the event of a misfire, the tool should be. re-triggered without moving
the tool from the work face. If the shot again fails, then the tool must be
held firmly in the tiring position for at least 30 seconds to allow for a
possible “Hang Fire” in the cartridge. The removal of the misfired
cartridge must be as per the manufacturer’s instructions. Do use nails,
knives, etc., to pry the cartridge loose.

14 Recoil from tiring can throw an operator off balance, especially when
working from ladders or scaffolds. Care must be taken to ensure that the
operator has a secure and safe work area. Safety belts should be wed if
“ecesary.

15 Do not leave cartridges loose on the job site or in the carrying case or
carry them in your pockets. Cartridges are of the ‘Rim Fire’ type and
could explode accidentally if in receipt of a knock from a pin, fixing, or
even a bunch of keys.

16 Before returning the tool to the stores, ensure that it is clean and complete
and that all cartridges are in their correct color coded box.

10.5.8 Maintenance and Repair

Before any repair/maintenance work is carried out, check to make sure that the
tool is NOT LOADED with a cartridge.

No person may operate, clean, maintain or repair any catridge tool without
possessing a certificate of competency which identifies the particular model that
the person is qualified to handle.

Tools must be dismantled, as far as the manufacturer’s instructions indicate, at

least once every week and checked for defects and excessive wear before being
cleaned and oiled. If any defect is found, the tool must be made serviceable
before being issued for use.
 only manufacturer’s authorized spare parts are to be. wed for repair/replacement.

NO CARTRIDGES must be. allowed in the repair/maintenance area. Test firing

of repaired tools must be done in a safe location away from work and store or
office *rea.s.

10.6 Electrically Operated Tools

10.6.1 General

10.6.1.1

All electrically operated hand tools shall be. rated and used at a
voltage not exceeding 125V to ground.

10.6.1.2

Before any electrical tool is used, a careful check shall be made by

the supervisor to ensure that the supply voltage is within the range
marked on the information plate on the tool. Ground Fault Circuit
Interrupters (GFCIs) are required for all 120 volt, single phase, 15
and 20 ampere receptacle outlets on construction sites which are not
a part of the permanent wiring system.

10.6.1.3

All electrical power hand tools shall be of the double insulated type
or properly grounded.

External metal parts of double insulated tools (drill chucks, saw

blades, etc.) are insulated from the electrified parts inside the tool
and, under normal conditions, contact with electrified parts of the
tool does not take place. However, under wet conditions, rain,
condensation, high humidity, damp locations, etc., the hazards are as
great as with faulty grounded tools. All electrical tools are
hazardous when used damp or wet, hut with double insulated tools
the moisture coupled with metal dust, carbon dust, etc. can form a
conductive path from inside the tool to the surface through the
ventilation holes or cracks. Since there is no ground wire to carry
this current away, the user can receive an electric shock. Double
insulated tools, like all electric tools, must be kept dry and should
not be used without a ground fault circuit interrupter.

10.6.1.4

All tools shall he used with extension cords which are as sholt as
possible. All extension cords shall be fitted with grounding pin and
blade-s to tit the socket outlet on the distribution board. Extension
cords shall be of the three-wire. conductor typz. Plugs and sockets
must meet the National Electrical Code requirement with respect to
grounding and polarity.
 Gvercurrent protection shall be provided to extension cords in
accordance with the requirements of the National Electrical Code.
Article 240. Factors to be considered for adequate overcurrent
protection are: type of conductors, size, and length of run.

m: Consider electrical equipment b&g used on a

construction site that may require 15 or 18 ampere (amp.) capacity.
Construction plans call for three No. 12 AWG (wire size) copper
conductors which run to a 20 amp. receptacle (120 v) 40 feet from
the electrical panel box. This circuit is protected by a 20 amp.
circuit breaker. Is this a problem? Yes - There may be three
problems: (1) the size of the conductors, (2) the length of cable run
and, (3) the circuit breaker size.

In order to prevent an employee from receiving an electric shock, the

breaker size and receptacle should be reduced to 1.5 amp. or the
conductors changed to a No. 10 AWG so that the breaker can
function at 20 amp. when required. Leaving the circuit the way it is
would allow considerable electrical leakage without tripping the
circuit breaker. Also conductor insulation would be subject to heat
damage causing electrical leakage and fire. Heavy duty construction
type extension cords are required for 20 ampere. circuits, No. 14
AWG or larger size.for 100 feet of run length. (See.Figure 11.41.)

10.6.1.5

Where it is necessary to nuke electrical splices, these shall be made

with proper connector blocks or by plug and socket connectors.
Taped joints shall not be permitted.

10.62 Maintenance and Storage

A proper inspection and maintenance routine shall be established by the

CO”tractor for all electrical tools. The inspection and maintenance of all tools
shall be carried out at least once in every working week by a competent
electrician.

All tools shall be stored in a clean, dry place, and a record of issue and receipt
shall be maintained by the storekeeper.

10.6.3 Personal Protective Equipment

The contractor shall ensure that all operators are provided with eye, head, and
ear protection. If there is any likelihood of harmful dust beiig emitted, dust
respirators should be wed.
10.6.4 Individual Tools, Precautions

10.6.4.1 Grinders

AI1 grinders shall be equipped with a protexztive guard which allows

only the working part of the wheel to be exposed. This guard must
not be removed.

Grinders shall be clearly marked with their maximum running speed.

The maximum numing speed of the spindle must not exceed tbe
maximum periphery sped marked on tbe grinding wheel. Wheels
should be checked for defects before mounting. All defective wheels
must be destroyed. (See Figure. 11.40.)

10.6.4.2 Drills

Care should be taken not to drill too large a hole at one time.
Drilling of large holes should be done in stages by using small bare.
drills and gradually increasing the size as necessary. If this is not
done, the drill may bind on breakthrough, and the torque set up
could hvist the tool against the user’s wrist.

10.6.4.3 Saws

Hand operated circular saws shall be fitted with spring loaded

guards which allow only the working part of the blade to be
exposed. (See Figure 11.42.)

Portable table saws shall be. provided with adjustable guards, anti-
kick-back devices, and push-type start/stop buttons within easy
reach of the operator. (See Figures II.43 and 11.44.) Fixed table
saws shall be hard wired to an emergency electrical disconnect
switch that has the capability of locking out in addition to having
start/stop buttons at the operator’s location, etc. Portable table
saws must be unplugged for repair, maintenance, or when not in
use.

Where a provision is made for a table saw riving knife to be. fitted,
it shall be kept clean and properly adjusted to the work at all times.
Push sticks must be provided and used when necessary on all bench
saws.

The work area shall be cleaned to prevent excessive build-up of

sawdust and scrap wood.

Operators shall wear eye and hearing protection.

10.6.4.4 Radial Saws
(Figurerl.45)

Radial saws must be provided with:

. An upper hood to enclose the top portion of the blade

down to a point that includes the end of the saw arbor.
The sides of the lower, exposed portion of the blade must
be guarded to the fit11 diameter of the blade by a device
that automatically adjusts to the thickness of the stock
being cut.

. Anti-kickback dogs (on both sides of saw) designed to

provide adequate holding power for all thicknesses of
ripping stock.

. An adjustable stop limiting the forward travel of the blade.

beyond the distance necessary to complete the cut in
repetitive operations.

. A saw housing which automatically returns to the starting

position.

. A marking on the hood showing the direction of the saw

rotation. In addition, a permanent label must be affixed to
the rear of the guard, reading: “DANGER. DO NOT RIP
OR PLOUGH FROM THIS END. ”

. Start/stop buttons at the operator’s position. Additionally,

in the case of fixed saws, each saw must be wired to an
emergency electrical disconnect isolation switch capable. of
locking out the saw.
FIGUREU.39: "RINGTE.W
 FIGURE lI.40: CORRECTLY MOUNTED GRINDING WIIEEL

Steel Reinforcing Ring (in Wheel)

Recessed Flange

Straight Sided Wheel

FIGURE II.41: WIRE CONVERSIONCHART

* Middle Ring American Wire * outer Ring Ahvance

Gauge Ampacitiea Of Insulated
Conductors Rate 0-2WU Volts,
60° To 90” (‘THWN” 7S’C
Cable Temperature Ratings)

* Inter Ring Metric or MM2

Note: Ambient Temperature. Corrections Factors Must Be Applied As Per SAES-P-104

54

41

230 A 200 A \

cMill.=t.d Example 500 mcm AWS 500000 = 250MM2 (Refemce N.E.C. Table 310.60)
19735 19733

Page 213
FIGURE X1.42: SELF ADJUSTING GUARD

I As the blade moves up through the stock, I

I the guard rises up to the stock surface.. I
 Fmm II.43: TADLE SAWS

. Table saws must be provided with e hood that covers the saw at all times.
. Table saws used for tipping must be equipped with en anti-kickback device and
spreader.
* The exposed part of the saw underneath the table must be guarded.
. Table must be secured in position.
* Guarded start/stop buttons shall be provided at the operator’s position.
e All fixed table. saws shall be hard wired to 80 emergency electrical disconnect switch
capable of locking out the saw.

Febnwy 1993 - 10.0 Hand Tool* And Poww Too,,

Page 21s
FWJRE II.44: TABLE SAWS - MACHINE GUARDING

BLADE GUARD
/
FIGURE II.45 RADIAL SAWS

Radial Saws must be provided with:

An upper hood to enclose the top portion of the blade down to B point that includes
the end of the saw arbor. The sides of the lower, exposed portion of the blade must
be guarded to the full diameter of the blade by a device that automatically adjusts to
the thickness of the stock being cut.

Anti-kickback dogs (on both sides of the saw) designed to provide adequate balding
power for all thicknesses of ripping stock.

An adjustable stop limiting the forward travel of the blade beyond the distance
necessary to complete the cut in repetitive operations.

A saw housing which automatically returns to the starting position.

A marking on the hood showing the direction of the saw rotation. In addition, a
permanent label must be affixed to the rear of the guard, reading: “DANGER. DO
NOT RIP OR PLOUGH FROM THIS END.”

Guarded start/stop buttons shall be located at the operators position.

Saw stand shall be secured in position.

All fixed radial saws shall be hard wired to an emergency electrical disconnect switch
capable of locking out the saw.
FIGURE D.46: THE WOODWORKING MACIIINE REGULATIONS

Circular saws are included under types specified as woodworking machines.

Training:
. No person should be employed on a woodworking machine who has not been trained and
instructed in its operation.

Duties Of Employed Persons:

. Employees using woodworking machines must use and keep properly adjusted guards and other
safety devices and use push sticks, jigs, holders and backstops provided.

Working Environment:
. Sufficient space to be. provided around machine to allow work without risk of injury.
. Floors to be. level, in good condition, free of loose material, and not slippery.

Gl”Wd.5:
. Cutters to be guarded to the greatest practicable extent.
. Guards to be of substantial construction, properly secured and adjusted, and constantly in
position while cutters are in motion.

Top Guard:
. Guard to be. strong and easily adjustable.
. Adjusted to extend from top of riving knife to a point as close as practicable to the surface of the
material being cut; or to 8 point not more than 12 nun above the material beiig cut where squared
stock is being hand held.

Bottom Guard:
. Blade below table to be guarded to the greatest extent practicable.

Push Sticks:
. Must be available for use WI every hand-fed circular saw, and used to feed material-
a) throughout any cut of 300 mm or less
b) during the last 300 nun of any cut more than 3M) nun in length
Push sticks should also be used to remove cut material from between the saw blade and the
fence.

Cmwn guard, \Blade

Notice
FIGURE 11.47: CARTRIDGE/TOOL ISSUANCE CONTROL

Warning: Above items can only be issued to workers with valid training certificate Storekeeper:
Safety officer:
11.0 PAINTS AND COATINGS
In addition to the usual hazards associated with construction activities, workmen engaged in surface.
preparation and paint application can be exposed to the dangers of fire, explosion, chemical hums,
toxic fumes, dust, and insufficient air. This section of the manual discusses these. hazards and how to
minimize them.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 2.100 Work Pennit System

GI 6.021 Safety Requirements For Abrasive Blast Cleaning

GI 8.003 Breathing Apparatus

Saudi Aramco Engineering Standards:

SAES-A-105 Noise

SAES-B-067 Safety Identification and Color Coding

SAES-H-102 Safety Requirements for Painting

Steel Structures Painting Council. Steel Struchues Painting Manual, Volumes 1 and 2.

United States of America Code of Federal Regulations, 29 CFR 1910.1ooO Air Contaminants.

11.1 Flammability Hazards of Coating Materials

11.1.1 Flammable Materials

In paint systems, it is normally the organic solvent vapor that is flammable. In

the Saudi Aramco paint system, all the solvents (except for the water based
paints) present a fire hazard.

11.1.2 Flash Point (Definition)

The flash point is defined as the lowest temperature at which a liquid will give
off sufficient vapor to ignite when exposed to an open flame. For most paint
solvents in the Saudi Amoco system, the flash point is less than the normal
ambient temperatures in Saudi Arabia. The danger of fire exists virhaally always
when solvents are in use.

11.1.3 Flammable (Explosive) Limits (D&&ion)

The lower and upper flammable (explosive) limits detine the range of vapor/air
concentrations that are potentially explosive. The lower flammable (explosive)
limit (LEL) is typically on the order of 1% to 2% by volume, a level readily
 obtained in the area near opened solvent containers and near the nozzle of a spray
painting gun in operation.

11.1.4 FireRecautions
Solvents in paints constitute a significant fire and explosion hazard when in the
presence of ignition sources. No painting should be carried out within 75 feet of
potential ignition sources, e.g., welding, flame-cutting, smoking areas, or
sparking tools, unless conditions wan-ant greater clearance.

Ventilation equipment should te used to maintain a maximum level of solvent

concentration, typically below 10% of the LEL.

All electrical lighting and equipment shall be explosion-proof when required in

areas where solvent vapors are likely to be. present.

All electrical equipment such as switches, panel boards, electrical motors and
associated equipment must be. de-energized before spray painting to eliminate
explosion hazards.

Solvents and solvent based paints shall not be applied to surfaces exceeding
Saudi Arabia summer ambient temperatures.

The use and storage of flammable paints and solvents shall be kept to restricted
areas and these areas should be suitably marked with the appropriate warning
signs. Flammable paints should be kept in a special building or in a sun shelter.

Fire extinguishers should be located at the work area and the area Loss
Prevention representative/Fire Chief shall agree upon their suitability.

Work areas should be kept as clean as practicably possible.

11.2 Health Hazards AssociatedWith Paints

Many paint ingredients are harmful to humans; most people can withstand these. materials
over a short time and in small quantities. However, some people are immediately sensitive
to some ingredients and almost everyone will be affected to some degree if exposed for
suffG=nt time.

There are hvo major groups of irritants: toxic materials and dermatitic or skin irritating
“lataials.

11.2.1 Toxic Materials

The most abundant toxic materials found in paints and coatings are. solvents.
Other toxic materials in paints include pigments (lead), binders (epoxies,
polyesters) and additives (organotin). Also, dust from cleaning operations or
application of the paint can generate toxic materials. These toxic materials can
enter tbe body through breathing, ingestion or skin absorption. Most solvents
are toxic to some degree depending on exposure. Tbe degree of toxicity can be
measured by the Permissible Exposure Limit (PEL) expressed as parts per

Fcbnuty 1993- I I .O PaintaAnd Coatings Fagc221

 million @pm) or milligrams of particulate per cubic meter (mg/M3) of solvent in
air over an exposure of 8 hours a day five days a week with no ill effects.

11.2.2 Dermatitic Materials

Demntitic materials irritate the skin which, if left untreated, can cause infections
or ulceration.

Solvents have a tendency to dissolve and remove natural oils and fats fmm skii.
Certain binders such as epoxy resins may also irritate the skin.

Other chemicals used in paint related work should be handled with care (e.g.
paint removers, acid and alkaline cleaners).

11.2.3 Prevention of Health Hazards

Many solvents and coatings contain hazardous ingredients. A copy of the

appropriate Material Safety Data Sheet (MSDS) should be obtained for all
materials used, studied carefully, and the required safety precautions
implemented.

The following precautions should minimize health hazards:

. Identify and seal all toxic and demutitic materials when not in use.

. Adequately ventilate all painting areas and provide National Institute for
Occupational Safety and Health (NIOSH), Mine Safety and Health
Administration (MSHA)-approved or equivalent respiratory protection
where necessary. All workmen spray painting shall wear chemical
cartridge respirators or airline hoods depending upon the hazards of the
paint.

. Minimize dust during surface preparation, and dispose of coating residue

in accordance with the recommendations of the Environmental
Engineering Division, Process and Control Services Department.

. Wear the appropriate personnel protective equipment for the work being
carried out.

. Avoid touching soy part of the body and wear protective equipment (e.g.
gloves, Tywag suits, etc.) when handling dennatitic materials. Personoel
involved in painting shall wash thoroughly before eating and at the end of
the day.

. Use ventilation control or respirators when working with paint removers

containing toxic solvents.

11.3 Ventilation in Confined Spaces

A supply of clean air is a necessity for all operations involving the application of coating
materials, and the paint curing/drying pmce.ss. A high quality air sopply is also required
for life support (refer to GI 8.003 - Breathing Apparatus).
 Ventilation is P necessity when painting in confined areas because solvents tend to be
heavier than air and migrate to lower levels. The fresh air inlet of the ventilation system
should be located near the top of the contined space, and the discharge should be located
near the bottom, positioned to eliminate dead air spaces. Supplementary fans may be
necessary to ensure good air circulation.

Natural ventilation through open man ways, etc. is rarely sufficient to keep local vapor
concentrations to a safe level in terms of PELs or LELs. As a general rule, forced
ventilation shall be used, especially in small enclosures and always during spray painting.

Ventilation requirements are proportionally greater for vessels with a capacity smaller than
1580 III~ (lO,GOO BBL’s or 56,ooO cu ft). The recommended ventilation requirements for
various vessel capacities are shown in Table 11.6; ref. SAES-H-102.

Ventilating to 10% of the LEL considerably reduces the likelihood of tire or explosion;
however, this level will no doubt exceed the Permissible Exposure Limits for toxic
materials. Hence, supplied air respiratory protection is required in confined spaces.

The preparation of air used for life support involves the following factors: PEL’s of
nuisance and toxic dusts: fume, gas and vapor content; air temperature. Air required for
breathing apparatus shall meet the requirements of GI 8.003, Breathing Apparatus.

TABLE II.6: VENTILATION REQUIREMENTS FOR CONFINED SPACES

Volume of Confined Area

11.4 Surface Preparation

Equipment and materials that are used in surface. preparation for paints and coatings can be
hazardous if used carelessly. There are several methods for preparing surfaces and these
include:

. Blast cleaning where abrasives in the form of sand, iron shot, grit, slag, etc. are.
used. Other types of blast cleaning use high pressure water or steam.

. Hand or power tool cleaning includes grinders, sanders, rotary wire brushes, impact
tools, chisels, hammers.

. Chemical cleaning using paint removers. or solvents, alkali, acids or detergents.

11.4.1 Abrasive Blast Cleaning

This section covers blast cleaning wing abrasives in the form of sand, iron shot,
grit, slag or similar materials.

Abrasive blast cleaning operators shall have pre-placement physical

examinations, including chest X-ray and pulmonary function tests with repeat
te.sts at least wery hvo years.

The abrasive blast cleaning operator shall wear an air supplied protective hood
approved (NIOSHIMSHA or equivalent) for the type of abrasive material being
used and any other toxic contaminants (lead, zinc, etc.) that are present. where
blast cleaning assistants could be exposed to silica sand dust or toxic
contaminants, then self-contained or air supplied breathing apparatus shall be.
worn by the assistant. The breathing apparahu and air quality specification shall
meet the standards referenced in GI 8.003, Breathing Apparatus. Personnel
(e.g. maintenance. workers handling abrasive supplies or clean up crews) within
the range of rebound abrasive contaminants shall wear approved (NIOSH/MSHA
or equivalent) dust-filter respirators for the specific airborne hazards.

A bonding system that bonds nozzle, hose, blasting equipment and the material
being cleaned shall be pmvided, and this bonding system shall be grounded to
prevent a build up of static charges. Ground continuity tests shall be conducted
periodically to ensure proper grounding.

To prevent ignition of hydrocarbons in classified areas, the appropriate

precautions listed in GI 2.100, Work Permit System, must be followed.

11.42 Hydroblast and Steam Cleaning

Hydmblast cleaning uses a high pressure. ambient tempemture water jet and
steam cleaning use a high pressure and high temperature steam jet. Extra
caution should be. exercised when using such equipment. These types of
equipment are used for removing dirt or rust scales and the personal protective
equipment requirements am shown in Table 11.7.

11.4.3 Hand and Power Tool Cleaning

This section briefly covers the safety aspects of hand and power tools used for
surface preparation.

Particular attention should be. paid to eye protection to guard against flying
particles, and where necessary, ear protection should he provided to prevent long
term hearing loss per SAES-A-105, Noise.

Tools should he correctly selected for the purpose, and also operated and
maintained to the manufacturer’s instructions.

Suitable respirators should be used if contaminant levels exceed Permissible

Exposure Limits.

Extreme care should be. used if tools have the ability to create sparks.
11.4.4 chemical Cleaning

This section is concerned with four types of chemical cleaners (organic solvents,
a
alkalines, acids and detergents) used to assist in the removal of surface
contaminants such as light oils, greases and rust.

Solvents such as kerosene, mineral spirits, and turpentine are used to dissolve
and remove oil contaminants. Hazards associated with solvents include their
flammable, toxic and demratitic characteristics. Safety precautions regarding
these solvents are included in sections 11.1 and 11.2.

Alkaline cleaners are composed of highly alkaline salts with wetting agents
and/or soaps. They function by wetting, emulsifying, dispersing and
solubilizing surface contaminants, and are generally used at elevated
temperahwes.

Acid cleaners are generally composed of strong acids. They remove

contaminants by chemical attack and are primarily used to remove metal scales
such as rust.

Detergent cleaners are comparable to alkaline cleaners except they are generally
used at low temperatures (60 to 100 degrees Celsius).

For all of the above chemical cleaners, personal safety precautions must be taken
to protect personnel from materials and conditions that present tire hazards or
cause personnel to experience dermatitic or toxic effects (such as inhalation
effects, skin bums, or eye irritants).

When using chemical cleaners, appropriate eye and body wash facilities shall be
available in the immediate area to minimize the effects of chemical bums in the
event of an accident.

Chemical cleaning agents such as solvents shall not be used for cleaning
personnel.

The following solvents shall not be used for cleaning purposes due to the very
toxic nature: benzene, gasoline, carbon tetrachloride, and chlorinated
hydrocarbons.

11.4.5 General Safety in Surface Reparation

Instruction and training of operators about correct use of the cleaning agents and
equipment are essential.

Surfaces other than those receiving preparation should be protected from damage
due to cleaning operations.

Where operators are using equipment such as blast cleaners or power tools, they
must have safe footing. Extra caution should be taken on scaffoldings.

Never point a cleaning gun or nozzle at anyone or any part of your body.
 Equipment such as blast guns and power tools must have automatic controls that
shut off the flow of abrasive and propellant if for any reason the operator
releases the control switch.

Power tools should be properly grounded to prevent electric shock.

All manufacturers recommendations on protective guards shall be implemented.

Fire and explosion hazards always exist when using solvents, especially in
confined areas. Adequate ventilation must be provided.

11.5 PersonalProtective Equipment

Personal protective equipment is required for the majority of operations that involve
surface preparation or paint application. The amount and type of personal protection
depends on the work being carried out and the location. Table II.7 gives a summary of
essential personal protective equipment that must be worn by personnel carrying out
specific duties. In addition, all personnel on Saudi Aramco industrial facilities and
potentially hazardous areas must wear safety shoes, a hard safety hat and safety spectacles.
Other protective details such as gloves, face shields, overalls and hearing protections
should be addressed to either the area Loss Prevention or Industrial Hygiene offices.
 TABLE 11.7: PERSONAL PROTECTIVE EQUIPMENT TO BE WORN OR USED DURING
SURFACE PREPARATION AND PAINT APPLICATION -

TYPE OF WORK PERSONAL PROTECTIVE PERSONAL PROTECTIVE

PERFORMED EQUIPMENT EQUIPMENT TO BE WORN
TO BE WORN Konfined soace) See kev
(Outside) See key ’
- .face preparation
twl operations 3,4,5,9,10,11 3,4,9,10,1 I
Abrasive blast cleaning
operator 1,9,10,11 1,8.9,10,11
Other workmen in the vicinity 1 3,4,5.9,10,11 1,8,9,10,11
Hydroblast and steam cleaning 3,4.5,9,10, I I 3,4,5,8,9,10.11

Inorganic zinc 2,5,6.10,11 1.5,6,10.11

(SAPCS -IA, 11A and 17)
Chlorinated rubber 2,5,6,10,11 1.5,6,10.11
(SAPCS - 9)
Bituminous (SAPCS - 10) 2,5,6,10,11 1,5.6,10,11
Polyurethane (SAPCS - 25) 2,5,6,10,11 1,5,6,10,11
Paint application (brush)
Epoxy and coal tar epoxy 4,6,10,11 2,4,6,10, I I
{SAF’CS - I ,2 and 3)
Alkyd (SAPCS - 4 and 6) 6,10,11 2,6,10,11
Inorganic zinc 6,10,11 4,6,10,11
(SAPCS -lA. IIA and 17)
Chlorinated rubber 6,10,11 2,6,10,11
(SAPCS - 9)
Bituminous (SAPCS - 10) 6,10,11 2,6,10,1 I
Polyurzthane (SAPCS - 25) 6,10,11 6,10,11

Note: Safety belts / harnesses shall be used when these operations are performed above ground levels
(1.82 m - 6 ft or more) if a guard rail system is not in place, and / or in confined spaces.
The workman should always refer to the MSDS for complete details.

February 1993 - I I .O Paints And Coatings Page 227

 Key to Table 11.7:

1. OSHA-approved, respirable air fed hood and filter, SAMS No. 21444-934
2. Respirator; chemical cartridge, SAMS No. 21-370~800/810/820
3. Dust respirator, SAMS No. 21-370-500
4. Face shield (1). SAMS No. 21-426-121
5. Goggles. safety impact, SAMS No. 21-434-249
6. Gloves, SAMS No. 21-432-XxX
7. Gloves; rubber, SAMS No. 21-432-630
8. Ear protection, SAMS No. 21-327-110
9. Gloves (leather and fabric), SAMS No. 21-432-353
10. Helmets (bard hats), SAMS No. 21-441-055 (MSA) I SAMS No. 21-441-050
(American Optical)
II Safety Shoes, SAMS Nos. 21-472-200 121-472-221 I21-472-300 121-472-350

11.6 Paint Application

There are numerous hazards associated with paint application and this section is concerned
with air and airless spraying, together with brush and roller painting.

11.6.1 Paint Materials

The majority of paint solvents, many pigments and some binders are toxic in
addition to having potential dennatitic hazards. Refer to the Material Safety
Data Sheet (MSDS) for information concerning the hazards associated with their
“SC

In that, solvent based painting materials also present a fire and explosion
hazards, painting shall not be carried out near an ignition source. Also,
additional care should be taken to provide adequate ventilation in confined
SPEWS.

Spraying paint using air or airless systems can be very hazardous and should
only be used by trained operators.

11.62 General Safety In Paint Application

All personnel involved with the application of paint to surfaces should wear the
appropriate personal protective equipment for the work being carried out at a
given location. For some paint jobs personal protective equipment may have to
exceed the requirements specified in Table II.7 due to the nature of the work
being performed. Some examples of these jobs are above ground and water
operations, use of special paints, etc.

Al1 pressurized equipment should be handled carefully. Operators and their

assistants should know how to operate and de-energize the equipment in
accordance to manufacturer’s recommendations.

No spray gun should be pointed at anyone or part of the user’s body.

The spray painting operation should be conducted fmm the upwind side of the
object being coated, wherever practicable.
 Before using airless spray equipment, all guards recommended by the
manufacturer shall be in place and the system shall be in good order and
correctly grounded to prevent static build-up.

Prompt professional medical aid shall be available to any person receiving paint
injuries.

The area around spray painting activity should be enclosed by hardboard fence or
equivalent to protect outside personnel from paint over spray.

11.7 Scaffolding and Ladders

Details concerning the use and hazards associated with scaffolding and ladders are included
in Section II.9 of the Construction Safety Manual.

Only good condition, correctly erected equipment shall be used that meets industry
standards (ANSI) or equivalent. Users and erectors of such equipment should be trained
about its use and limitations.

11.8 Tarring Operations

Tarring operations are commonly used in roof work, and hazards associated with this type
of work include body bums, tire and toxicity. Precautions that are required for tar
operations include:

. The heating of tar shall not be carried out on roof tops or in similar potentially
hazardous locations.

. Tar heating operations shall be carried out using approved fuel gas in the correct
cylinders. The heating operations shall be at ground level and at a minimum distance
of 4.5 m (15 feet) away from fuel gas cylinders, buildings or similar structures.

. The transferring of hot tar to its required location shall be carried out using the safest
mode of transport available (preferably pumped). Lifting of hot asphalt in buckets is
not allowed.

. The temperature of the asphalt shall be monitored with a temperature gauge and must
not exceed 450°F at any time during the tarring operations.

In addition to personal protective equipment (safety shoes, safety glasses and hard hats),
the following shall be provided for all personnel directly involved in tar operations: face
shields, leather gloves, cotton overalls, and heat resistant aprons. Also, respiration
protection may be required in confined spaces.

11.9 General Safety for Paints and Coatings

Safety precautions concerning various stages of paints and coatings are mentioned under
their respective sub-headings of Section 11. This section is provided to highlight areas of
paints and coating operations not covered under an individual sub-heading.
* Colon - All color coding shall conform to the requirements in SAES-B-067: Safety
Identification and Color-Coding. Colors reserved for safety use within Saudi
Ammco are red, green, yellow and black, orange and blue. Some equipment
identified by color coding that may be required by painters include:

Fire protection: red.

Emergency stops: red.
Danger signs: red.
Emergency safety equipment and instructions (eye wash, showers, first aid):
green.
Hazards (physical and radioactive): yellow/black.
Potable water: blue.

Breathine Air - Before breathing air used for respiration purposes, it must be checked
to ensure it meets the quality requirements referenced in GI 8.003. once
compressors providing breathing air have conformed to the requirements of GI
8.003, they shall be re-tested every quarter to ensure that air quality remains
satisfactory.

Personal Protective Eauipment - Depending on the work being carried out and its
location, appropriate personal protective equipment must be worn that meets both the
manufacturers requirements and those of Saudi Aramco. Personal protective
equipment shall be in good condition.

Blast Cleaning - Abrasive blast cleaning equipment and abrasive materials shall be
suitable for the work to be carried out; substandard products will be removed from
Saudi Aramco facilities.

Sims and Barricades - Areas where hazardous work is being carried out (such as
abrasive blast cleaning and airless spraying) shall be suitably barricaded to keep
personnel out of the hazardous area, or the timing of the work shall be such that only
the work crew doing the job is present at the site, or a lookout is posted around the
site. Warning signs shall be posted in hazardous areas with suitable warnings of the
potential dangers (i.e., “No entry, sand blasting in progress”).

Paints and Solvents - The amount of paints and solvents stored at the site shall be
restricted to a day’s requirements. Bulk storage of paints and solvents shall be in a
designated, well marked safe area away from the work area and protected from the
sun’s heat.

Work Permits - The Saudi Aramco work permit system shall always be used where
necessary for all aspects of paints and coatings (reference GI 2.100).

Eauipment - Before any equipment is used, operators and assistants shall be trained
on the equipment’s use and operation. Also, the equipment shall be in good working
order, have a” automatic shut-off system and all safety guards installed.

Personal Health - Personnel involved with using paints, solvents and cleaning
equipment (i.e., sand blasting) shall be. in good health and have medical examinations
by professional medical staff at least every hvo years.
* Assistants - No one shall work alone in hazardous areas. An assistant shall always be
available or the ‘buddy” system wed.
12.0 CONCRETE,CONCRETEFORMS,ANDSHOFUNG

12.1 General

All equipment and materials used in concrete construction and masonry work shall meet
the applicable requirements for design, construction, inspection, testing, maintenance, and
operations.

12.2 Reinforcing Steel

Employees working more than 1.8 meters (6 feet) above any adjacent working surfaces,
placing and tying reinforcing steel in walls, piers, columns, etc., shall be provided with
proper work platforms with a guardrail system. When work is to be accomplished outside
a work platform, a safety belt shall be worn that is securely fixed to a dropline or anchor.

Employees shall not be permitted to work above vertically protruding reinforcing steel
unless it has been bent over or capped.

Guying: Reinforcing steel for walls, piers, columns, and similar vertical form work
structures shall k guyed and supported to prevent collapse and to guard against possible
wind pressures.

Wire mesh rolls: Wire mesh rolls shall be secured at each end to prevent dangerous
recoiling action.

12.3 Bulk Concrete Handling

Bulk storage bins, containers, or silos shall have conical or tapered bottoms with
mechanical or pneumatic mans of starting the flow of material.

12.4 Concrete Placement

12.4.1 Concrete Mixers

Concrete mixers equipped with 0.75 cubic meter (1 cubic yard) or larger loading
skips shall k equipped with a mechanical device to clear the skip of concrete.

12.4.2 Guardrails

Mixers of 0.75 cubic meter (I cubic yard) capacity or greater shall be equipped
with protective guardrails installed on each side of the skip.

12.4.3 Bull Floats

Handles on bull floats, used where they may contact energized electrical
conductors, shall be constructed of non-conductive material. or insulated with a
non-conductive sheath whose electrical and mechanical characteristics provide
the equivalent protection to a handle constructed of non-conductive material.
 12.4.4 Powered Concrete Trowels

Powered and rotating-type concrete troweling machines that are manually guided
shall be equipped with a control switch that will automatically shut off the power
whenever the operator removes his hands from the equipment handles. The
rotating blades shall be. guarded at the top and outer perimeter.

12.4.5 Concrete Buggies

Handles of buggies shall not extend beyond the wheels on either side of the
buggy. Installation of knuckle guards on buggy handles is recommended to
protect the hands.

12.4.6 Fkmpcrete systems

Pumpcrete or similar systems using discharge pipes shall be provided with pipe
supports de&& for IO0 percent overload. Compressed air hose in such
systems shall be provided with positive fail-safe joint connectors to prevent
separation of sections when pressurized.

12.4.7 Concrete Buckets

Concrete buckets equipped with hydraulic or pneumatically operated gates shall

have positive safety latches or similar safety devices installed. Prevent aggregate
and loose material from accumulating on the top and sides of the huckat.

Riding of concrete buckets for any purpose shall be prohibited, and vibrator
crews shall be kept out from under concrete buckets suspended from cranes or
cable ways.

12.4.8 Discharging on Slope

When discharging on a slope, the wheels of ready-mix trucks shall be blocked

and the brakes set to prevent movement.

12.4.9 Back-Up Man, Truck Spotter

Back-up man, ready-mix truck spotter shall he used to back ready-mix trucks.

12.4.10 Pneumatic Hose

Nozzleman applying a cement, sand, and water mixture through a pneumatic

hose shall be required to wear protective head and face equipment.

12.5 Vertical Shoring

12.5.1 General Requirements

When temporary storage of reinforcing rods, material, or equipment on top of

form work becomes necessary, these areas shall be strengthened, shored to meet
the intended loads.
 The sills for shoring shall be. sound, rigid, and capable of carrying the maximum
intended load.

All shoring equipment shall be inspected prior to erection to determine that it is

as specified in the shoring layout. Any equipment found to be damaged shall not
be used for shoring.

Erected shoring equipment shall be inspected immediately prior to and

immediately after the placement of concrete. Any shoring equipment that is
found to be damaged or weakened shall be immediately reinforced or re-shored.

Re-shoring shall be provided when necessary to safely suppott slabs and beams
after stripping, or where such members are subjected to superimpaed loads due
to construction work done.

12.5.2 Tubular Welded Frame Shoring

Metal tubular frames used for shoring shall not be loaded beyond the safe
working load recommended by the manufacturer.

All locking devices on frames and braces shall be in good working order;
coupling pins shall align the frame or panel legs; pivoted cross braces shall have
their center pivot in place; and all components shall be in a condition similar to
that of original manufacture.

When checking the erected shoring frames with the shoring layout, the spacing
between towers and cmss brace spacing shall not exceed that shown on the
layout, and all locking devices shall be. in the closed Position.

Devices for attaching the external lateral stability bracing shall be securely
fastened to the legs of the shoring frames.

All base plates, shore heads, extension devices, or adjustment screws shall be in
firm contact with the footing sill and the form.

12.6 Form and Shoring

12.6.1 General Provisions

Form work and shoring shall be designed, erected, supported, braced, and
maintained so that it will safely support all vertical and lateral loads that may be
imposed upon it during placement of concrete.

Personnel shall not be allowed under or in close. proximity of the form work
during pour operations.

Personnel not engaged in the pour operation shall stay clear of the pour area. A
clear area shall be maintained at l-112 times the highest point of the form work.

Drawings or plans showing the jack layout, form work, shoring, working decks,
and scaffolding, shall be available at the job site.
 Stripped forms and shoring shall be. removed and stockpiled promptly atIer
stripping, in all areas in which persons are required to work or pass. Protruding
nails. wire ties, and other form accessories not necessary to subsequent work
shall be pulled, cut, or other means taken to eliminate the hazard.

Imposition of any constnrction loads on the partially completed structure shall

not be permitted unless such loading has been considered in the design and
approved by the engineer-architect.

12.6.2 Vertical Slip Forms

The steel rods or pipe on which the jacks climb or by which the forms are lifted
shall be specifically designed for the purpose. Such rods shall be adequately
braced where not encased in concrete.

Jacks and vertical supports shall be positioned in such a manner that the vertical
loads are distributed qually and do not exceed the capacity of the jacks.

The jacks or other lifting devices shall be provided with mechanical dogs or
other automatic holding devices to provide protection in case of failure of the
power supply of the lifting mechanism.

Lifting shall proceed steadily and uniformly and shall not exceed the
predetetined safe rate of lift or concrete cure.

Lateral and diagonal bracing of the forms shall be provided to prevent excessive
distortion of the structure during the jacking operation.

During jacking operations, the form structure shall be maintained in line and
plumb.

All vertical lift forms shall be provided with scaffolding or work platforms
completely encircling the area of placement with intermittent tie breaks to ensure
that superimposed loads on the scaffold/work platforms cannot pull down the
entire scaffold works.

12.6.3 Tube and Coupler Shoring

Couplers (clamps) shall not be used if they are deformed, broken, or have
defective or missing threads on bolts. or other defects.

The material used for the couplers (clamps) shall be of a struchlral type such as
drop-forged steel, malleable iron, or structural grade aluminum. Gray cast iron
shall not be used.

When checking the erected shoring towers with the shoring layout, the spacing
behveen posts shall not exceed that shown on the layout, and all interlocking of
tubular members and tightness of couplers shall be checked.

All base plates, shore heads, extension devices, or adjustment screws shall be in
frm~ contact with the footing sill and the form material and shall be snug against
the posts.

February1993 12.0 Concrete,ConeraeForms,And Shoring Page235

12.6.4 Single Post Shore

For stability, single post shores shall be horizontally braced in both the
longitudinal and transverse directions, and diagonal bracing shall also be
installed. Such bracing shall be installed as the shores are being erected.

All base plates or shore beads of single post shores shall be in firm contact with
the footing sill and the form materials.

Whenever single post shores are used in more than one tier, the layout shall be
designed and inspected by a structural engineer. Lay-out to be submitted to
Saudi Ammco for approval.

When form work is at an angle, or sloping, or when the surface shored is

sloping, the shoring shall be designed for such loading.

Adjustment of single post shores to raise form work shall not be made after
concrete is in place

Fabricated single post shores shall not be used if heavily rusted, bent, dented, re-
welded, or having broken weldments or other defects. If they contain timber,
they shall not be used if timber is split, cut, has sections removed, is rotted, or
otherwise structurally damaged.

All timber and adjusting devices to be used for adjustable timber single post
shores shall be inspected before erection.

Timber shall not be used if it is split, cut, has sections removed, is rotted, or is
otherwise structurally damaged.

Adjusting devices shall not be used if heavily rusted, bent, dented, re-welded, or
having broken weldments or other defects.

All nails used to secure bracing or adjustable timber single past shores shall be
driven home and the point of the nail bent over if possible.
III. Mechanical Equipment And
Materials
1.0 CRANES AND LIFI’ING EQUIPMENT
SAUDI ARAMCO INSTRUCTIONS AND STANDARDS

ALL REFERENCED STANDARDS ARE INCORPORATED INTO THIS SECTION.

Saudi Aramco General Instructions:

GI 2.180. Work Petit System

GI 2.702. Electrical Safety for Boom or Derrick Type Hoisting Equipment

GI 6.029. Reporting and Recording Of Motor Vehicle Accidents

GI 7.024. Marine and Offshore Cranes and Rigging

GI 7.025. Mobile Heavy Equipment Operator Testing and Certification

GI 7.026. Cranes and Heavy Equipment Accident Reporting

Cl 7.027. Personnel Work Platform Operations

GI 7.028. Crane Lifts: Types and Procedures

GI 7.029. Inspection, Testing and Maintenance of Wire Rope Slings

GI 7.030. Inspection and Testing of Cranes, Elevators, Powered Platforms, and Mobile Aerial
Baskets

Refinery Instruction Manual:

1.087. Precautions to be taken for Operating Cranes near Overhead Power Lines

1.808. Operating Cranes

Heavy Equipment Operator Licensing Information, Attachment No. 111.1

Schedule ‘D’:
Saudi Aramco Safety, Health and Environmental Requirements - Cranes and Rigging
Equipment

Saudi Aramco Crane Safety Handbook

Riggers Handbook

American Petroleum Institute:

API SPEC 2C Specification for Offshore Cranes

API SPEC 2D Operation and Maintenance of Offshore Cranes

Contractor Liaison Notice No. 5.

Procedure for Obtaining Crane and Heavy Equipment Operator’s Licenses for
Expatriate Employees (See Appendix F)

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI A10.4. Safety Requirements

ANSI30.2. Overhead and Gantry Cranes

ANSI B30.3. Hammerhead Tower Cranes

ANSI B30.4. Portal, Tower and Pillar Cranes

ANSI B30.5. Mobile and Locomotive Cranes

ASME B30.6. Derricks

ASME B30.8. Floating Cranes and Floating Derricks

ASME B30.14. Side Boom Tractors

ANSI B30.16. Overhead Hoists

ANSI B30.22. Articulating Boom Cranes

1.1 Competent Person

A competent person is a person who, by possession of a recognized pertinent degree or
certificate of professional standing, or who by extensive knowledge, training and
experience has successfully demonstrated the ability to solve or resolve problems relating
to safe crane operations and procedures (e.g. Rigger Technician, Crane and Rigging
Specialist, etc.). A competent person shall supervise all lifts.

1.2 Saudi Aramco Crane Operations (General Requirements)

Before beginning any crane operation, the supervisor and operator should complete the
pre-operation checklist (Figure 1II.I). A lift plan required as a part of this procedure must
provide the following information:

1. Crane radius
2. Boom length
3. Safe working limits of the crane (load chart)
4. Weight of the load
5. Ground and site conditions
6. Placement of the crane
7. Swing and tail clearances
8. Necessary communication to be used
9. Explanation of hand signals
10. Rigging hardware
 11. Rigging sketch for critical or hazardous lifts
12. Rated capacity of rigging components
13. Sling angles
14. Strain calculations
15. Wind velocity
16. Load moment indicator
17. Other

One competent person shall be placed in charge of the lift with the responsibility of
explaining in detail, the duties of all involved in the lift before the a&al lift commences.
The outriggers must be fully extended prior to the lift, and the nabber tires must be off the
ground (see Figure 111.2, Crane Lift Plan).

Cranes shall have a valid Crane Safety inspection sticker issued by the Saudi Aramco
Crane, Communication, and Facilities Inspection Unit. (See GI 7.030.)

1.3 Saudi Aramco Crane Operator Qualifications

A valid SAG heavy equipment license and Saudi Aramco Crane Operator Certificate are
required for all contractor mobile crane. operators. Contact the Vehicle & Heavy
Equipment Training and Testing Unit (Tel. Nos. 875-4347/874-1857) to operate specific
mobile heavy equipment. (See GI 7.025.)

1.4 SpecialCrane Operating Procedures

Heavy lifts, critical lifts, and crane personnel work platform operations require special
procedures outlined in the Saudi Aramco General Instructions. The Heavy Haul Unit,
Transportation Dept., Abqaiq should be contacted and lift plans/work permits submitted.
(See Gl’s 7.027, and 7.028.)

1.5 Effect of Wind Speedson Crane Operations

When wind velocities are above 32 km/b (20 mph), the rated load and boom lengths shall
be reduced according to manufacturer specifications. Wind forces are greater at height by
as much as 35% or more. All lifts above ground level, must account for wind force, i.e.,
side loads, down drafts, etc. a.s applied to the load and boom. (See TABLES III.1 and
111.2.)

1.6 Overhead Power Lines

There is an area surrounding every power line that is referred to as the absolute limit of
approach. It is strictly forbidden to move any crane boom or load line or load into this are
unless the line has been de-energized or insulated. There are no exceptions.The
absolute limit of approach varies according to the following table:

Line Voltage Absolute Limit Of Approach

up to 250,m volts 20 feet (6 meters)
over 250,ooo 25 feet (7.5 meters)
FIGURE III.1: PRE-LIFI- OPERATION CHECKLIST

OPERATOR:

CURRENT SAUDI ARAB GOVERNMENT CRANE OPERATORS’ LICENSE

CURRENT SAUDI ARAMCO OPERATORS’ CERTIFICATE

OUTRIGGERS:

FULLY EXTENDED
LEVEL GROUND
COMPACT SOIL
HEAVY PAD SUPPORTS
LOCKING PINS/LOCKS SET
NO HYDRAULIC LEAKS
NO DAMAGE
GOOD CONDITION
WHEELS OFF THE GROUND

OPERATION:

CURRENT CRANE SAFETY INSPECTION STICKER

CLEAR 360” VISIBILITY
NO SHADES/CURTAINS IN CAB
LOAD CHARTS IN CAB
CLEAR VISIBILITY
WIND, ABOVE 20 mh (32 km/h), NO GO
DO NOT OPERATE DURING STORMS AND AT NIGHT
LIGHTNING, NO GO
BARRICADE CRANE CAB SWING AREA
TAG LINES IN USE
CLEAR OVERHEAD POWER LINES
CLEAR AREA OF PERSONNEL I-112 x BOOM LENGTHS
NO LIFTS OVER WORKERS OR CRITICAL PROPERTY
TRIAL LIFT, FLOAT LOAD ONE METER OFF GROUND TO CHECK
BALANCE
CLEAR VIEW OF SIGNAL MAN (RIGGER)
DO NOT PULL LOADS WITH CRANE
LOAD RADIUS INDICATOR
MAN LIFT WORK PERMIT
ANTI-TWO BLOCK OPERATIONAL
LMI (LOAD MOMENT INDICATOR) OPERATIONAL

RIGGING:

CHECK ALL RIGGING FOR DAMAGE

CHECK SLING LOAD CAPACITY
CHECK BLOCK, HOOKS, etc. FOR DAMAGE
HOOK SAFETY LATCH IN PLACE
RECORD WEIGHT OF LOAD
RECORD WEIGHT OF CRANE GEAR, ADD CRANE GEAR WEIGHT TO
TOTAL WEIGHT
 LIFT PLAN APPROVED
USE LOAD WEIGHT MEASURING DEVICE FOR UNKNOWN LOADS

. TRAVELING:

BLOCK SECURED
TIRES PROPERLY INFLATED AND IN GOOD CONDITION
BRAKE LIGHTS, SIGNALS, MIRRORS, HORN OPERATIONAL
ROUTE PLAN CHECKED FOR FIRM GROUND, OVERHEAD AND SIDE
RESTRICTIONS
ESCORT VEHICLES REQUIRED WITH FLASHING BEACON LIGHTS
SPEED TO BE MAINTAINED FOR SAFE LIMITS (SLOW AS POSSIBLE)

. PARKING:
BOOM AND HOOK BLOCK(S) LOWERED TO TRAVEL POSITION
APPLY SWING BRAKE AND POSITIVE SWING LOCK
TIE DOWN HOOK BLOCK(S)
RETRACT STABILIZERS
RETRACT OUTRIGGERS
EXTEND STABILIZERS AND LATCH ONTO FLOAT PADS
WEIGHT OF CHASSIS OFF THE TIRES
LET ENGINE IDLE 3-5 MINUTES
REMOVE ALL FOREIGN MATERIAL FROM CAB(S)
CLOSE ALL DOORS, WINDOWS, SKYLIGHTS AND COMPARTMENTS
TURN OFF SWITCHES
STOP ENGINE
FIGURE IlI.2: LIFT PLAN FOR CRANES

1. Contractor: J.O. No.:

2. Crane Inspection Sticker valid: Yes:0 No:0 Date of e
3. Operator Saudi Aramco certified: Yes: 0 No: 0 4. lescription of load:
5. *Type of crane to be used stowed Erected NIA (Ibsntgs)
*Boom length (total) ftlm Jib: Cl cl 0
*Jib length ftlm Extension: 0 q 0
Hookblock (Main): - - -
Aux. Boom Head: 0 0
Headache Ball: Cl 0
Slings, Shackles, etc.:
Others:

Total (Gross Load Weight):

6. l Weight of load -lbs/kgs . Effective weight of jib ~ Ibsikgs (see jib chart)
l Effective weight of jib headache ball - lbsikgs . Weight of load block - Ibs/kgs
l Weight of hoist rope below boom tip- lbsikgs l Weight of spreader bar - lbslkgs
l Weight of other rigging - lbs/kgs
Total load weight - lbsikgs
7. Hoisting clearance ft/m. 8. Lift quadrant zone 9. Operating radius ftlm.
10. Crane capacity at operating radius (Note: Do not make lift if total load is greater than crane capacity shown in Item IO. Refer to GI
7.028 for appropriate derating based on type of Ii&)
11. Crane capacity for jib configuration: 12. Ground and site conditions:
13. Wiidspeed: mph (Maximum 20 mph)
14. Work permit required: YesO No:0
15. Load moment indicator: Yes: 0 No: 0 Type:
16. Sketch and sutwlementarv information for crane lift is reauired to be attached to this plan. fNote: The sketch of the crane should include the
following rig&g inform&n: size of each component; &fe working load (SWL) ca&ity; ‘length of slings; type of component; component
diameter; weight of component and sling angles).
Contractor: Date: Crane operator: Date:
Approved: Date: Reviewed by: Date:
(Competent Person) (Saudi Aramco Site Reuresentative)
Approved: - Date:
(Heavy Haul/Rig Move Unit, Transportation Dept., Abqaiq)
Footnote: This form is to be filled out for the following lifts: 1. At all construction sites and opemting plants; 2. Associated with offshore and
marine sites and opemtions; 3. Within safety zones of power lines; 4. Involving personnel platforms (as per GI 7.027, 7.028 and 7.030).
TABLE IILl: WINO SPEED(MILES Put HOUR) vs. FORCE OF WIND Irv POUNDSPER SQUARE
Foot

MILES FORCE PER SQUARE

DPD unrm PnnT DnllNnf

2 I ,014
1 l-36
.---
4 364
5 .l
10 .4
15 .9
20 1.6
TABLE III.2: WIND SPEED DEFINITION

The fokwing table lists speed, in the major units, relative to Beauforhvind Scale Numbers, the
internationally accepted reference for wind force:

Reference: GROVE COLES CRANE SPECIFICATION BULLETIN NO. 045

Pebnmry 1993 - 1.0 Craw* And Lifting Rquipmca Page 244

2.0 SLINGS AND LImING GEAR (RIGGING)
Saudi Ammca General Instructions:

GI 7.027. Personnel Work Platform Operations

GI 7.029. Inspection, Testing and Maintenance of Wire Rope Slings

American National Staadanls:

ANSI B30.5. Mobile and Locomotive Cranes

ANSI B30.9. Slings

ANSI B30.10. Hooks

ANSI B30.u). Below the Hook Liftiig Devices

ANSI B30.21. Manttally Lever Operated Hoists

Saudi Ammco Crane Safety Handbook (See Appendix E)

Saudi Aramco Riggers Handbook

Saudi Aramco Inspection Procedures

07-AIP-OI-P Inspection of Steel Wire Rope Slings

2.1. Safe Working Load (SWL)

Slings and other rigging equipment must be constructed according to a recognized
standard.

The safe working load of rigging equipment is the maximum load which the equipment
should be subjected to; this load should never be. exceeded.

Before use. all new equipment should be subjected to a proof load test by tbe manufacturer
and certified. The safe working load and serial number shall be clearly marked on the
sling and the lifting gear, either by tagging, stamping, engraving, or embossing. Riggers
shall not use lifting gear unless the safe working load is clearly visible (see Figures III.3
and 111.6).

Slings shall not be tagged with a0 safe working load in the field. Approval by the
Inspection Department and subsequent review by the Loss Prevention Department is
required.

Febnvry ,993 - c-ction SafetyMamu,: stii And Lifling cur hge 245
2.2. Chain Slings

2.2.1 Grades

only alloy steel chain complying with ASTM A391 shall be wed. Other grades
are subject to approval by the Saudi Aramco Crane, Communications and
Facilities Imp&on Unit [CCFIU] (see.Figure III.5).

Each grade of chain should be clearly tagged by the manufacturer, and riggers
should be trained to look for the safe working load marked on each sling. They
shall be forbidden to use any equipment unless the safe working load is clearly
visible.

All attached fittings (hooks, rings, etc. ,) shall be a prescribed by the

manufacturer. Hooks, shackles, and eyebolts shall be equal to or exceed the safe
working load of the chain.

2.2.2 Repairs

Modem chains are produced under closely controlled factory conditions using
proper heat treatment and testing procedures. On-site welding repairs cannot
provide the necessary controlled conditions to safely repair a damaged chain.
Damaged chains must be returned to the manufacturer for repair or destroyed. In
particular, watch for bent links, cracked welds, and excessive wear.

2.2.3

Logger chains or chains used to secure truck loads shall not be used for rigging.

2.3 Wire Rope Slings

2.3.1

Wire rope is the most common type of sling in use on construction sites. It is
essential that each wire rope sling is properly constructed and used. All wire
rope. slings shall be manufactured, inspected, and load tested by a recognized
manufacturer. Homemade wire rope slings shall not be allowed at Saudi Aramco
unless they meet all standards and pass inspection by CCFIU.

2.3.2 Damagedslingsshall he destroyedif thereare:

2.3.2.1
* 10 random broken wires in one lay.
* 4 broken wires in one strand of a rope lay.
* One bmken wire at the fitting.

2.3.2.2

* Severe localized abrasion or scraping.

 2.3.2.3

* Kinking, crushing, birdcaging, or any other damage causing

distortion.

2.3.2.4

* Evidence. of heat damage.

2.3.2.5

* End attachments are cracked, defomxd, or excessively worn.

2.3.2.6

* Bent or opened hooks.

2.3.2.7

* Severe corrosion.

2.3.3

Each sling shall bear a permanent manufachmzr’s identification stating the safe
working load (SWL.) in tons and serial number. Proof load test and
documentation of testing is required from the manufacturer (see Figures III.3 and
111.6).

2.3.4

Wire rope clips (bulldog clips or Crosby clips) shall not be used to make. slings.

2.4 Synthetic Webbing Slings

These are manufactured from woven man-made fiber. Their strength lies in the width of
their bearing surface. These slings must not be subjected to point loading, sharp edged
objects, and non-vertical lifting (see Figure 111.7). Synthetic web slings shall be marked
with a stitched in label to show:

(a) Name or trademark of manufacturer

(b) Rated capacity for each type of hitch
(c) Type of material

2.4.1 Removal fmm Service

Slings which have been damaged or are defective in any way shall be
immediately removed from service, cut up and destroyed.

2.4.2 Repaired Slings

The use.of repaired slings is prohibited.

2.5 Synthetic and Natural Fiber Rope Slings

2.5.1

Each synthetic and natural fiber rope sling shall be permanently marked to show:

2.5.1.1 Name or trademark of manufacturer

2.5.1.2 Manufacturer’s code or stock number

2.5.1.3 Rated loads for the types of hitches wed

2.5.1.4 Type of natural or synthetic material

2.5.1.5 Date of manufacture

2.5.2

All associated rigging hardware shall equal or exceed the safe working load
rating of the rope sling.

2.5.3

Slings shall be removed from service and destroyed when:

2.5.3.1

* The fibers we. cut, badly abraded or seriously worn.

2.5.3.2

* There is considerable filament or fiber breakage (a light fuzzing

is acceptable) on the surface.

2.5.3.3

* There are particles of broken filament or fibers inside the rope

between strands.

2.5.3.4

* There is other damage visible such as: melting or charring,

kinks or hackles, knots, damaged fittings.

Fcbtumy 1993- 2.0 Stings And Lifting Our Page248

2.6 Care of Slings
The following points must be considered in tbe storage and handling of slings:

2.6.1

Slings will undergo shock loading when a load is suddenly lifted or when the
hoisting is abruptly stopped. This can be cawed by tbe sudden application of tbe
crane brake, tbe jerking of tbe load by poor operation, or tbe sling slipping on
the load. A shock load can increase tbe normal working load by as much as five
times its value.

2.6.2

As tbe angle behveen the legs of a multiple sling increases, tbe safe working load
decreases. Tbe included angle should be no more than 90° and must never
exceed 120“ under any circumstances (see Figure 111.9).

2.6.3

Before storage, chain and wire rope slings should be cleaned, lightly lubricated,
and inspected. Slings must be stored in a location where they are not liable to
suffer mechanical damage, away from extremes of beat, cold, and especially
dampness.

2.6.4

Contractors shall maintain a job site log of slings containing tbe following
information: ID. number; date in service; safe working load as stated in proof
load certificate; full details of periodic inspections (see Figure III. 13).

2.6.5

AI1 rigging shall be inspected at last every six months per ANSI B30.9, and a
Sling Inspection Report shall be completed and tiled for review by tbe Crane
Inspector to comply with GI 7.029.

2.7 Hooks

2.7.1

Hooks should be fitted with a safety catch on the book opening, or should be
mowed with wire and a shackle used or the book should be designed so that tbe
slings cannot be displaced (Figure III. 11).

2.7.2

Loads should be. applied on the book only in the part designed to take them (i.e.
the tend [bow] of tbe book). Point loading can result in over stressing tbe hook
causing it to open or break. Therefore, point loading shall not be permitted.
 2.7.3

Hooks should be regularly inspected for signs of damage.

2.7.4

The hook shall be removed from service for the following reasons:

1. If there are visible cracks

2. If it is hvisted 100 out of place
3. If there is a 15 96 throat opening beyond the manufachwer’s specification

A thorough examination shall be carried out each year by a qualified inspector.

2.8 Spreader Bars

2.8.1

All spreader bars shall be manufactured, tested, and inspected to ANSI BN.20.

2.8.2

Spreader ban shall be permanently identified with the safe working load,
manufacturer’s name and serial number.

2.8.3

Spreader bars shall be stored away from moistire, and protected from physical
damage.

2.9 Eyebolts And Safety Hoist Rings

Sometimes machinery or other equipment is delivered to the site with eyebolts
attached as lifting points. For such situations, the design and function of each of
the three basic types of eyebolts should be known (sea Figure 111.10.).

2.9.1

Standard eyebolts are the weakest and are dependable only for vertical lifts.

2.9.2

Shouldered eyebolts can be used at slight angles, but are unsafe at less than 45
degrees with the horizontal.

2.9.3

Safety hoist rings (swivel eyes) are bolted in place with a calibrated torque
wrench and maintain maximum capacity at all angles.
2.10 Shackles
Shac.kles (cl&s) are used for making connections in rigging. They should be
tested by the manufacturer and marked with the safe workiig load.

The pins are separate but matched parts of the shackles, so care must be taken to
use the correct pin for each shackle. Rebar, mild steel bolts or similar items are
not acceptable replacements for shackle pins (see Figure 111.12.).

2.11 Rigger
The job of rigger requires thorough training. The man assigned must be well-
acquainted with tbe capabilities of the crane being used, hand signals, the
different functions of lifting gear, and the various methods of loading.
FIGURE III.3: IDENTIFICATION TAGS

VERT.
LCUD 4400u
150 Lam 31coY

All slings shall carry permanent

manufacturer’s identilicalion.

Febnury 1993 - 2.0 Slingr And LiRi~ Gur hge 2.52

FIGURE III.4: INSTALLING A WEDGE SOCKET ON A ROPE

FIGURE III.5 TWO-LEGGED CHAIN SLING: MAJOR COMPONENTS

FIGURE u1.6: SLING FIXINGS

(Sling No. 123

SWL I3 Tons)
 Flcum III.7: SYNTUETIC WEDDING SLINGS

TYPEII Slingmade with a triangle fitting on both ends. It canbe uwd in a ve,,ical o, basket hitch only

TYPE III Sling made with a flat 100~eye 0” each end with loop 8,‘~ opening O” sameplana as ding body. This fyp~ 01 ding is wrne.
firms calleda flat eye and eye. eye and eye, 0, double eye sling.

__-- _I
c====, +--------A
c----, ----.

TYPE ” Endlessding. sometimesrsferred fo af a grommat. It is a continuous loop formed by joining tha sndr of the fabric together
with a splice.

----_-------__
=-------------_
_-- ----------

TYPE “I Rstu,” BYOireverred eveJding is formed by usingmullipts widths of webbing held edge 10edge. A ~a, pad is attached on
one or bofh sidst of the sling body and on one 0, both rider of fh* loop ~YBL10 form a loop BYBat eachend which is at a right angle fo
fh8 plane of the ding body.

February1993_2.0 SlingsAnd LiRi”g Gca, Page254

 ~CUREl~.s: SLINC~~ADINC FICUREIII.~: EYEBOLTS

THETENSlONON A SLINGLEGDEPENDSWON ITSANGLETO THE

mm AS WELLAS UPONTHEWEIGHTOF THELOADTO BE LIFTED. STANDARD EYEBOLTWITH LINK

hCURE~I.lO: CRANEHOOKS FICUKEIII.~~: SHACKLE

SAFETY CATCH
ROCKER TYPE SAFETY CATCH

BOW SHACKLE

“C” HOOK

MOUSED HOOK

“D” SHACKLE
FIGURE 111.12: WIRE ROPE SLING INSPECTIONLOG

Contractor: Location:

BI/JO Number: Project Title:

3.0 MECHANICAL EQUIPMENT
The widespread use of mechanical equipment in the construction industry improves the quality and
efficiency of the work but it can lead to sihtations which are potentially hazardous.

This section cannot cover all the sihtations which could arise, but it outlines some of the hazards likely
to be encountered from specific items of equipment and their use.

The only safe way of using mechanical equipment is to have properly trained operators, running
equipment that is well maintained and carrying out the work for which it was designed.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 7.025 Mobile Heavy Equipment Operator Testing and Certification

GI 7.026 Cranes and Heavy Equipment Accident Reporting Procedures

GI 7.030 Inspection, and Testing Requirements Of Elevating I Lifting Equipment

GI 8.003 Breathing Apparatus

Cl 447.002 Pressure Relief Valves - New Installation, Change in Set Pressure, Replacement or
Retirement from Service

GI 447.003 Pressure Relief Valves _ Routine Test, Inspection, Quality Assurance and
Regulation

Saudi Aramco Engineering Standards:

Inspection Procedures

17-SAIP-6.01 Diesel Electric Generating Set

20-SAll’3.01 Welding Generator

31-SAIP-l.01 Pumps

31-SAIP-1.02 Compressor

31-SAIP-8.05 Vibrating Roller

31-SAW-B.10 CAT Motor Grader

31-SAIP-8.15 Road Rollers

31-SAIP43.16 Scraper

31-SAIP-10.01 Concrete Mixers

31-SAW12.04 Diesel Fork Lift Truck

31-SAW12.05 Electric Fork Lift Truck

Schedule ‘D’:

Saudi Ammco Safety, Health and Environmental Requirements - Mechanical

Equipment

AMERICAN NATIONAL STANDARDS:

ANSI-A 10.441

Safety Requirements For Personnel Hoists

ANSI-B 15.144

Safety Code for Mechanical Power Transmission Apparatus

ANSI-B 30.146

Safety Code for Jacks

ANSI B30.5. Mobile and Locomotive Cranes

ANSI-B 56.1-M

Safety Standard for Low and High Lift Trucks

3.1 operators
3.1.1 Qualifications

Only trained pxsamel shall operate any mechanical equipment. Operators shall
be trained in the procedures and functions relevant to a specific piece of
equipment; they must be fully aware of the capabilities and limitations of the
machine and have a knowledge of the day-to-day maintenance that it requires.

It is recommended that contractors train and test all equipment operators and
issue them with written authorization specifying the equipment which they are
competent to operate.

3.1.2 Licensing Requirements

Operators of mobile heavy equipment must be. in possession of a Saudi Arab

Government (SAG) license for that particular class of machinery and a Saudi
Aramco certificate issued by the Saudi Ammco Heavy Equipment Operator
Testing and Training Unit (see GI 7.025).
3.2 Machmery Guards
All moving parts of machinery must be shielded by guards. This is particularly tme with
gears, pulleys, V-belt drives, fans, and revolving shafts. All of these are present on most
of tbe static equipment used on or around construction sites. Other examples of equipment
which must be guarded include cooling fans on compressors and generators, the main drive
shafts on pumps and dumpers, and the cable drum on winches and concrete mixers.

Guards must be installed on equipment before it arrives on site and maintained in position
at all times while the equipment is operating. Guards removed for routine maintenance or
for repair must te replaced before the equipment is retimed to service.

3.2.1 Multi-Piece Tire Rims and Locking Rings

As safety equipment like tire cages, restraining bars, racks and clips during tire
check-out cannot fully protect employees working on or near the tire. repair area,
always deflate the tire first before making repairs. Inflate tires inside a strong
restraining device (tire cage) by increasing the tire pressure very slowly.

3.3 General Requirements

3.3.1

Before any mechanical equipment is used in a Saudi Aramco restricted area, all
required work petits must be obtained.

3.3.2

All machinery should be inspected before being placed in service and at regular
intervals thereafter.

3.3.3

Maintenance schedules should be established for each piece of equipment and

strictly followed.

3.3.4

No repair, adjustment, or replacement of parts on moving machinery is

permitted. Before making any repairs. all equipment must be stopped and
deactivated so that it cannot be unintentionally started.

3.3.5

At the start of each shift, the operator must check oil, water, fuel, and hydraulic
levels, that all gauges are operating and that the machine is functioning
smoothly. Safety equipment (e.g., guards, limit switches, governors) must be
checked daily.
 3.3.6

Equipment traveling or working on the highway must have lights and reflectors.
Park equipment clear of the roadway. If this is not possible, use flashing lights,
cones, or other warning devices to alert approaching traffic.

3.3.7

When vehicles are left unattended (even overnight), enginea must be stopped,
parking brakes applied and the wheels chocked. Blades, scraper bowls, and
other hydraulic equipment must be lowered to the ground before the operator
leaves the machine. The ignition key should be. removed and/or battery cables
disconnected to avoid start-up by unauthorized personnel.

3.3.8

Unless othenuise instructed, operators must dismount from machines while

maintenance or repair work is being carried out.

3.3.9

Cabs fitted to equipment must give 360” visibility. Cabs must be kept clean and
clear of such items as rubbish and loose tools. Windows must be kept clean at
all times and should be replaced if the glass becomes pitted, cracked or broken.

3.3.10

Where the operator of a mobile machine cannot see the area all around his
machine, an attendant must be in a position to direct and assist the operator.

3.3.11

All equipment must be located so that exhaust fumes will not affect workers in
the area. Gasolinedriven equipment shall not be used inside a building or other
confined space.

3.4 Compressors
Compressors are one of the most common pieces of equipment used in construction work.
They can be used to supply air for portable power tools or to supply air to sustain men
working with breathing apparatus in extremely hazardous atmospheres. There is a
considerable difference in the quality of the air used for these hvo functions.

3.4.1

All employees on site must know the dangers of compressed air. Never use
compressed air to dust off clothing or machinery. Horseplay with compressed
air must be. strictly forbidden. When compressed air is used in special
cleaning/purging tasks, goggles and full face shield must be worn.

February1993- 3.0 MechanicalEquipment hgc 260

 3.4.2

Compliers must be properly designed, inspected, tested and maintained.

Relief valves shall be installed in accord~ce with GI 447.002/3, and the air
receiver must be periodically inspected.

3.4.3

Before start up, a daily check should be made of the compressor’s pressure relief
valve, fuel, oil and water levels and the air reservoir should be drained of
trapped water. The. operating manual for the particular type of compressor used
should be strictly followed.

3.4.4

When compressors supply air for breathing:

1.) The air intake must be located so that it does not draw in exhaust gas.
2.) There must be * filter to remove oil mist.
3.) They must be equipped with an automatic high temperature alarm.
4.) The air must be tested periodically to be certain it is safe to breathe (see
Administration, I. lo., 1.3.)

3.5 Concrete Mixers and Batching Plants

A concrete mixer of some type will be used on almost every construction site. The
principles of good maintenance and properly trained operators apply equally whether it is
only a small mixer for masonry work or a full batching plant with a large capacity cement
silo, sand and aggregate bins, and a power shovel.

3.5.1

All chains, gears, and revolving shafts must be guarded.

3.52

Safety chains and catches must be operative, and the lifting mechanism must be
in good order.

3.5.3

Men must not be allowed to work under or near the loading skip unless it is held
in position by a safety chain or catch or positively blocked.

3.5.4

The. miner dorm and the area around the machine must be thoroughly cleaned at
the end of each day’s operation.
 Dumper drivers must be. properly trained and experienced and must hold P
current Saudi Arab Government license. The equipment is designed for the
movement of material only. Passengers must not be allowed to travel in the skip
or anywhere else on the machine. Dumpers must be regularly maintained with
particular attention to brakes, steering, and skip release mechanism. If they are
to be used for towing, a proper towing eye with a shackle or pin must be
provided.

4.2.2 Tractors and Trailers

Tractors and trailers are useful for moving larger loads around the site. In
addition to the nonnal precaution of good maintenance, it is essential that safety
chains or wire ropes be fitted between the tractor and trailer so that if the towing
connection should break or become separated for some reason, the trailer caa
still be. brought to a controlled stop by the tractor. Trailer and its load shall not
exceed the towing capacity of the tractor and shall be fitted with an independent
braking system if it is designed to carry more than 9,072 kilograms (20,000
pounds). Trailers used for carrying pipes should be fitted with side stops, and
loads must be securely tied down before being transported.

4.2.3 Conveyor Belts and Monorails

Conveyor belts and monorails are occasionally wed for transporting concrete,
sand, or aggregate on site. They require. B complete maintenance program.
Because of the many problems associated with them, thorough consideration
must be given to their use. All pulleys, rollers, gears and pinch points shall be
guarded. On/off switches shall be clearly marked and readily accessible.

4.2.4 concrete Pumps

Concrete pumps are used for the placement of concrete in difficult situations.
They have the advantage of being able to move large amounts of concrete very
speedily to the area where it is required. The operation of this equipment
demands specialized knowledge of concrete technology; however, placing
concrete by this method can significantly reduce the number of dumpers
employed or the crane usage time expended on a civil engineering contract.

4.3 Site Stores

For small or valuable materials which cannot be conveniently stored in outside areas, it is
essential that an indoor stores shed, under the control of a responsible person, be
established on site. Because of the nahlre of the materials stored in such an area, the main
considerations must be security and fire prevention.

The issuing and receiving of stores must be under the control of a responsible person.
Adequate tire fighting equipment must be readily available in the area. Materials should
be stored on shelving or with small items such as nuts and bolts, etc. in bins suitably
marked with the contents. The safe loads allowed on racks and the maximum stack heights
should be established. All hazardous material, such 8s paints, fuels, chemicals, etc.,
should be separated and stored in an isolated flammable storage area (see Appendix C).
Notices warning of the dangers associated with these. materials should be posted in the
hazard area.
 in the raised position, it must be. blocked. Do not rely on the hydraulic ram to
support the raised body for an extended period.

3.6.4

All vehicles with cabs shall be. equipped with windshields and powered wipers.
Cracked or broken windshields or windows shall be replaced. All cab glass shall
be safety glass or equivalent.

3.7 Excavators

Excavations are carried out using very specialized equipment which roughly falls into hvo
categories: 1) fixed position machines, and 2) moving machines.

The choice of equipment to be used is detertnined by the size. of the project, topography,
volume of earth to be. hauled out and many other factors. Fixed position machines include,
but are not limited to, face shovels, backhoes, draglines and grabs. The “fixed” excavator
loosens the soil and loads from a stationary position. They are useful to perform specific
excavation tasks at a single location. Their loss of mobility is compensated by the fact that
greater force can be applied at the excavation face. “Moving” machines include, but are
not limited to, bulldozers, loaders, scrapers, graders and trenching machines. They
remove, transport and deposit excavated material all in one cycle of operation. They are
used in applications where large volumes of earth need to be moved over uneven ground.
In this process, they also help to level the ground over which they operate. (Also see
General And Civil, 11.2 of this manual.)

3.7.1

The excavation work pennit may require that underground pipelines or cables be
located by manual digging. The petit must be counter-signed by the Power
Distribution Department (PDD) and the area Utilities Services Department.

3.7.2

Operators of excavators must possess a valid Saudi Arab Government license for
the machine and a valid Saudi Aramco certificate issued by the Saudi Aramco
Heavy Equipment Operator Testing Unit.

3.7.3

Outriggers must be fully extended when operating a mechanical excavator so

fitted.

3.7.4

An attendant must be appointed and be available at all times during excavation to

assist and guide the operator.

3.7.5

Excavators with a swinging motion must have a clearance of at least 0.6 meter (2
feet) from any fixed object.
 3.7.6

Booms on excavators must be latched before travel.

3.1.7

Do not excavate closer than 10 feet to the nearest pipeline or other equipment in
phCe.

3.8 Fork Lift Trucks

Fork lift trucks are designed to operate on firm, level ground. This type of equipment has
a limited use in construction operations. They are, however, sometimes used in materials
handling yards and for placing loads where there are firm ground conditions. Operators of
fork lift trucks must have a valid Saudi Arab Government heavy equipment license and a
valid Saudi Aramco cetiifkate.

3.8.1

It is essential that drivers be fully trained and experienced. They must be able to
manipulate loads smoothly and efficiently.

3.8.2

A specific course of instruction should be established for fork lift driven. They
should not be allowed to use the vehicles on site until they have taken the course.

3.8.3

Special equipment fitted to the truck, in addition to or in place of the forks, must
be designed for the specific machine.

3.8.4

The truck shall be equipped with overhead protection.

3.8.5

When traveling with a load on the forks, the forks should be as low as possible
to maintain stability.

3.8.6
If the load being carried obstructs the operator’s forward view, he should travel
in reverse..
 3.8.7

Operators, loaders, helpers and other workers should never place any part of
their bodies behveen the mast uprights, cross members, or other moving parts of
tbe fork lift truck. Stay well within limits of the truck body or cab.

3.9 Generator5
A competent electrician shall be available to ensure that electrical connections are
properly made. The operator should be responsible only for the mechanical
function of the machine.

3.9.1

All pulleys, belts, and fans must be totally enclosed or otherwise guarded.

3.9.2

The side panels to the engine. cover are designed to give access to the machinery
for maintenance or repair. They must be closed at all times when the engine is
running.

3.9.3

The machine must be properly grounded before each use.

3.9.4 Fire Prevention Guide for Portable Generators

The following is a typical check list of the major items to look for. There may
be other potential fire hazards not listed, therefore a thorough inspection must be
made.

. Repair all fuel leaks.

. Check hose and pipe connections for wear and cracks.
. Clean up all combustible trash smund the generator.
. Clean up all fuel spills and place clean sand around area when required.
. Sheds constructed of combustible materials placed around generators and
wooden base frames are prohibited.
. Exhaust piping system shall be kept away from work areas and
combustible materials.
. Generator sets shall be located at least 50 feet from buildings or materials
that may catch fire.
. Inspect all wiring for damage or improper splices/repairs.
. Electrically ground all generator sets (system and frame ground).
. Fire extinguishers must be readily accessible. One CO2 extinguisher for
the generator and a dry chemical extinguisher for the engine drive is
recommended.
. Conduct daily inspections of all generator sets using this guide.
3.10 Graders, Dozers, Scrapers, Loaders And Miniloaders
Heavy earth moving equipment only allows the operator a limited view of the immediate
mea. It is, therefore, essential that a banksman be appointed to warn the operator of
hazards that cannot be seen from the operator’s position.

This equipment shall be equipped with rollover protection. A valid Saudi Arab
Government heavy equipment license and a valid Saudi Ammco certificate issued by the
Saudi Ammco Heavy Equipment Operator Testing Unit are required for each operator of
such equipment.

3.10.1

Before moving his machine, the driver must walk around it to see that the area is
clear.

3.102

Men must not be allowed to sit or lie in the area around the machine.

3.10.3

The engine shall not be left running when the. driver is not at the controls.
Before leaving his machine, a driver must shut off the engine and remove the
ignition key.

3.10.4

Blades, scraper bowls, etc. must be lowered to the ground before the driver
leaves his unit. The wheels should be properly chocked.

3.10.5

If there is work to be. done underneath such hydraulic equipment, the equipment
must be blocked in position.

3.1 Woodworking Machinery

only fully trained operators may be allowed to use woodworking machinery. This
machinery is inherently dangerous since the hazardous parts, knives, blades, etc., cannot
be. fully enclosed. only that part of the blade necessary to carry out the work shall be
exposed at my one time.

3.11.1

The area around saws, planers, and muters must be. barricaded and only
authorized and trained persormel allowed within the barricaded area.
 3.11.2

The ground around such machinery must be kept clear of off-cuts and other
tripping Ilazuds.

3.11.3

Machinery should be securely anchored to prevent movement during use.. (See

General And Civil, II of this manual.)

Febnmy 1993 - 3.0 hG4amic.l Equipen hge 267

4.0 MATERIALS HANDLING
Materials handling forms a large part of construction work. How construction materials are handled
can have a considerable effect on the efficiency of production and on the safety record of the site.
Because of the temporary nature of site work and the frequent change of the work place, it is not
possible to mechanize material handling to the same extent as it would he in a more stable operation.
However, there are many areas in which labor intensive, inefficient, costly, and frequently dangerous,
manual material handling work can be replaced by the use of machines.

INSTRUCTIONS AND STANDARDS

Saudi Ammco General Instructions:

GI 355.001 Identifying, Ordering, Receiving, Storing, Issuing And Disposing Of Hazardous

Materials

GI 1130.013 Vehicle Loading

GI 1131.165 Use of Trailer Brakes

GI 1131.921 Use of Trailer Safety Chains

4.1 Planning
Successful mechanization of material handling requires that the correct machines be
available and properly used. The storage and movement of the various materials must be
carefully arranged to make optimum use of the machines so that efficient service can be
provided and ensure that all vehicle, crane and heavy equipment operators hold current
Saudi Arab Government License and Saudi Aramco Certification where required.

Planning for materials handling operations begins as the production schedule is being
drawn. Ensure that the layout of storage areas provides for adequate access for necessary
mechanical equipment.

4.1.1

Selection of the storage area should be made with due consideration for drainage
and protection from rain and sandstorms (see Figure III. 13 Typical Construction
Materials Store Yard).

4.1.2

Open storage areas should be planned to minimize the reversing and

maneuvering of trucks especially into and out of contined areas.

4.1.3

Access ways must be. wide enough to allow for the passage of fire trucks. Fire
fighting equipment should te located throughout the area. Contact the Fire
Prevention Group of Loss Prevention for information (see Figure 111.13 Typical
Construction Materials Store Yard).
 4.1.4

Cribbing timber, racks, or pallets should be used to ensure that all materials are
stored off the ground.

4.1.5

Protection should be provided for materials such as cement, insulation, and other
bulk material which could be damaged by moishue.

4.1.6

All machinery, equipment, and valves should be maintained fully assembled and
securely closed. All machined surfaces must be covered and fully protected from
exposure to the weather.

4.1.7

The quantity of material on site at any one time must be restricted to a minimum
stock. Flammable stores shall be kept separated. Such a policy should greatly
reduce losses due to pilferage or damage (see Figure III. 13 Typical Construction
Materials Store Yard).

Once these factors have been established, the staffing of the storage areas can
then be considered.

4.1.8

On larger projects, the movement of materials could justify the employment of a

loading and unloading gang, whereas small jobs would probably need only one
man assigned to this responsibility.

4.1.9

Routinely, on most sites, there should be a man appointed as a materials

controller responsible for materials from the planning stage through to the tinal
unloading, storage, and distribution stage.

4.2 Machine Transport

A wide variety of mechanical equipment is available for transporting and distributing
materials on and around a job site. They range from simple equipment such as a dumper
or a tractor and trailer to more sophisticated equipment such as a concrete pump or a large
crane.

42.1 Dumpers

Dumpers are one of the most commonly used pieces of construction equipment
and have proved very useful in transporting concrete and other small loads
around site. Unforhmately they are also a common source. of injuries and
damage.
 Dumper drivers must be. properly trained and experienced and must hold P
current Saudi Arab Government license. The equipment is designed for the
movement of material only. Passengers must not be allowed to travel in the skip
or anywhere else on the machine. Dumpers must be regularly maintained with
particular attention to brakes, steering, and skip release mechanism. If they are
to be used for towing, a proper towing eye with a shackle or pin must be
provided.

4.2.2 Tractors and Trailers

Tractors and trailers are useful for moving larger loads around the site. In
addition to the nonnal precaution of good maintenance, it is essential that safety
chains or wire ropes be fitted between the tractor and trailer so that if the towing
connection should break or become separated for some reason, the trailer caa
still be. brought to a controlled stop by the tractor. Trailer and its load shall not
exceed the towing capacity of the tractor and shall be fitted with an independent
braking system if it is designed to carry more than 9,072 kilograms (20,000
pounds). Trailers used for carrying pipes should be fitted with side stops, and
loads must be securely tied down before being transported.

4.2.3 Conveyor Belts and Monorails

Conveyor belts and monorails are occasionally wed for transporting concrete,
sand, or aggregate on site. They require. B complete maintenance program.
Because of the many problems associated with them, thorough consideration
must be given to their use. All pulleys, rollers, gears and pinch points shall be
guarded. On/off switches shall be clearly marked and readily accessible.

4.2.4 concrete Pumps

Concrete pumps are used for the placement of concrete in difficult situations.
They have the advantage of being able to move large amounts of concrete very
speedily to the area where it is required. The operation of this equipment
demands specialized knowledge of concrete technology; however, placing
concrete by this method can significantly reduce the number of dumpers
employed or the crane usage time expended on a civil engineering contract.

4.3 Site Stores

For small or valuable materials which cannot be conveniently stored in outside areas, it is
essential that an indoor stores shed, under the control of a responsible person, be
established on site. Because of the nahlre of the materials stored in such an area, the main
considerations must be security and fire prevention.

The issuing and receiving of stores must be under the control of a responsible person.
Adequate tire fighting equipment must be readily available in the area. Materials should
be stored on shelving or with small items such as nuts and bolts, etc. in bins suitably
marked with the contents. The safe loads allowed on racks and the maximum stack heights
should be established. All hazardous material, such 8s paints, fuels, chemicals, etc.,
should be separated and stored in an isolated flammable storage area (see Appendix C).
Notices warning of the dangers associated with these. materials should be posted in the
hazard area.
4.4 Manual Handling
There are many areas of construction work where mechanization cannot take the place of
sheer muscle, and it is in such areas that the majority of injuries occur. The inevitable
results of lifting incorrectly are strained backs, slipped discs, sprains and strains, and a
complexity of internal injuries.

It is, therefore, essential that workers be trained in the correct methods of manual
handling. Safe liftiig can only be carried out by the proper use of the right muscles. Back
and abdominal muscles are. weak, while the leg and thigh muscles are strong. The spine
has a natural and comfortable shape when a man is standing upright; however, if he bends,
the spine. arches and becomes weaker. If the spine can be kept in B straight position when
lifting, the strain of the lift goes to the strong muscles of the leg and thigh and loads can be.
lifted safely, with much less physical effort. This is the basic principle of manual
handling.

4.4.1

There are four significant points in a proper lift:

1. Grip: A good grip makes maximum use of the palm of the hand, the ball
of the thumb, and base of the fingers.
2. Back: The back must 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 so as to act as a counteweight.
3. Feet: The feet should be apart the width of the hips with one foot slightly
in front of the other so that a natural lead off is obtained.
4. Arms: The arms must be kept as close as possible to the body.

4.4.2

The important factor in manual handling is that a man should know his
capabilities and ask for assistance with loads beyond his capabilities. In dual
lifting, partners should be approximately the same height and weight so that the
load does not become. unevenly distributed.

4.4.3

Loads, even when properly lifted, can slip. The man lifting must be prepared
for such a possibility and wear the proper protective equipment. Safety foohvear
is mandatory to pro&t feet and gloves should be worn to protect hands from
laceration or splinters and to give some protection if the fingers are trapped
behveen the load and the other surfaces.

February 1993 -4.0 MatmialsHmdling Fnge271

FIGURE 1II.U: TYPICAL CONSTRUCTION MATERIALS STORE YARD

PLUMB

COMBUSTIBLE
DOWN
WIND
/

L
t- 4l I
I-
WATER SUPPLY
ATTACHMENT III.1: HEAVY EQUIPMENT OPERATORLICENSING INFWMATION

GENERAL INFORMATION

All crane and other heavy equipment operators working on Saudi Ammu, projects are required to have
a valid heavy equipment operator Saudi Arab Government (SAG) license and a Saudi Aramco Heavy
Equipment Operator Certificate. This applies to Saudi Ammco employees as well as contractor
WllplOYeeS.

Saudi Arabs and non-Saudi citizens employed by Saudi Aramco or contractors working on Saudi
Ammco projects may obtain their SAG license by following the established procedure.

SAUDI ARAMCO EMPLOYEES (SAUDI AND NON-SAUDI)

WITHOUT HEAW EQUIPMENT LICENSE

Application forms for SAG Heavy Equipment License are completed and
processed at the Saudi Aramco License Unit, Building # 510, Dbabran. (Saudi
Aramco employees in all other areas apply to local Saudi Aramco License Unit).
After completion of an eye examination and blood test, the applicant is scheduled
for an operator competency test by the Heavy Equipment Operator
Training&sting Unit, Dbabran (Tel. 874-1857). Upon successful completion
of the test, application forms are returned to the Saudi Aramco License Unit for
processing through tbe SAG Traffic Department, Dammam, for SAG License
issue.

SAUDI ARAMCO EMPLOYEES (NON-SAUDI)

WITH HOME COUNTRY HEAW EQUIF’MENT LICENSE

Employees with valid home country licenses need only apply through the Saudi
Aramco License Unit, Building # 510, Dbabran (Saudi Aramco employees in all
other areas apply to their local Saudi Aramco License Unit). After completion of
an eye examination and blood test, application forms are forwarded by the Saudi
Ammco License Unit for processing to the SAG Traffic Department, Dammam,
for SAG License issue. A company test is not required.

CONTRACTOR EMPLOYEES (SAUDI AND NON-SAUDI)

WITHOUT HEAVY EQUIPMENT LICENSE

Application for SAG Heavy Equipment License is made directly to the SAG
Traffic Department, Dammam.

Upon completion of the eye examination and blood test, the contractor company
representative contacts the Saudi Aramco Heavy Equipment Operator
Training/Testing Unit (Tel. 874-1857) for scheduling of tbe competency test.
(Application form is to accompany contractor employee to the test site).

After the successful completion of the competency test, the test sheet is attached
to the application form. The application form is then taken to the SAG Traffic
Department. Dammam, for processing and license issue.

Fcbmuy 1993 - 4.0 Materials Handling Page 213

CONTRACTOREMPLOYEES(NON-SAUDI)
WlTHHOMECOUNTRYHEAVYEQUIPMENTLICENSE

Contractor employee with a valid home country license need only apply for SAG
license. to the SAG Traffic Department, Dammam, for processing and license
issue. A competency test is not required for SAG license.

On receipt of the SAG license, the contractor company representative contacts

the Saudi Aramco Heavy Equipment Operator Training and Testing Unit (Tel.
874-1857) for scheduling of the Saudi Ammco certification test.
IV. Electrical And Radiation
1.0 ELECTRICITY

The human senses (smell, taste, hearing, etc.) do not provide a warning of an electrical hazard. The
great majority of electrical accidents result in burns. Fire and explosion from sparks in flammable
atmospheres can and does lead to loss of life and serious damage to property. AI1 electrical
installations, no matter what voltages are used, should always be treated with great caution.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 2.100 Work Permit System

GI 6.012. Isolation, Lockout And Use of Hold Tags

Power Distribution Instruction:

No. 10.0. Power Distribution System Operations

No. 11.0. Hold Orders, Clearances and Permission to Test

No. 50.0. Safety Grounding

Saudi Aramco Engineering Standards:

Electrical Power Manual (SAES-P series)

SAES-B-064 Onshore And Near Shore Pipeline Safety

Operations Instructions Manual:

No. 1.111. Electrical Connections

NFPA 70: National Electrical Cc&.

ANSI/IEEE CZ-90

National Electrical Safety Code

ANSI 830.5. Mobile and Locomotive Cranes

29 CFR 1926 Subpart N - Cranes, Derricks, Hoists, Elevators And Conveyors

US Department of Labor, Occupational Safety And Health Administration (OSHA)

1.1 Voltage
The severity of electric shock is not entirely dependent upon the voltage of the power
source. The ratio of the voltage to resistance determines the current that will flow through
the body and the resulting injury.

In terms of a formula this ratio is:

Current through the body = Voltane amlied across the body

Resistance of the body + contact resistance

The hazard is greater if working conditions are. wet or if the worker perspires freely. This
produces a combination of wet skin and body salt which provides low resistance to current
flow.

1.2 Temporary Installations

Distribution of electricity on a construction site is different from a permanent installation.
As construction work proceeds, the type of equipment in use changes. From excavation to
completion, there is a constant need for convenient means of connecting equipment. This
requires a variety of voltages, phases, and current in different places at different times.
Load requirements will vary considerably. All temporary electrical systems shall conform
to the National Electrical Code.

1.2.1

The contractor is responsible for the temporary electric supply system on a

construction site and the safety measures associated with the National Electrical
Code.

1.2.2

Cables on site are subject to rough treatment. Special care should be taken to
ensure that the grounding conductor remains intact. If the conducting wire
breaks, the supply will not be interrupted under a ground fault condition and the
system will no longer be safe. Only UL, FM or other recognized testing lab
approved extension cords baring appropriate lab trademarks shall be used.
Damaged or spliced cords are not acceptable to Saudi Aramco.

1.2.3

Special care shall be taken to ensure that the correct fuse or breaker ratings are
strictly enforced and that the Ground-Fault Circuit Interrupters (GFCIs) are
installed properly on all circuits.

1.2.4

All installation work must be carried out by qualitied, experienced electricians.

Before connecting temporary electrical installations to existing installations.
prior approval must be obtained from the Saudi Aramco proponent department.
 This is to ensure that no overloadiig of electrical devices will occur and system
protection will not he compromised.

1.2.5

A competent person must be made directly responsible for the overall safety of
the installation. Its general usage, its maintenance, and any alterations and
extensions to the system should be under his control. He must be at the site
whenever work is being done. Before any part of a newly installed electrical
system or its equipment is energized, it must be thoroughly tested. Safety can be
ensured by regular inspection and maintenance.

1.3 Hand Tools and Lighting

1.3.1

Many injuries, fires, and explosions have resulted when extension lights with
defective cords or fittings have been used or when bulbs have been broken,
exposing the live filament wire to an explosive atmosphere. All electrically
operated tools shall be rated and used at a voltage not exceeding 125V. The “se
of 220V is prohibited.

1.3.2

Defective extension lights and electric hand tools shall be repaired or replaced.
A defective electrical tool or cord can cause bums, falls as a result of sudden
shocks, or even fatalities.

1.3.3

Portable electric twls, extension lights and cords should be inspected each time
they are issued and retimed. This should be part of a tool store procedure.
Frequent random checks should be made where those tools, lights and plugs are
being used on site.

Portable hand lamps shall comply with the following:

(1) Metal shell, paper-lined lamp holders shall not be used.

(2) Hand lamps shall be equipped with insulated handle.

(3) Substantial lamp guard shall be attached to the handle or holder.

Metallic lamp guards shall be grounded. Three-wire power cords with
grounding conductor shall be. used.

1.3.4

Failure of electrical equipment, because of misuse, is a frequent cause. of shock.

Workers are prone to abuse extension cords by pulling them over sharp metal
objects, hanging them across equipment, kicking them, or letting them be run
over by industrial equipment. They often strain the cords during use, causing
the plug and fixture to part and expose live wires.
 1.3.5

Many accidents occur when lower volt equipment is plugged into higher volt
systems. Before any portable tool or extension light is plugged in, the voltage
required for the tool or light must be the same as the power source, and the plugs
must be checked for damage.

1.3.6

The importance of grounding all portable tools and lights cannot be emphasized
too strongly. All non-current carrying metal parts of any electrical equipment
must be properly grounded. This will reduce the electrical shock hazard.

1.3.7

In hazardous areas, more. stringent rules apply as to the type of equipment which
may be used. Explosion proof light fittings for extension lights is one example.
As with all work carried out on Saudi Aramco installations, Work Permits must
be obtained and the type of equipment to be used discussed and agreed upon
before the pennit is issued.

1.3.8 General Precaution9:

Only qualified electricians should make repairs and carry out maintenance
checks. All extension lights must be fitted with protective guards, so if
accidentally dropped, the lamp remains intact. Up to a 120 volt maximum rated
AC portable. lighting system may be used for illuminating inside confined spaces
and vessels, provided it is protected by an externally located ground fault circuit
interrupter and also meets the provisions of GI 520.001 Section 5.5.5.1 and
520.0014 (Supplement 4) - “Confined Space Entry Procedure” (Abqaiq Plants).

1.3.9

Ground fault circuit interrupters shall be used on all electrical circuits including
portable power electrical supplies (see NFPA Handbook of the National Electric
Safety Code, Section 30.5-b for GFCls) on temporary wiring.

1.3.10

The National Electric Safety Code defines requirements for the construction and
use of portable extension and electric cords in industrial service. This code shall
be followed by constmction groups.

1.4 Work on Live Equipment

1.4.1

Whenever workmen are. required to work on energized equipment, the job must
be planned thoroughly and the workmen should proceed with caution.

February 1993 - 1.0 Electricity Page219

 Before any work on live equipment starts, there must be a thorough knowledge
of the work involved, personal protective equipment must be available, and all
necessary work pennits must be obtained.

1.4.2

Employees must never work alone on live equipment. IO addition to the man
doing the job, there must be another electrician standing by. A foreman or
supervisor should also be in attendance while this work is b&g carried out, and
he must know how to isolate the equipment.

1.4.3

Before starting a job, the exact voltages should be known. This is important as it
determines the type of personal protection required for the work and the
procedures established in the work petit. If there is any doubt about voltages,
a check must be made before the work is started.

1.4.4

Work platforms and equipment used near energized equipment shall be properly
grounded.

1.4.5

Work on live equipment can be as safe as work on isolated equipment if the

following are observed:

I There must be a thorough knowledge of the equipment and the job to be

done.
2 If there is any doubt, the advice of the supervisor or responsible person
should be sought.
3 The work must be correctly planned before starting.
4 Protective equipment must be used correctly.

1.5 Overhead and Underground Cables

On any construction site, power supplies may have already been installed below ground or
overhead.

Contact should be made with the appropriate Saudi Aramco department at the planning
stage of the job to determine the work permit requirements, route and depth of any
underground cables and the recommended safe clearances. If rerouting existing cables is
necessary, this should be done before the main contract starts.

1.5.1 Overhead Lines

(Figure IV.1)

High voltage or overhead lines are usually uninsulated. Therefore, any kind of
metallic object coming near or in contact with them can cause a hazardous
sihmtion. High voltage can easily arc across a considerable distance. (See
OSHA 29 CFR I926 Subpart N.)

Fcbnmry 1993 I .O Ehctricily Page 280

 1.5.2 The Contractor Should Arrange for Power Lines to be:

1 Rerouted clear of all construction work or placed underground if

possible.
2 Made “dead”, grounded, and certified as such by Saudi Aramco.
3 Protected by barriers and timber or wire “goal-posts”, so that no part of
any mobile crane, earth moving equipment, etc. can approach the live
cable. Clearance distances should be agreed upon with Saudi Aramco.
Access below the powerlines shall be restricted by barriers to where the
“goal-posts” are located (see Figure IV.l).

The. need for caution in working with overhead lines cannot be over-emphasized.
High voltage overhead lines have been mistaken for telephone cables.

It should never be. assumed that there is enough clearance; it should always be
proved. It should never be assumed that a cable or line is “dead”; it should
always be checked.

1.5.2.1 Spacing Between Powerlines and Pipelines

Special precautions are required during installation, operation or

maintenance of above grade or below grade onshore pipelines. (See
SAES-B-064.)

1.5.3 Underground Cables

Normal depth of underground cables varies between 46 centimeters (18 inches)

and 0.9 meter (3 feet). (Changes in ground level, due to the work, can mean
that the “as built” depth is no longer correct). No mechanical excavations should
be started before test trenches have been dug by band and cable locations
established. Unless cables have been laid very deep, heavy vehicles should not
be allowed to pass over them.

Underground cables, exposed during excavation work should be assumed to be

energized and not repositioned or moved until certified to be de-energized.
Exposed buried cables in open trenches should be properly supported and the
area barricaded.

Accidental damage to any cable exposed during excavation shall be immediately

repated to Saudi Aramco. The area must be barricaded until the damaged cable
has been made safe.

1.6 Overhead Power Transmissionand Distribution

The standards given in this section provide minimum requirements for safety and health
during construction.

1.6.1 Initial Inspections, Tests, or Determinations

Existing conditions shall be detetined before starting work, by an inspection or

a test. Such conditions shall include, but not be limited to, energiz4 lines and
 equipment, condition of poles, and the location of circuits and equipment,
includiig power and communication lines.

Electrical equipment and lines shall be considered energized until determined to

be de-energized by testing and grounding.

Operating voltage of equipment and lines shall be determined before working on

or near energized parts.

1.6.2 De-energizing Lines and Equipment

The procedures outlined in GI 2.100 and GI 6.012 shall be followed, and all
circuits will be identified, tagged, locked, and tested.

Equipment shall be checked for potential and protective grounds shall be applied.

Guards or barriers shall be erected as necessary near to adjacent energized lines.

When more than one independent crew needs to work on the same line or
equipment at the same time, a separate. “clearance” shall be given to each crew
by the Saudi Ammco Power Dispatcher, and a prominent tag and lock for each
such independent crew shall be placed on the line or equipment by the designated
crew leader.

Upon completion of work on de-energized lines or equipment, the crew leader

shall determine that all members in his crew are clear and that protective grounds
installed by his crew have been removed. He shall release his clearance to Saudi
Am”K!O.

1.6.3 Emergency Pmcedures and First Aid

The Contractor shall provide training or require that his employees are
knowledgeable and proficient in the following:

1 Procedures involving emergency situations;

2 First-aid timdamentals including cardiopulmonary resuscitation; and
3 Remote field crews shall have an employee certified in First-Aid.

1.6.4 Night Work

When working at nigbt, spotlights or portable lights for emergency lighting shall
be provided as needed to perform the work safely.

1.6.5 Work Near/Over Water

When crews are engaged in work over or near water and when danger of
drowning exists, suitable protection such as buoyant work vests shall be worn.
Life rings, ropes and at least one skiff shall be provided.

Fcbnmy 1993 - 1.0 Ucetricity Page282

 1.6.6 Hydraulic Fluids

All hydraulic fluids used for the insulated sections of derrick trucks, aerial lifts,
and hydraulic tools which are used on or around energized lines and equipment
shall be of the insulating type.

1.6.7 Live-Line Tools (Hot Sticks)

Only live-line tool poles having a manufacturer’s certification meeting the

following requirements shall be used:

1 100,000 volts per foot of length for 5 minutes when the tool is made of
fiberglass, or
2 75,OCOvolts per foot of length for 3 minutes when the tool is made of
wood; or

All live-line tools shall be visually inspected and wiped clean before use each
day. Tools with any hazardous defect shall be removed from service.

1.6.8 Material Handling

1.6.8.1 Unloading

Prior to unloading steel, poles, cross a-, and similar material, the
load shall be thoroughly examined to ascertain if the load has
shifted, binders or stakes have broken, or the load is otherwise
hazardous to employees.

1.6.8.2 Pole Hauling

During pole hauling operations, all loads shall be secured to prevent

displacement and a red flag shall be displayed at the trailing end of
the longest pole.

Precautions shall be exercised to prevent blocking of roadways or

endangering other traffic.

When hauling poles during the hours of darkness, illuminated

warning devices shall be attached to the trailing end of the longest
pole and haul truck brake lights shall not be obscured.

1.6.8.3 storage

No materials or equipment shall be stored under energized bus,

energiti lines, or near energized equipment.

1.6.8.4 Framing

During framing operations, employees shall not work under a pole.

or a structure suspended by a crane, A-frame, or similar equipment
ttttles~ the pole or stmchtre. is adequately supported.

Febnury 1993 - I .O Uechicity Page 283

 1.6.8.5 Attaching the Load

The hoist rope shall not be wrapped around the load. Tbis provision
shall not apply to electric construction crews when setting or
removing poles.

Non-conductive tag lines or other suitable devices shall be wed to

control loads being handled by hoisting equipment.

1.6.9 Grounding for Protection of Workers

1.6.9.1 Isolation and Voltage Testing

Equipment to be worked on when it is deenergized shall be isolated

from the system and tested for voltage using test equipment rated for
the system, and be grounded.

1.6.9.2 Applying and Removing Grounds

(See Figure IV.2)

Grounding cables shall be connected to ground first, and then the

equipment. Grounding cables shall be installed and removed using
hot sticks or insulating gloves and protective apparel.

Grounding cables shall first be disconnected from the line or

equipment and then be disconnected from ground.

Grounding cables shall be at, or as close as practicable to, tbe work

location.

Protective grounds shall be installed so that it is not possible for

workers to come in contact with a grounded component and an
ungrounded component simultaneously.

1.6.9.3 Grounding Distance

If tbe work is to be performed at more than one. location in a line

section, the line section must be grounded and short circuited at each
end of the line section and the conductor to be worked on shall be
grounded at each work location.

1.6.9.4 Removal of Grounds for Testing F’urposes

Grounds may be temporarily removed with the permission of the

Power Dispatcher. Extreme caution shall be. exercised while the
equipment/line is not grounded.

1.6.9.5 Grounding Electrode

When grounding electrodes are utilized, such electrodes shall exhibit

low resistance to ground; thereby, rapidly diminishing the electrical
 hazard to personnel. Gtberwise, insulated tools (or other operating
equipment) must be used by personnel.

1.6.9.6 Grounding Cables And Clamps

Grounding cables and clamps shall be capable of conducting tbe

anticipated fault current and shall have a minimum size of No. 2
AWG standard copper.

1.6.10 Overhead Lines

Prior to climbing pales, ladders, scaffolds, or other elevated struchlres, an

inspection shall be made to determine that the structures are capable of sustaining
the additional or unbalanced stresses to which they will be subjected.

Where. poles or stnxhue.v may be. unsafe for climbing, they shall not be climbed
until made. safe by guying, bracing, or other adequate means.

Before installing or removing wire or cable, strains to which poles and structures
will be subjected shall be considered and necessary action taken to prevent
failure of supporting structures.

When setting, moving, or removing p&s using cranes, derricks, gin poles, A-
frames, or other mechanized equipment near energized lines or equipment,
precautions shall be taken to avoid contact with energized lines or equipment.

Unless using protective equipment suitable for the voltage involved, employees
standing on the ground shall avoid contacting equipment or machinery working
adjacent to energized lines or equipment.

Lifting equipment shall be bonded to an effective ground or it shall be

considered energized and barricaded when utilized near energized equipment or
lines.

Pole boles shall not be left unattended or unguarded. Even in desert areas,
unguarded pole boles are a hazard.

Tag lines shall be of a non-conductive type when used near energized lines.

1.6.10.1 Metal Tower Construction

When working in unstable material, tbe excavation for pad or pile-

type footings in excess of 1.52 meters (5 feet) deep shall be either
sloped to the angle of repose. ax required or shored if entry is
required. Ladders shall be provided for access to pad or pile-type
footing excavations in excess of 1.2 meters (4 feet). (See.Section II,
2.4, Excavations, Trenching, And Shoring for depth and slope
CIitHi~.)

When working in unstable material, provision shall be made for

cleaning out auger-type footings without requiring an employee to
enter the footing unless shoring is used to protect the employee.
A designated employee shall be used in directing mobile equipment
adjacent to footing excavations.

No one shall be permitted to remain in the footing while equipment

is being spotted for placement.

Where necessary to assure the stability of mobile equipment, the

location of use for such equipment shall be graded and leveled.

Tower assembly shall be carried out with a minimum exposure of

employees to falling objects when working at hvo or more levels on
a tower.

Guy lines shall be used as necessary to maintain sections or parts of

sections in position and to reduce the possibility of tipping.

Members and sections being assembled shall be adequately

supported.

No one shall be permitted under a tower which is in the process of

erection or assembly, except as may be required to guide and secure
the section being set.

When erecting towers using hoisting equipment adjacent to energized

transmission lines, the lines shall be de-energized when practical. If
the lines are. not de-energized, extraordinary caution shall be
exercised to maintain the minimum clearance distances required.

Erection shall be set on timl level foundations and when the cranes
are so equipped, outriggers shall be used.

Tag lines shall be utilized to maintain control of tower sections being

raised and positioned, except where the use of such lines would
create a greater hazard.

The loadline shall not k detached from a tower section until the
section is adequately secured.

Except during emergency restoration procedures, erection shall be

discontinued in the event of high wind or other adverse weather
conditions which would make the work hazardous.

Equipment and rigging shall be regularly inspected and maintained

in safe operating condition.

Adequate traffic control shall be. maintained when crossing highways

and railways with equipment.

An employee shall b-eutilized to determine that required clearance is

maintained in moving equipment under or near energized lines.
 1.6.10.2 Stringing/Removing Deaergimd Conductors

when stringing or removing de-energized conductors, tbe provisions

of tbe following paragraphs shall be complied with.

Prior to stringing operations, a briefing shall be held setting forth tbe

plan of operation and specifying the type of equipment to be used,
grounding devices and procedures to be followed, crossover methods
to be employed, and tbe clearance authorization required.

Where there is a possibility of the conductor accidentally contacting

aa energized circuit or receiving a dangerous induced voltage
buildup, to further protect the employee from the hazards of the
conductor, the conductor beiig installed or removed shall be
grounded.

When the existing line has been de-energized, proper clearance

authorization shall be secured and the line grounded on both sides of
the crossover, or the line being strung or removed shall be worked
00 a.5if energized.

When crossing over energized conductors in excess of 600 volts,

rope nets or guard structures shall be installed unless provision is
made to isolate or insulate tbe workman or the energized conductor.
Where practical the automatic re-closing feature of the circuit
interrupting device shall be made inoperative. In addition, the line
being strung shall be grounded on either side of the crossover or and
worked on as if energized.

Conductors being strung in or removed shall be kept under positive

control by the use of adequate tension reels, guard structures,
tielines, or other means to prevent accidental contact with energized
circuits.

Guard structure members shall be sound and of adequate dimension

and strength, and adequately supported.

Anchors, riggings, and hoists shall be. of ample capacity to prevent

loss of the lines.

The manufacturer’s load rating shall not be exceeded for stringing

lines, pulling lines, sock connections. and all load-bearing hardware
and accessories.

Pulling lines and accessories shall be inspected regularly and

replaced or repaired when damaged or when dependability is
doubtful.

Fcbnury 1993 - I .O Electricity Page 287

 Conductor grips shall not be used on wire rope unless designed for
this application.

While the conductor or pulling line is b&g pulled (in motion)

employees shall not be permitted directly under overhead operations,
nor shall any employee be permitted oo the crossarnx

A transmission clipping crew shall have a minimum of hvo struchwes

clipped in between the crew and the conductor being sagged. When
working cm bare conductors, clipping and tying crews shall work
behveen grounds at all times. The grounds shall remain intact until
the conductors are clipped in, except on dead end structures.

Except during emergency restoration procedures, work from

structures shall be discontinued when adverse. weather (such as high
wind or ice on structures) makes the work hazardous.

Stringing and clipping operations shall be discontinued during

electrical stomls.

Reel handling equipment, including pulling and braking machines,

shall have ample capacity, operate smoothly, and be leveled and
aligned in accordance with the manufacturer’s operating instructions.

Reliable communications behveen the reel tender and pulling rig

operator shall be provided.

Each pull shall be snubbed or dead ended at both ends before

subsequent pulls.

1.6.10.3 Stringing Adjacent to Energized Lines

Prior to stringing parallel to an existing energized transmission line,

it shall be determined whether dangerous induced voltage buildups
will occur in the system, particularly during switching and ground
fault conditions.

When stringing adjacent to energized lines, the tension stringing

method or other methods which preclude unintentional contact
behveen the lines being pulled and any employee shall be used.

All pulling and tensioning equipment shall be isolated, insulated, or

effectively grounded.

A ground shall be installed behveen the tensioning reel setup and the
first stluctllre in order to ground each bare conductor, sub-
conductor, and overhead ground conductor during stringing
operations.

During stringing operations, each bare conductor, sub-conductor,

and overhead ground conductor shall be grounded at the first tower
adjacent to both the tensioning and pulling sehlp and in increments

February 1993 - I .O Eketrieity Page 288

 so that no point is more than 3.218 kilometers (two miles) from a
ground.

l The grounds shall be left in place until conductor installation is

cmpleted.

l Such grounds shall be removed at the last phase of aerial

cleanup.

l Except for moving type grounds, the grounds shall be placed

and removed with a hot stick.

. Conductors, sub-conductors, and overhead ground conductors

shall be grounded at all dead-end or catch-off points.

A ground shall be located at each side and within 3.2 meters (IO
feet) of working areas where conductors, or overhead ground
conductors are being spliced at ground level. The two ends to be
spliced shall be. bonded to each other. It is recommended that
splicing be carried out on either an insulated platform or on a
conductive metallic grounding mat banded to both grounds. When a
grounding mat is used, it is recommended that the grounding mat be
roped off and an insulated walkway provided for access to the mat.
(See Power Distribution Instruction No. SO.)

All conductors, sub-conductors, and overhead ground conductors

shall be bonded to the tower at any isolated tower where it may be
necessary to complete work on the transmission line.

. Work on dead-end towers shall require grounding on all de-

energized lines.

l Grounds may be removed as soon as the work is completed,

provided that the line is not left open circuited at the isolated
tower at which work is being completed.

When performing work from the structures, clipping crews and all
others working on conductors, sub-conductors, or overhead ground
conductors shall be protected by individual grounds installed at every
work location.

1.6.11 Underground Lines

Warning signs shall be promptly placed when covers of manboles, hand holes, or
vaults are removed.

Before an employee enters a street opening, such as a manhole or an unvented

vault, it shall be promptly protected with a barrier, temporary cover, or other
suitable guard.

When work is to be performed in a manhole. or unvented vault, GI 2.100, Work

Permit System, shall be enforced.
. No entry shall be permitted unless forced ventilation is provided or the
atmosphere is found to be safe by testing for oxygen deficiency and the
presence of explosive gases or fumes.

. Where unsafe conditions are detected, by testing or other means, the

work shall be ventilated and othenvise made safe before entry.

. Provisions shall be made for an adequate continuous supply of air.

1.6.11.1 Work in Manholes

While work is being performed in manholes, an employee shall be

available in the immediate vicinity to render emergency assistance as
required. This shall not preclude the employee in the immediate
vicinity from occasionally entering a manhole to provide assistance,
other than for emergencies. This requirement does not preclude a
qualified employee, working alone, from entering for brief periods
of time, a manhole where energized cables or equipment are. in
service, for the purpose of inspection, housekeeping, taking
readings, or similar work if such work can be performed safely.
However, someone on the surface must be aware of this type of
entry and know the expected duration of the task.

Before entering or using open flames in a manhole excavation in an

area where combustible gases or liquids may be present, such as near
a gasoline service station, GOSP, refinery, etc., the atmosphere of
the manhole or excavation shall be tested and found safe or cleared
of the combustible gases or liquids (See GI 2.100).

1.6.11.2 Trenching and Excavating

During excavation or trenching, in order to prevent the exposure of

employees to the hazards created by damage to dangerous
underground facilities, efforts shall be made to determine the
location of such facilities and work in accordance with GI 2.100,
Work Permit System.

When underground facilities are exposed (electric, gas, water,

telephone, etc.) they shall be protected as necessary to avoid
damage.

When multiple cables exist in an excavation, the cable to be worked

on shall be identified by electrical means unless its identity is
obvious by reason of distinctive. appearance.

Before cutting into a cable or opening a splice, the cable shall be

identified and verified by the proponent department.

when working on buried cable or on cable in manholes, metallic

sheath continuity shall be maintained by bonding across the opening
or by equivalent means.
 1.6.12 Construction in Energized Substations

When construction work is performed in an energized substation, authorization

shall be obtained from the local power service dispatcher and a work permit shall
he issued. (See GI 2.100)

When work is to be done in an energized substation, safety precautions shall be

detailed in the work petit (See GI 2.100).

Extreme caution shall be exercised in the handling of busbars, tower steel,

materials, and equipment in the vicinity of energized facilities.

1.6.12.1 Barricades and Barriers

Barricades or barriers shall be installed to prevent accidental contact

with energized lines or equipment.

Signs indicating the hazard shall be posted near the barricade or

barrier.

1.6.12.2 Control Panels

Work on or adjacent to energized control panels shall be performed

by designated employees.

Precaution shall be taken to prevent accidental operation of relays or

other protective devices due to jarring, vibration, or improper
wiring.

1.6.12.3 Mechanized Equipment

Use of vehicles, gin poles, cranes, and other equipment in restricted

or hazardous areas shall at all times be controlled by designated
employees.

All mobile cranes and derricks shall be effectively grounded when

being moved or operated in close. proximity to energizul lines or
equipment, or the equipment shall be considered energized. (See
OSHA 29 CFR 1926 Subpart N.)

Fenders shall not be required for low-boys used for transporting

large electrical equipment, transfonnen or breakers.

1.6.12.4 Substation Fencez

When a substation fence must be expanded or removed for

construction purposes, a temporary fence affording similar
protection, when the site is unattended, shall be provided. Adequate
bonding and grounding interconnections shall be maintained between
temporary fence and permanent fence.

February 1993 1.0 Electricity Page 29 I

 All gates to all unattended substations shall be locked, except when
work is in progress.

1.7 Electric Shack

Speed is essential in dealing with any electrical accident. A copy of “The Treatment for
Electric Shock” placard in Arabic and English should be pmminently displayed so that
everyone knows what to do in an emergency. Employees will be. trained in First Aid and
cardiopulmonary resuscitation (CPR).

In brief, the sequence for dealing with an electrical accident is:

1 If at all possible, switch off the power supply. If this is not instantly possible,
release the victim from contact with the conductor by using dry gloves, dry blanket,
dry wood, dry clothing, rubber sheets, or properly insulated equipment.
2 If breathing has stopped, begin CPR and continue as necessary.
3 Call for first aid assistance, a doctor, and an ambulance. The Saudi Aramco
emergency number is I IO.

Febmsry 1993 - 1.0 Eleclricity Page 292

FIGURE 1V.l: TEMPORARY CROSSINGFOR CONSTRUCTION EQUIPMENT

Overhead power lines are usually uninsulated and any kind of

metallic object coming near or in contact with them can cawe a
hazardous situation. High vollage can easily BIG across
considerable distance. Overhead lines should therefore be re-
routed, “made dead” or protected by timber “goal posts’ and
barriers. Clearance distances should be agreed upon with Saudi
Aramco before work starts.

Pebnmry1993 1.0 Elecwicity Page293

FICIJRE IV.2 PROPERUSE OF INSULATING TOOLS AND PROTECTIVE APPAREL

Note: Grounding Cables Shall Be Isolated And Removed Using Insulating Tools And Protective
Apparel
2.0 IONIZING RADIATION

Ionizing industrial radiation, such as x-rays generated by equipment or gamma rays emitted
spontaneously by radioactive materials, are widely used in industry for nondestructive testing, e.g.,
testing of welds in pipes and pressure vessels, without damaging the material. The material tested does
not retain any radioactivity when testing is completed.

For all practical purposes, the radiation produced by x-ray equipment or emitted by radioactive sources
are the same. X-rays and gamma rays both have properties which should be understood. Even though
they penetrate the body, they cannot be perceived by any of our five senses; they can be absorbed and
scattered by matter; they travel in straight lines at the sped of light; they ionize gases; they affect
photographic emulsions; and by far the most important, they can be harmful to the living cells of the
MY.

INSTRUCTIONS AND FORMS

Saudi Aramco General Instructions:

150.003 Ionizing Radiation Protection

Ilo-AID-08 Radiation Safety Manual

Saudi Aramco Forms:

Saudi Aramco 2654 Personal Radiation Exposure

Saudi Aramco Standard Drawings:

AB36895 Radiation Warning Sign

2.1 Methods of Protection Against Radiation

Distance, time, and shielding are the usual methods of reducing radiation exposure.

2.1.1 Distance

Distance is an effective method of protection because gamma and x-rays obey the
inverse square law, that is, the radiation intensity decreases with the inverse
square of the distance. Conversely, dose. rates at close distances can be
extremely high, even for low activity sources. It is essential, therefore. that
unshielded sources are. kept at a sufficient distance. from personnel so as not to
pose a health hazard to them.

2.1.2 Time

Time is a useful method of protection because high dose rates can be accepted
over very short periods of time. However, the cumulative dose must remain at
acceptable limits given in Cl 150.003-2.
 2.1.3 Shielding

To lessen harmful radiation, materials of high density, such as lead, depleted

uranium, or tungsten, are used to absorb emitted radiation.

In the use of x-ray equipment, precautions against emitted radiation are necessary
until the electric power is turned off and locked out. On the other hand,
radioactive materials constantly emit radiation and cannot be switched off.
Consequently, to absorb unwanted radiation and facilitate handling, sealed
sources are housed in shielded containers or bunkers.

2.2 Classification of Personneland Exposure Limits

In order to control human exposure to industrial radiation, all employees and contractors
are classified as either radiation workers or non-radiation workers according to their
training and need to use radiation sources. Classification does not guarantee safety; safety
procedures and adequate equipment must be used at all times.

2.2.1 Radiation Worken

A radiation worker is an occupationally exposed person or employee whose job

involves routine use of ionizing radiation and who has reasonable chance of
being exposed to radiation from a radioactive source.

Radiation workers are further categorized as Competent Persons or

Radiographers. Competent Persons do not normally use radiation sources, but
by training and experience are capable of supervising both routine operations and
emergency situations involving radiation. Radiographers are expected to safely
use radiation sources in the course of their work and must be in possession of a
valid “Saudi Aramco Permit to Use Material/Equipment Producing Ionizing
Radiation” before they can work with a radioactive source.

Radiographers must wear two personal dosimeters when working with radiation,
a direct-reading pocket dosimeter and an integrating permanent dosimeter (film
badge or thennoluminiscent dosimeter [TLD]).

2.2.2 Non-Radiation Workers

Non-radiation workers should not receive more than those dose limits given in
GI 150.003-2.

2.2.3 ExposureLimits

Radiation doses to workers should always be kept as low as reasonably

achievable (ALARA). Under no circumstances shall the doses exceed those
limits given in GI 150.003-2 for occupational or non-occupational people.

Special controls (see GI 150.003-2) are imposed on persons who are, or are
capable of b&g, pregnant. No occupational exposure is allowed for persons
less than IS years of age.

February 1993 2.0 hizing Rdiition Page 2%

 Over exposure shall be reported to the Saudi Ammca proponent, the
Occupational Medicine Services Unit, and the Loss Prevention Department.

2.3 Responsibilitiesfor Safe Handling

The Radiation Protection Committee (see GI 150.003) has full responsibility in all matters
concerning the safe use, storage, and transportation of industrial sealed sources and x-my
machines wed on Saudi Ammco property.

2.3.1 Contractor

The contractor appoints competent persons to be responsible for the immediate

supervision and the enforcement of instructions and standards. PWSONlel
involved in performing nondestructive testing must be certified and bold a valid
“Permit to Use Material/Equipment Producing Ionizing Radiation”.

2.3.2 Competent Person

Each radiographer will check at the beginning of each shift on the zeroing and
recharging of dosimeters and on the condition of the equipment. A competent
person familiar with all of Saudi Aramco radiation use requirements will make
field audits to ensure compliance with Company instructions and standards. He
must report the results of these audits to the applicable department responsible
for the operation. Also he must be familiar with all equipment and procedures
so that the proper corrective action can be taken in any emergency situation
involving radioactive equipment.

2.3.3. Radiographer

At the start of each shift, radiographers must ensure that all equipment is in safe
working order. All malfunctions must be reported to the supervisor or
Competent Person immediately. The radiographer must also make sure that he is
wearing a valid TLD or film badge and a direct-reading pocket d&meter which
has been charged and zeroed. One radiation monitoring instrument must be
available for each source in use. Equipment must be transported to the work site
with safety locks in place. Under no circumstance is equipment to be transported
in an unassembled or open condition.

Upon arrival at the job site and prior to operating with any sealed source, the
radiographer must ensure that non-radiation workers are not subject to radiation
levels that would exceed that which is permitted. Radiation areas must contain
radiation warning signs (see Figure IV.3) and be clearly displayed around the
circumference of the radiation area. In addition, in populated work areas, a rope
or tape barrier shall be erected around the radiation area. The area will be
monitored with approved survey meter to ensure safe area for non-radiation
workers is maintained. Further guidance on industrial radiography is provided
in GI 150.0034 and OO.AIP-08.

A weekly report on the condition of all equipment should be passed to the

supervisor.
2.4 Shipping and Transportation
Government Permits are required for shipping radioactive materials into and out of Saudi
Arabia. Additional information is available from Purchasing Services Division.

Transporting radiation sources to work locations requires a locked container located out of
the passenger compartment. The vehicle shall have radiation signs on the front and rear.

2.5 Storage Areas

Upon completion of work or at the end of each work period, every sealed source must be
returned to a storage area approved by the Saudi Aramco Radiation Protection Committee.
Storage is usually within fenced area. All permanent or temporary storage areas (bunkers)
must be approved of by the Saudi Aramco Radiation Protection Committee. Sources may
not be stored in the back of a truck whether or not they are. under lock and key. Radiation
readings must be taken at the perimeter of the storage area and the radiation level must be
within the acceptable limits given in GI 150.003. Radiation signs must be fixed to the
barriers of all storage areas. (See Figure IV.3.)

. A log shall be maintained of radiation sources in storage, logged in or out, by source

and responsible competent person in charge of source.
~GURE w.3: sTANIMD SIGN - RADIATION
V. Chemicals And Operations
1.0 LIQUEFIED PETROLEUM GASES

Liquefied Petroleum Gases (LPG) are. now being widely used in the construction industry. The
precautions covered in this section are directed to those industrial operators who handle these gases,
i.e., stores personnel and the actual operators using the gases. LPG is a term applied to combinations
of hydrocarbons known under various trade names and also widely known as propane and butane.

INSTRUCTIONS AND STANDARDS

Saudi Ammco General Instructions:

GI 355.020 Control of Compressed Gas Cylinders

Saudi Aramco Engineering Standards:

SAES-D-5 Liquefied Petroleum Gas Equipment, Installation

SAES-B.057 Safety Requirements: Refrigerated and Pressure Storage Vessels

Saudi Aramco Bottled Gas Manual:

Part 1.7 Liquid Petroleum Gas

American National Standards:

NJTA 54-88 Fuel Gas Code

ANSI A10.10-81

Safety Requirements for Temporary and Portable Space Heating Devices &
Equipment Used in the Construction Industry

NFPA 58-89 Liquefied Petroleum Gases, Storage and Handling

1.1 General

These gases are colorless, heavier than air, and normally odorless, but for commercial
usage, an odorizing agent is added for the obvious reason of facilitating detection in the
event of accidental escape of the gas.

At normal temperahues, they are gaseous and can be changed into a liquid by the
application of moderate pressure. In the liquid form, relatively large quantities of LPG
can be safely transported and stored in suitably designed containers. The approximate
ratios of gas volume to liquid volume are 275: 1 for propane and 240: I for butane.

Both gases are heavier than air at normal temperatures. Any leakage will form a gas cloud
which will settle at the lowest possible level. It may ignite if a flame or sparks are present.
This could happen at some. considerable distance from the source of leakage. The gases
form an explosive mixture with air, and they react vigorously with oxidizing materials.
These gases can be highly dangerous; if the container is exposed to heat or flame, there is a
 high risk of explosion. To reduce the risk of explosion, the cylinders must be equipped
with relief valves or fusible plugs.

1.2 Storage

1.2.1

Cylinders, whether empty or full, should be stored under cover for protection
against the elements. The storage. place should be detached from any other
buildings and constructed of non-combustible material. It should preferably be a
well-ventilated one-story building with all doors leading directly to the outside.

LPG cylinders must be. stored at least 6. I meters (20 feet) away from oxygen or
oxidizers or must be separated from them by a tire wall rated at 30 minutes.

1.2.2

The building should be fenced+ff and signs should be displayed both in Arabic
and English: “No Smoking”.

Water and dry chemical fire extinguishers shall be available.

1.2.3

Natural ventilation points should be positioned at both high and low levels.

1.2.4

All electrical fixtures should be of an explosion-proof type.

1.2.5

All gas valves, tittings, connections, and piping shall be made of stainless steel,
brass or copper; rubber/plastic hoses are prohibited.

1.3 Handling of Cylinders

1.3.1

Cylinders must not be dropped or allowed to come into violent contact with each
other.

1.3.2

They must he stored and used in an upright position, thus preventing the liquid
from passing through the relief valve regulator and into the equipment.
 1.3.3

They must not be placed in or near excavations or any low level area.

I .3.4

They must be placed on level ground and secured to prevent accidental tipping
over.

1.3.5

Care should he taken that the valve assemblies are not damaged. The main valve
should be closed and the valve cap in position when the cylinder is not in use.

1.3.6

Smoking is not permitted when handling cylinders.

1.4 Leakage
1.4.1

Cylinders, valves, connections, hoses, and pipings should be regularly inspected

for damage or leakage. Detection can be carried out by the following methods,
if flammable gas meter is unavailable:

1 Smelling
2 Touching: Leaking cylinder may be colder than those around it.
3 Listening: Sound of escaping gas.
4 Looking: Localized condensation or frosting.

1.4.2

Small leaks may he coniimxd by using soapy water.

1.4.3

A leaking cylinder must be immediately removed to an open space, clear of all

buildings and people or any potential source of ignition.

1.4.4

The cylinder must be placed with the leak uppermost.

 1.4.5

The supplier must be notified immediately.

1.5 Transportation
1.5.1

Full or empty cylinders which are loaded on vehicles must be placed in an

upright position, be adequately secured to prevent movement, and have valve
caps in place.

1.5.2

The vehicle should have tire fighting and first aid equipment.

1.53

The vehicle must also display all the necessary warning notices.

1.6 Operation
1.6.1

In permanent or semi-permanent installations, the cylinder must be placed

outside the building out of direct sunlight and the gas piped to appliances inside.

1.6.2

The cylinder must be secured in an upright position, away from excavation, pits,
and other low lying areas.

1.6.3

The regulator and other equipment is to be connected and a test made to ensure
that all joints are gas tight.

1.6.4

The regulator capacity must be suitable for the equipment being used

1.6.5

Before lighting, a check is to be made to ensure that there is sufficient ventilation

for the burner and that all combustible materials are removed from the work
area.

1.6.6

Once the burner has been lit, it should bum with a steady blue flame with blue-
green base cones.
 1.6.7

A dry chemical tire extinguisher must be readily available at the work area.

1.6.8

Shut off valves shall be installed at the main tank supply and at the operating
source. (See Loss Prevention Booklet, “Hazards of Gas Cylinders”)

1.7 Action in Caseof Fire

1.7.1

When cylinders are exposed to severe tire conditions and are engulfed in flames,
no attempt should be. made to extinguish the tire. In such condition, cylinders
are likely to explode immediately.

1.7.2

The action to be taken in such an instance is to evacuate the area immediately and
call the Fire Protection Department.

1.7.3

Cylinders which have been exposed to tire conditions must be adequately cooled
with water before any attempt is made to remove them.

1.7.4

If cylinders are equipped with automatic relief valves and the fire exposure is
severe, ignited jets of gas from these valves can extend as far as 6 meters (20
feet).

1.7.5

In the case of a small tire arising from gas leakage, it is possible to extinguish
the fire by immediately hlming off the cylinder valve. The cylinder should be
approached from the opposite direction to the source of tire.

1.7.6

If a fire does not directly involve other cylinders in the vicinity, water hoses
played on those cylinders will prevent increased internal pressure. and minimize
the risk of explosion.

1.7.7

All cylinders which have been involved in a fire must be rehu-ned immediately to
the supplier, alerting the supplier that the cylinder was involved in a tire.

February 1993 - 1.0 Liquefd Rtdcum Oares Page 305

1.8 Bulk Installations

Before any bulk storage installation is undertaken, the LPG supplier should be. consulted
on the size of the tank required and the most suitable fittings for that particular installation,
including relief capacity.

1.8.1

Temporary tanks are to be installed above ground on a dry, hard foundation

away from drains, culverts, or hollows where it would be possible for any
leaking gas to collect.

1.82

Tanks should not be exposed to heat or direct rays of the sun and they must be
adequately protected against accidental or unauthorized interference.

1.8.3

Only trained personnel are to install bulk tanks and equipment. All items used
must be of approved design and comply with the appropriate standards.

1.8.4

All pipeline systems must be tested to a safe working pressure after completion
of the assembly.

1.8.5

Fire water protection shall be provided

1.9 First Aid

If LPG has been inhaled, the affected person must be removed from the area, kept warm
and restul, and not allowed to move about. If the affected person is not breathing, mouth-
to-mouth resuscitation should be applied. No attempt should be made to give an
unconscious person anything to drink. If the person is breathing, oxygen must be.
administered by a competent person. If liquid has gone to the eyes, they must be
thoroughly washed out with water.

Medical aid must be obtained as soon as possible.

February 1993 - I .O Liquefied Petmlcum Gases Fags 306

2.0 PLANT OPERATIONS

The safe processing and movement of oil from underground to ship or transmission pipeline is the
primary Saudi Aramco objective. Any construction operation which could affect the safety of oil
processing and movement must be planned and performed in accordance with the operating procedures
of the area in which the job is located.

Every plant area in Saudi Aramca operations has a specific set of operating instructions and the
operating supervisor for that area has full responsibility for safety precautions. With this
responsibility, he also has authority to issue work permits and stop any work if it is not in accordance
with proper procedures.

It is therefore necessary for anyone expecting to work in an area where oil or gas is handled to know
the rules and regulations and obey them.

Failure to follow the operating rules can result in not only destruction of Saudi Aramco property but
also death of construction and operating personnel. This type of disaster must be prevented.

INSTRUCTIONS AND STANDARDS

GI 2.100 Work Petit System

GI 2.710 Mechanical Completion & Performance Acceptance of Plant/Unit

GI 441.014 Repair Procedures on Hydrocarbon Pipelines

SAES-A-005 Safety Instruction Sheet

Schedule ‘D’:

Saudi Aramco Safety, Health and Environmental Requirements - Plant Operations

2.1 Additional Information On Saudi Aramco Instructions and Standards

There are a number of additional instructions and standards which apply to construction
operations, either inside or outside Restricted Areas. The contractor must determine which
of these apply to him and ensure. that his supervisory staff is familiar with them. This can
be accomplished through discussions with operations management for the area and with the
construction engineer. A meeting of al1 concerned prior to starting a job shall be
conducted and a Hazard Identification Plan shall be prepared for review by Saudi Aramco
Loss Prevention Department.

Because of the large number of instructions which might be applicable to a specific job, it
is not practical to list all of them. The following, however, will be helpful in locating
applicable instructions and standards.
 2.1.1 GeneralInstruction Manual

This manual is one which provides general instructions applicable to all Saudi
Aramco areas and operations. The contractor will find most of the instructions
applymg to him in this manual.

2.1.2 ProducingInstructionManual

This manual is designed to provide producing operating personnel with

instructions on operating practices and procedures for specific operations. The
contractor would find it useful to know in advance what these procedures are and
how they affect him.

2.1.3 RefineryInstruction Manual

This manual is designed for use. in refinery operations. Its design and use is
similar to the Producing Instruction Manual except that it applies to refinery
operations.

2.1.4 SaudiAramco EngineeringStandards

These provide detailed instnrctions on how to do specific jobs and establish

minimum standards to follow. The contractor must use all applicable
engineering standards in the performance of his job. Failure to do so will result
in immediate shutdown, a delay for which the contractor will be responsible.
The Saudi Aramco construction engineer is familiar with the Engineering
Standards and will assist the contractor. Saudi Aramco Loss Prevention
personnel will advise and provide guidance on tire and safety problems.

2.2 Work Permit System

Any contractor planning to do work in a restricted area must obtain a work permit from the
operations supervisor for the area.

To obtain this pemGt, the contractor must have personnel with a valid certificate to receive
work permits. GI. 2.100, Work Pennit System, provides the information needed to obtain
such certificates and explains how to use them.

The work petit is a written permission to proceed with the work in accordance with the
plans and the restrictions written on the form. Without a proper petit, work will not be
allowed in the area. (See Work Permit System, Section II.1 of this Manual.)

2.3 Operation of Plant Equipment

It is expressly forbidden for any construction personnel to operate any valves, switches,
push buttons, or other devices in an operating area. If the work dictates such action, the
contractor personnel must call the operations supervisor to perform the service.

If the job involves work on equipment which is in service, a specific set of written
procedures will have to be prepared and approved in advance by Operating and Safety
personnel. The contractor must strictly follow these procedures. No deviations will be

February 1993 - 2.0 Plant Operations hge 308

 petitted without the prior approval of the operation supervisor. Close contractor
supervision will be required in these. types of jobs.

2.4 Shutdown and Maintenance in Plant Operations

Shutting down a plant is tbe sole responsibility of operating personnel. Construction
pwsormel should not, under any circumstances, be. involved in any operational activity.

In certain emergency sib&ions, it may be necessary for the contractor to shut down the job
and even move his equipment to petit access for operating and maintenance. personnel.
This emergency activity must be done as requested.

2.5 Commi.ssioning
GI 2.710, Mechanical Completion and Performance Acceptance of Plant/Unit, outlines the
procedures and requirements for accepting new plants or additions to plants after they have
been completed by the contractor. This is to assure. that the plant is safe to operate. in
every respect. The contractor should familiarize. himself with this instruction before he
starts work.

If there is any question on the tire and safety aspects of this instruction, the contractor
should contact the Saudi Aramco Loss Prevention Department for clarification and
assistance.

2.6 EmergencyProcedures: Saudi Aramco Disaster Plan

It is necessary for all contractors to familiarize themselves with the Disaster Control Plan
for the plant and area in which the job is located. Each person working for the contractor
must know exactly what to do when the emergency evacuation or stop work alarms are.
sounded and do it without delay.

The Disaster Control Plan does not normally require the assistance of any constmction
personnel. Saudi Aramco personnel are trained to handle the emergency.

If the emergency is the result of a construction operation, construction personnel will

notify operating personnel immediately. The operating personnel will initiate alarm
procedures and direct activities in controlling the emergency.

when tbe emergency alarm is sounded for any reason, all contractor personnel will
immediately shut down their job, make it safe, and proceed in an orderly manner to the
designated assembly point. They will be checked out by Security and should assemble at a
point outside the area and await further instructions from the Saudi Aramco Disaster
Commander.

Periodically, Saudi Aramco holds Disaster Drills to ensure. the smooth functioniog of its
Disaster Plan. The contractor is required to participate in these drills just as if it were an
actual emergency.
2.6.1 Gas Release Emergency Procedures

If there is a reason to suspect a gas release in the area through which. you are
driving:

1. immediately shut off the vehicle engine and do not try to restart it.
2. Check the wind direction by looking at the windsock.
3. Get out of the vehicle and walk to a safe location generally in a crosswind
direction away from the point of r&a.se.
4. Inform plant operation employees of the situation.
5. Do not go and investigate, leave this to operations.
3.0 PRESSURE TESTING
It is essential that safe practices be observed during pressure testing, due to the potential hazards
associated with high pressure liquids and gases.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 2.100. Work Permit System

GI 2.102. Pressure Testing Safely

GI 2.710 Mechanical Completion And Performance Acceptance Of Plant/Unit

GI 432.00 Pipeline Hydrotest Water Disposal

GI 434.000 Pipeline Repair and Maintenance

GI 447.002 Pressure Relief Valves - New Installation, Change. in Set Pressure, or Retirement
from Service

GI 447.003. Pressure Relief Valves - Routine Test, Inspection, Quality Assurance And Regulation

Saudi Aramco Engineering Standards:

SAES-K-001 Refrigerant Piping

SAES-A-004 Pressure Testing

SAES-A-005 Safety Instruction Sheet

SAES-A-007 Hydrostatic Testing Fluids And Lay-Up Procedures

SAES-B-55 Plant Layout

Construction Specification Manuals:

Form Saudi Aramco 2642

Engineering (Pressure Test Report - I l/90)

Form Saudi Aramco 2642-l

Engineering (Pressure Test Information Sheet - 11/90)

American Petroleum Instihrte Standards:

API-STDW91

Steel Gate Valves - Flanged And Butt-Welding Ends, Ninth Edition

API-STD-620~90

Design and Construction of Large, Welded, Low Pressure Storage Tanks, Eighth
Edition

American National Standards Institute:

ANSIB 16.5-88

Steel Pipe Flanges and Flange Fittings

ANSI B 31.3-90

Chemical Plant And Petroleum Refinery Piping

ANSI B 31.4-89

Liquid Transportation Systems For Hydrocarbons, Liquid Petroleum Gas,

Anhydrous Ammonia, And Alcohols

ANSI B 31.8-89

Gas Transmission and Distribution Piping System

American Society of Mechanical Engineers Standards:

Section VIII. ASME Boiler and Pressure Vessel Code

3.1 Preparation
3.1.1 SAES-A-004 (Pressure Testing)

The person in charge of hydrostatic testing should have read SAES-A604 and
GI 2.102, and fully understand the safety requirements and procedures involved
with pressure testing. All persons who will work on the pressure test must be
informed of the potential hazards and the necessary safety precautions. A work
pennit shall be issued prior to commencement of hydrostatic test operations.

3.1.2

Piping, vessels, supports and foundations designed for gas service shall not be
overloaded by the extra weight of the test liquid. Temporary supports and braces
may be required.
 3.1.3 Vents and D&u

Vents of adequate capacity shall be installed at high points, to vent air / gas from
the item while it is being tilled with the test liquid. Hazardous gases or vapors
must be vented clear of any area where personnel are working or where there is
any possible source. of ignition. Drains must be installed at a suitable location to
allow removal of the test liquid.

3.1.4 VdVtS

Where isolation valves are used to contain test pressures, they must be of
adequate rating for the pressure to be encountered. If isolation valves are used in
lieu of blinds, provisions shall be made to ensure that no over-pressurizing can
occur in equipment that is not being tested, due to possible valve leak.

3.1.5 pipings And Joints

Prior to testing, investigations shall be carried out to verify whether or not

temporary restraints are required to restrict the movement of pipings and joints
during testing; when necessary, adequate restraints shall be provided.

3.1.6 VZWlllIllS

On vessels or tanks which could collapse if subjected to a vacuum, there must be

sufficient vent relief capacity to assure that the vessel cannot be subjected to a
vacuum by draining the test fluid or by sudden cooling.

3.2 General Requirements

3.2.1

Do not approach system never previously tested, corroded piping or vessels, or

vessels with welds never previously tested during the stepwise increase in
pressure to the strength test pressure. After the strength test pressure has been
reached and held for a specitied interval, in accordance with SAES-A-004, the
equipment may be approached. The actual pressure at which the system under
test will be approached for close inspection shall be. specified in the test
pIOCdUre.

3.2.2

Pressure relief valve(s) shall be used to prevent over pressuring of the

equipment.

3.2.3

Any ancillary equipment not under test must be isolated by valves (subject to
part 3.1.4) or blind flanged and vented or disconnected.

February 1993 - 3.0 Rcslun Testing Fagc 313

3.2.4

Only calibrated test gauges shall be used and they should be mounted in the
upright position. Pump discharge gauges must be visible to the pump operator
for the duration of the test.

3.2.5

The equipment / vessel shall have adequate vacuum relief capacity to avoid
damage or collapse, when draining the test liquid.

3.2.6

Lines should be drained and dried mechanically when the test liquid is corrosive
or otherwise hazardous.

3.2.7

The pressure rise during a pressure test should be gradual and under control to
allow time for material to strain, and time for personnel to check for leaks, see
SAES-A-004 and Cl 2.102.

3.2.8

A system under test shall be depressurized (with the exception of pressure due to
a liquid head) before any work is done to stop leaks or repair weakness,
including the tightening of bolts. In tightness tests, bolts may be tightened
without depressuridng, if specifically approved in the written test procedure.

3.2.9

A block valve is required on the line from the test pump to the equipment under
test.

3.2.11

Air shall not be used to displace test fluid from underwater equipment unless it
has been determined that the equipment will not float.

Test Liquid

3.3.1

Water is a normally the preferred test liquid. Alternatives must be approved by a

deviation from standard or they may he used if they are specifically permitted by
SAES4004.

3.3.2

Salt water must not be used for testing any material subject to stress corrosion
cracking in the presence of chloride ions (such as stainless steel type. 304 or 18.8
- CrNi).
3.3.3

Pneumatic (gas) testing may be required as per SAES-A-004. Pneumatic testing

other than as specified in SAES-A-004 may be done only with the explicit
permission of the Consulting Services Department. Testing with air or other
gases under pressure can be hazardous due to the explosion potential.

3.3.4

Possible changes in pressure due to thermal expansion, contraction or hydrostatic

heads must be taken into account.

3.3.5

Written procedures approved prior to testing shall be followed for the disposal of
test mediums containing chemical additives for control of corrosion or bacteria,
as per the requirements of Cl 432.000.
4.0 CHEMICALS
There. are thousands of chemicals in existence. and hundreds of new ones are being developed for
commercial use every year. While almost all of these chemicals are beneficial in some. way, they can
be. dangerous too. In fact, of the thousands of chemicals in existence, it is difficult to find any that are
absolutely hartnless.

when dealing with ao unfamiliar chemical, it is always wise to assume that it is hazardous. The
exposure to hazards associated with a material depends largely on its proper identification, handling,
usage, transport, storage and disposal. In addition, materials which may be completely harmless in
one application may be deadly in another.

There are too many chemicals and too many possible combinations to deal with them individually here.
In the references listed, there are many sources of information on the identification, storage,
transportation, use, and disposal of hundreds of chemicals. In the literature there are tables of
hazardous chemical reactions. If the name of the chemical is known, the names of others with which it
is likely to react dangerously can be found. The proper identitication and labeling of chemicals is a
very important safety precaution.

When dealing with a potentially harmful chemical, precautions should be taken to ensure that
employees do not swallow it, inhale it, or allow it to contact their skin. The chemical must not be
allowed to accidentally mix with other substances in transportation, storage, or use. It must not be
subjected to undue shock, pressure, or heat. When the chemical is no longer needed, it must be safely
disposed of or recycled.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 150.001. Asbestos Regulation

GI 330.87. Bulk Deliveries of Oil Field Treatment Chemicals from Local Vendors

GI 355.001. Identifying, Cataloging, Ordering And Tracking Of Hazardous Materials

GI 355.002 Receiving, Storing, And Issuing Hazardous Material

GI 355.003 Disposing Of Hazardous Materials

GI 355.004 Handling And Storing Polychlorinated Biphenyls (PCBs) For disposal

GI 355.015. Requisitioning, Receiving, Storing and Issuing Explosives

GI 355.015-l Deterioration And Disposal Of Explosives

Refmety Instruction Manual:

No. 5.001. Caustic And A Dip Diluting Plant 20 - Safety Regulations

No. 10.740. LPG Plant, Salt Water Chlorination

No. 13.850. Sulfuric Acid Safety Regulations - Air And Water Unit

Operating Instruction Manual:

No. 5.244. Inhibitor, Handling Procedure

Saudi Aramco Engineering Standards:

Saudi Aramco Bottled Gas Manual

Saudi Aramco Chemical Hazard Bulletins (CHBs)

American National Standards:

ANSI 288.2. Standard Practice for Respiratory Protection

American Petroleum Institute:

API 2202-91

Dismantling And Disposing Of Steel From Tanks Which Have Contained Leaded
Gasoline

National Fire Protection Association Standards:

NFPA 321. Basic Classification of Flammable and Combustible Liquids

NFPA 325M. Fire Hazard Properties of Flammable Gases, Liquids, and Volatile Solids

NFPA 49. Hazardous Chemical Data

NFTA 491M. Manual of Hazardous Chemical Reactions

NFPA 704. Standard System For The Identification of Fire Hazards of Materials

Threshold Limit Values for Chemical Substances and Physical Agents in the Work Environment -
American Conference of Government Industrial Hygienists (ACGIH)

Material Safety Data Sheets (MSDS) - Manufacturer’s literature on chemicals approved by US.
Department of Labor

Dangerous Properties of Industrial Materials - Dr. N. Irving Sax

4.1 Hazard Identification System

The hazardous natllre of a material is related to the manner m which it is tramported,

stored or used; the materials with which it may come in contact; and how it is disposed of
or recycled. There is no single identification system which can briefly indicate the hazards
for all these conditions. Saudi Aramco uses NFPA 704 Identification of Fire Hazard
Materials, which indicates the fire hazards associated with any chemical and also describes
the hazards which might be encountered in storage, transportation, use. or disposal of the
chemical.

l=ebmaly ,993 - 4.0 chemicals psgc317

 Many of the materials in the Chemical Section, Class 26, of the Saudi Aramco Material
System Catalog are marked by the use of hazard identification labels. The container may
not be so marked, but it is iodicated in the catalog description of the chemical. The system
is based on four different symbols or numbers ammged in a diamond pattern (see Figure
V.1).

The degree of possible. iojurioos health effects, susceptibility of the materials to burning
and to release of energy are rated by numbers (see Figures V.2 and V.2.A.). A zero (0)
rating indicates little or no hazard end a four (4) indicates a high degree of hazard. It
should be remembed that although a zero health hazard rating indicates that the material
offers oo ham& to fire fighters beyond that of ordinary combustible material subjected to
fire, it does not mean that the material is harmless if inhaled or swallowed.

4.2 Health Hazards

Hazards to health arise from inhaling, swallowing, or skin contact. The severity of the
hazard ranges from nuisance chemicals that produce no injury, to chemicals that on short
exposure cm cause. severe injury or death. For industrial workers, the most prominent
means of entry of a hazardous chemical into the human body is through the respiratory
tract by inhalation. The next most important means of entry is through skin absorption.
The least hazardous pathway is through swallowing the chemical, BSthis seldom occurs in
industry. (Reference: Chemical Hazard Bulletins.)

4.2.1 Inhalation Pathway Hazard

Chemicals may be in the form of gases, vapors, dusts, or a mixture of these.

The senses of sight or smell cannot be depended upon to warn of chemical
hazards. Some gases are harmful in concentrations which cannot be detected by
their odor. Furthermore, some gases paralyze the sense of smell. Hydrogen
sulfide, at low concentrations, can very quickly paralyze the olfactory nerves so
that harmful concentrations cannot be detected through smell. Ordinary
automotive gasoline, to some extent, does the same thing.

When handling a volatile liquid, the maximum allowable concentration (MAC)

of the vapor should be known and not exceeded. Where exhaust ventilation is
oat available, good mechanical ventilation must be provided or the work must be
done outdoors.

In the case of a chemical spill, it may not be possible to control the maximum
allowable concentration. Therefore it is necessary to keep the worker from
breathing the vapor by limiting the amount of vapor through careful handling or
through the use of local exhaust ventilation. If the concentration of the chemical
in the air exceeds the thnxhold limit value (TLV) or MAC, then respiratory
protective devices are needed. It is important that the right kind of device for the
particular hazard be obtained. (See Breathing Apparatus, Section 1.10 of this
MUOWl.)

Dust is a common hazard. Whenever dusty material is handled, a respiratory

hazard may exist. Exhaust ventilation, fans, blowers, and proper handling
procedures most be used to keep the dust from enteriog the worker’s breathing
zone. If these methods fail, dust masks must be provided and their use enforced.

Pcblwy 1993- 4.0 chmicalr Page318

 Fine droplets of liquid form wheaever liquids are sprayed or splashed so suitable
precautions must be taken to prevent the tine droplets of liquid from entering the
worker’s breathing zone. Ventilation is also recommended. If such methods are
not adequate, suitable respiratory protection must be provided.

4.2.2 Skin Hazarb

Skin contact/exposure hazard may not be as dangerous to life as respiratory

hazards, but they are far more common. Dermatitis resulting from contact with
harmful chemicals is a comma work injury. Proper handling methods are the
first step in protection. The second step, in the case of materials which act
rapidly on the human body, such as corrosive chemicals (i.e. acids and caustics)
is to provide a physical barrier in the form of goggles, face shields, hoods,
gloves, aprons, suits, etc. The third step is to provide eyewash fountains and
safety showers, which flush the material from the eyes or skin.

The type of personal protective equipment required depends on the hazardous

characteristics of the chemical and the way it is used. Personal cleanliness is
itnportant. Thorough washing of the hands and face before meals, daily bathing,
and a regular change of clothing will reduce harmiid contact with chemicals.

4.2.3 Hazards of Swallowing Chemicals

In industry, swallowing chemicals does not occur frequently. The “lain

precaution is to ensure that employees know that the material is hazardous if
swallowed, and that they must wash their hands free of harmful chemicals before
smoking, drinking or eating. Never store harmful chemicals in food containers
or handle chemicals near food.

4.3 Emergency Treatment

4.3.1 Artiticial Respiration

Persons overconte by hanntid gases and vapors must be taken out into the fresh
air and, if they have stopped breathing, given artificial respiration; if there is no
heartbeat, commence cardiopulmooary resuscitation (CPR). Call emergency
assistance immediately by telephoning I IO.

4.3.2 First Aid

In case of accidental swallowing of chemicals, it is not wise to induce. the patient

to vomit. The hospital must be informed of the chemical injury or chemical
swallowed and the person should be moved to the hospital immediately for
medical treatment. In the case of caustics or corrosives, drinking a large amount
of water, followed by medical treatment, is rwxnmended. Telephone 877-8056,
Saudi Ammco Emergency Medical Services, for poison information.

4.3.3 Showers and Eyewash Fountains

For skin hazards, the best treatment is thorough water washing under the
emergency shower or eyewash fountain. Field treatment should only consist of

Febnwy 1993 - 4.0 Chcmicds Fagc 319

flus&g away the chemical. The patient should then be taken to the. hospital for
treatment.

These water flushing devices are required, because. working pmxdures end
personal protective equipment may fail. In the case of materials that are
immediately harmful to the eyes or skin, safety showers or eyewash fountains
should be provided. llxy should be within 6 meters (20 feet) of the exposure
site and accessible in an uoobstmcted straight line from the work location.
Emergency showers shall be properly identified with signs and color background
in accordance with SAES-B-55. A person who is blinded by a chemical must
immediately be taken to tbe shower or eyewash fountain. Some emergency
showers or eyewash fountains are designed so that standing under or near them
activate.5 the water supply. Others have bioged gates which are. pushed to
activate the shower, but all should be easily activated.

If the water piping to the shower or fountain is exposed to the sun, the water will
become so hot during summer that it could scald the user. Tbe piping must be
buried, insulated or shaded from the sun or the line must be only a very short
branch from a main water line that is used frequently enough to keep the water
from overheating in the sun. Emergency showers and eyewash fountains should
be checked daily.

CAUTION:

There are two important points that workers must be taught about the correct use
of emergency fountains and shower:

1 Before removing goggles, face shields, or other personal protective

equipment, the user must get under the shower or use the eyewash
fountain to wash off as much of the chemical as possible.

2 It is a mistake to start for tbe hospital without first doing everything

possible to flush out the harmful chemical. Tbe eyes or skin must be
washed for quite a long time to remove the chemical. It is necessary to
wash the eyes holding the eyelids open with the tingers for at least fifteen
minutes to free. the eyes of bases or caustics. This will be painful, but it is
absolutely necessary. In the case of acids, water will remove the acid
quickly, but it is necessary to hold the eyelids open with the fingers,
painful as this may be, and roll the eyes around under the shower or in the
eye fountain to make sure that all acid is removed. At least fifteen
minutes of thorough washing are required in the case of acid contact to
skin or eyes.

Caustic alkalis such as sodium hydroxide and potassium hydroxide are much
more difficult to wash from the skin or eyes. Strong alkalis of this type mixed
with water feel slippery to the touch. The skin should be washed until the
slippery feeling has gone and washing should be. continued for at least 15
minutes.
4.4 Fii Hazards
4.4.1

only the necessary amount of hazardous materials should be brought into the
work place, usually not more. than one day’s supply. Hazardous materials must
not be allowed to accumulate, and any extra amounts should be cleared from the
work area. Slop liquids or trash should be cleared away immediately. All
flammable materials should be stored according to the specifications of their
Chemical Hazard Bulletins, (CHBs) or Material Safety Data Sheets (MSDS).

4.4.2

Smoking and the use of sparking devices near flammable liquids or finely
divided combustible solids must be prohibited.

4.4.3

Blocking off air to a burning object is often possible in acid dip tanks or rubbish
containers where a cover can be provided and dropped down on the container to
smother the flames.

4.4.4

The use of fire fighting equipment, such as fire. extinguishers or water streams,
must te available in case.all effective tire prevention nxasures fail to prevent a
fire.. (See Fire Prevention, Section 1.11 of this Manual). Ordinary sand is a
good extinguishing agent for smothering small fires. The fire hazards of most
common materials can be found in the references given in this section. The
proper fire extinguisher should be at the job site and readily available at all
locations where a fire hazard is possible.

4.5 Reactivity Hazards

The manual of Hazardous Chemical Reactions, NFPA 491M, lists many of the chemicals
which are likely to have dangerous reactions with other chemicals. As a general
precaution, rough handling and shock should be avoided. Chemicals should not be
allowed to mix with other chemicals unless it is known that no harmful reaction will occur.

4.6 Transportation, Storage and Disposal

4.6.1 Transportation

During transpoltation, hazardous materials must be protected against shock,

accidental mining with other materials, damage to containers, undue heat from
the sun or other source.s, and theft, which could allow the hazardous materials to
cane into contact with people who arz unaware of the dangers. Specific
recommendations for the particular material may be obtained from the Area Loss
Prevention Office. The Saudi Aramca Chemical Engineering Response Team or
Fire. Protection Department also handles spills which occur during
 transportation. A vehicle transporting hazardous chemicals must be suitably
labeled.

4.6.2 Storage

The. NFPA fire codes contain recommendations for safe storage of flammable
liquids, compressed gases, and typical highly combustible or explosive solids.
Precautions must be taken to avoid shock, undue heat, or unplanned mixing.
There are some cases where separating walls or specified distances are required.

Specific storage recommendations for hazardous materials contained in tbe Saudi

Aramca Chemical Hazard Bulletins (CHBs) and manufacturer-provided Material
Safety Data Sheets (?&SDS) should he followed. IncompatibIe chemicals should
not bc stored together.

A list of hazardous materials shall be kept by the. contractor indicating type and
quantity of materials used in each case. its hazardous classification rating and tbe
quantity disposed of.

4.6.3 COllhlifl~

Hazardous materials must be stored in containers that are safe for the
transportation and we of tbe material. Containers must be labeled with the
appropriate hazardous materials label to indicate tbe actual contents. All safety
factors must be observed when transferring material from one container to
another and tbe receiving container must be labeled to correctly describe tbe
contents. Empty containers previously used to hold hazardous material must be
washed free of the. material or destroyed.

4.6.4 Disposal
(Se GI 355.003 and 355.004)

Hazardous/toxic waste is liquid, solid and semi-solid material, which, because.of

tbe quantity involved, the concentration, and/or tbe biological, physical,
chemical or infectious characteristics, pose B hazard to human health and/or the
environment if it is improperly managed.

The following are some examples of waste materials which are considered
hazardous/toxic, and are to be disposed of in accordance with established Saudi
AIwmx procedure.

. Waste paints and related products

. Asbestos
. Resins
. Wood preservative products
. Insecticides and pesticides
. Flushing fluids I chemicals
. Compressed gases (acetylene, oxygen, chlorine)
. Flammable. I combustible liquids (gasoline, diesel oil)
. Corrosive liquids (acid)
. Cleaning fluids
. Explosives

Iummy 1993 - 4.0 chemtcall Fags 322

 l Flammable solids
. Poisons and infectious chemicals
l Radioactive materials
l Magnetized materials
. PolychIorinated Bipbeoyl (PCB (electrical transformer oil)

The disposal of hazardous material most be. conducted by the contmctor/~r

(c/u). The latter is obligated to perform the following:

step 1:

The hazardous material most be identified by composition or content. If this is

not possible, prior to armoging for disposal of the material the contractor/o.%
should notify the AM&RD (Al Midra and Reclamation Division). The material
will be provided to AM & RD in containers clearly marked “Hazardous
Material” only, with no other conflicting or confusiig words.

step 2:

The c/u must follow manufachuers or literature safety guidelines (Material

Safety Data Sheets, MSDS, Chemical Hazard Bulletins, CHBs, etc.) in addition
to the Saudi Aramco procedures contained here. In cases where procedures
overlap, the c/u should use the more conservative methods of disposal. Hazed
rating codes assigned to SAMS material indicate the degree of hazard. (See
Figure V.2A.) Obtain advice as needed from the Hazardous Materials Advisor,
MHED (Materials Handling Engineering Division) at telephone number 872-
7419 or from individual specialist tits listed below:

Specialist Unit Telephone Number

Central Area Storehouse Dept. (CASD) 872-7419
Laboratories Dept. (LP) 876-672s
Loss Prevention Dept. (LPD) 873-8779
Process Aod Control Systems Dept. (P&CSD) 875-3131
District Medical And Support Services 877-842s
(DM&SS)
Industrial And Environmental Affairs Dent. 874-1402
(IkEAD)
Fire Protection Dept. (FPD) 874-3345

step3:

The hazardous waste material must he adequately sealed up in contaioers to

prevent leakage and labeled to denote composition or content.

Request a safety inspection of the material by the Hazardous Material Advimr.

 step5:
when a large quantity of hazardous material needs to be. disposed of, inform the:

a). Chemical Storage Segment, Material Disposal Unit, Reclamation Operations

Section, AM&RD.
b). Hazardous Materials Advisor, MHED.

step 6:

Follow the directives of the Hazardous Materials Advisor. (See GI 355.003.)

step7:
Transport the hazardous material to Dhabran Reclamation Yard using own truck
or request suitable vehicle from the Transportation Department by following
their established procedure.

step 8:

Contact Assistant Superintendent, Reclamation Operations Section (ROS), AM &

RD before a large volume of hazardous wste material is to be delivered. This
person may request that the material be delivered directly to Delivery Point Code
(DPC), 280 Reclamation Chemicals Storage And Handling Facility located near
Abqaiq GOSP 3.

See GI 355.004 for any deviation from this established procedure for the
handling, storage. and disposal of Polychlorinated Biyphenyls (PCBs).

4.7 Work on Equipment Which Has Contained Tetraethyl Lead (Organic

Lead Compounds)
4.7.1 Introduction

Tetraethyl lead (TEL) is an organic compound of metallic lead which is used to

improve the octane rating of gasoline. This compound is highly poisonous. The
hazard with tetraethyl lend is that, beiig a liquid it gives off vapors which can
come into contact with the body by breathing or skin contact. Tetraethyl lead is
very hazardous as its vapors can be. inhaled, absorbed through the skin, or
ingested through contaminated food or cigarettes. ‘Ihe best protection is to avoid
any contact.

To make it easier to detect spills of tetraethyl lead, it has been dyed a bright
orange. color.

Febtuary 1993 - 4.0 Chemicds F-age 324

 Tetraetbyl lead, or sludges containing organic lead compounds, are likely to be
found in the following places:

1. Wherever drums of the compound are transported, stored, or used.

Leaking drums can contaminate ships’ holds, trucks, and storage areas.

2. Wherever leaded gasoline is blended, handled, or stored

3. In controlled disposal sites designated to receive organic-lead-containing

“laterials. The sludge removed from leaded gasoline tanks is
decontaminated by spreading and weathering prior to mining with inert
solids to reduce the total lead concentration to no more than 0.5 % and
transfer to a final burial site. Since tetraethyl lead is delivered dissolved
in organic solvents, it also presents a tire hazard.

4.7.2 Reeautions

Tanks that have once. contained leaded gasoline (TEL) are considered dangerous
tbereatk even though they may have been used in other service for years. Such
tanks should be permanently marked on tbe manholes with a sign warning that
the tank has contained leaded gasoline and must not be entered without special
precautions. Sludge pits where. lead-bearing sludge from the leaded gasoline
tanks has been buried must te marked with permanent warning signs.

Before entering any tank, an inquiry should be made. as to the tank’s previous
service and a work permit obtained. Likewise, before marking excavations in or
around refineries or gasoline storage depots, it is wise to determine whether
leaded gasoline (TEL) sludge may be encountered. Work in cleaning, repairing,
or dismantling tanks which have contained leaded gasoline requires special
training and special precautions.

The workers must he medically certified and periodically examined before and
during tbe course of the work. Using regular monitoring of TEL workers, any
over-exposure to TEL should he reported to the Saudi Aramco proponent
department, the Saudi Aramco Loss Prevention Department and the Industrial
Hygiene Services.

The Saudi Aramco Industrial Hygiene Services and the Loss Prevention
Department should be notified when work is to be done in TEL tanks or in areas
with TEL contaminated equipment.

February1993- 4.0 chcmicats page32.5

FIGURE V.l: IDENTIFICATION OF MATERIALS BY HAZARD SIGNAL DIMENSIONS AND ARRANGEMENT
 EXPLANATION
OF
HAZARDRATINGCODES
IDENTIFICATION IDENTIFICATION IDENTIFICATION
OF HEALTH HAZARD OF FLAMMABILITY OF REACTIVITY
SUSCEPTIBILITY TO RELEASE
TYPE OF POSSIBLE INJURY SUSCEPTIEILITY TO BURNING ENERGY

:GoE H CODE F CODE R

EXTREME HEALTH HAZARD EXTREMELY FLAMMABLE EXTREMELY REACTIVE
Materials rvhich on brief intense Gates and matwialr which rapidly Materiab which are basically un-
4 exposure or repeated low level ex- 4 Vaporize at ambient temperature 4 stable: i.e. will violently poly-
paturs could cause death or mrior and preaurs, and which burn merize or decompose explosively
injury. readily. Includes liquids with at normal temperatures and
llashpoinu below 73QF W.G’W. PWrt”,%

HIGH HEALTH HAZARD HIGHLY FLAMMABLE HIGHLY REACTIVE

Materialr which on brief intense Materials which can be ignited Materials which will explode il
axporurs or repeated law level ex- under almost all ambient tern. heated, detonated. or react ex-
3 posure cm eaure serious tcmpar- 3 perature conditions. Includes 3 ploriwly if mixed with hydro-
ary or permansnt injury. lncludar liquids with flashpoints between carbons or oxidizers. Includes
potent mnsitizem. 73OF and lOOoF lZZ.GQCpnd materials which react explosively
37.GW. with water.

MODERATE HEALTH HAZARD MGOEAATELY FLAMMABLE MODERATELY REACTIVE

Materials with on intense or con- Matedab which must be moder- Materials such .ss strong oxidizars
tinucd exporurs could cause tern. ately heated or exposed to relati- which are incompatible with many
2 pomry incapacitation or injury. 2 vely high ambient temperatures 2 other materials and will undergo
Includes allargenr. before ignition can ocwr. In- violent but not explosive chemical
eludes liquids with flashpointt reaction when mixed with incorn.
between 1OWF and patible chemicals.
200°F 137.8% - 93.4W.

SLIGHT HEALTH HAZARD SLIGHTLY FLAMMABLE SLIGHTLY REACTIVE

Materiala which on ~XPO~UR Materiab which mutt be pre- Materials which am normally
I cum irritation but only minor. 1 heated before ignition can occur. 1 stable but may become incompat-
rawsibla injurY. Includes liquids with Gashpoints ible with other chemicals at
above ZOOoF f93.4W. elevated temperaturar and prar-
*“MS.

NO SIGNIFICANT HEALTH NO SIGNIFICANT FLAMMA- NO SIGNIFICANT REACTIVE

HALARG GLE HAZARD HAZARD
0 0 0
Mamrialt which will produce Materials that will not burn. Materials which are stable even
toxic effects only with wwwhslm- under firs exporur~ conditions.
ing dosage.

Fcbnwy 1993 - 4.0 Chendcal, Page 327

FIGURE V.3: IDEN~F~CATIONOFHEALTHHAZARD,FL AMhfABlLlTYANDREACTlVIn

Identification of Health Hazard identification of Flammability Identificationof Reactivity

ColorCode: BLUE Color Code: RED (Stability) Color Code: YELLOW

Signal Typeof Possible fnjwy Signal Susceptibility of Material to Burning Signal Susceptibility to Release of Energy

Materials which on very short Materials which will rapidly or com-

exposure could cause death or pletely vaporize et atmospheric Materials which in themselves are
major residual injury even though preeeure and normal ambient readily capable of detonation or of ex.
4 prompt medical treatment were 4 temperature, or which are readily 4 plosive decomposition or reaction at
given. dispersed in air and which will burn normal temperatures and pressures.
readily.

Materials which in themselves are

Materials which on short ex-
posure could cause serious Liquids and solids that can be ig. capable of detonation or explosive
reaction but require e strong initiating
3 temporary or residual injury even
though prompt medical treat-
3 nited under almost
temperature conditions.
elf ambient
3 sowoe or which must be heated under
merit were given. confinement before initiation or which
react explosively with water.

Materials which on intense or. Materials which in themselves are

continued exposure could cause normally unstable and readily undergo
temporary incapacitation or Materials that must be moderately violent chemical change but do not
2 possible residual injury unless 2 heated or exposed to relatively high
ambient temperatures before igni- 2 detonate. Also materials which may
prompt medical treatment is react violently with water or which may
given. tion can occur. form potentially explosive mixtures
with water.

Materials which in themselves are

Materiale which on exposure normally stable, but which can become
would cause irritation but Only Materials that must be preheated unstable at elevated temperatures and
1 minor residual injury even if no 1 before ignition can occur. 1 pressures or which may react with
treatment is given. water with come release of energy but
not violently.

Materials which on exposure Materials which in themselves are

under fire conditione would offer nOrmally stable, even under fire 6%.
0 no hazard beyond that of ordinary 0 Materials that will not burn.
0 posure conditions, and which are not
combustible meterial. reactive with water.
VI. Marine
1.0 COFFXRDAMS

A cofferdam is an enclosure constructed to exclude water from a work area during construction.
Cofferdam construction ranges from simple dikes to complicated timber or steel structures.
Cofferdams must satisfy hvo basic requirements:

1. They must be strong enough to withstand the forces caused by water, soil conditions,
and floating debris.

2. They should be as watertight as practicable, although some leakage, requiring

pumping, must always be expected.

The most common type of cofferdam encountered in Saudi Aramco is constructed from steel sheet
piling. The piles must be driven to design and penetration specifications and must encounter the pre-
specified driving resistance. The steel piling is generally braced by a system of horizontal wales and
struts which are. designed to resist external forces.

INSTRUCTIONS AND STANDARDS

Saudi Aramco Instructions and Standards:

Schedule ‘D’: Saudi Aramco Safety, Health and Environmental Requirements

Part 19 Excavations

F5u-t 20 Work Over Water

1.1 Design
All cofferdams in excess of 1.2 meters (4 feet) in depth must be designed by a qualified
engineer. Any deviations from the design encountered in the actual construction of the
cofferdam must have the approval of a qualified engineer.

1.2 Before Work Starts

Any cofferdam which is to be constructed in a navigable waterway or which would

constitute an obstruction or hazard to the operation of small boats or pleasure crafts must
be approved in advance by the Manager, Saudi Aramco Marine Department. The latter
will be responsible for coordinating its approval with the approval of required Government
agencies.

1.3 Construction

All cofferdam construction work must be performed in strict compliance with the design
drawings and specifications. All work must be accomplished by qualified craftsmen in
accordance with accepted trade practices. Any unexpected soil or hydrographic conditions
encountered during the construction must be reported immediately to the design engineer
for evaluation and a possible modification of the structure.
 1.3.1

If overtopping of the cofferdam by high waters is possible, means shall he.

provided for controlled flooding of the work area.

1.32

Emergency evacuation warning signals shall be provided and procedures

developed. Notices shall be posted at the entrance to the job site, and throughout
the area.

1.3.3

Walkways, ramps or bridges on cofferdams shall have at least hvo exit points.
These shall be provided with standard guardrails.

1.4 Potential Hazards

The construction and the use of cofferdams have three primary hazards which merit special
consideration.

1.4.1 Structural Collapse

Cofferdam struchlres may collapse as a result of the imposition of unexpected

structural loads or the failure of the soil inside the cofferdam struchlres as
evidenced by an upward heave or “blow-out” of the bottom. Such failures often
occur with little or no warning, therefore a means of rapid exit from the enclosed
cofferdam strwhlres must be provided for all workmen engaged in work inside
the structures.

1.42 Overhead Loads

Sump pumps, equipment, and machinery shall be mounted on a cantilevered

platform outside of a cofferdam. This will eliminate overhead obstructions,
which could present a hazard to the workmen engaged in construction within the
confines of the cofferdam.

1.4.3 Dislodgment of Struts and Wales

All internal supporting structures must be secured against accidental

dislodgment. The we. of locking devices on wedges will prevent their accidental
removal and the resulting collapse of the structure.

1.5 Inspection
1.5.1

General inspection should be carried out daily or after any weather condition or
incident which might affect the safety of the cofferdam.
 1.52

The security of all wedges should be carefully checked at the start of each shift.

1.53

Leaks can indicate a movement of the piles. Serious leaks should be reported at
once to the engineer in charge of operations.

1.5.4

Pump intake fastenings and the pumping sump should be carefully checked at the
start of each shift.

1.6 Leaks
1.6.1

Small leaks can be sealed by lead caulking in the clutches from the inside of the
cofferdam. Minor leaks over a large area can be sealed by dropping light
granular material into the water surrounding the cofferdam. The material will be.
sucked into the gap between the piles where it will form a seal.

1.6.2

Where large leaks are encountered which cannot be sealed as described above or
there is an indication that the piling has moved, the cofferdam area shall be
immediately evacuated of all perso~el and the problem brought to the attention
of the design engineer for correction.
2.0 MARINE OPERATIONS
This section, Marine Operations, is only concerned with the transportation of material, equipment, and
perscmel to off-shore job sites. This is carried out through the Saudi Ammo Marine Department by
using company~wmd and/or contractors’ crafts.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions :

GI 6.020. Personal Flotation Devices for Work Over, On or Near Water

GI 1185.003. Death or Injury Aboard Seagoing Vessels

GI 1186.502. Marine Craft Fueling, Taaajib or West Pier

GI 1186.504. SAG Regulations and Practice as Applied to All Types of Marine Craft at the Port of
Ras Tanurn

GI 1187.001. Collision & Damage By or To Marine Equipment or Craft

GI 1192.001. Operating Practices for Harbor Tugs, Offshore Vessels and Launches, Including
Safety Rules

GI 1192.002. Operating Prwedum for Barges Including Safety Rules

GI 1192.502. Operating Procedures for Marine Oil Recovery and Storage Barge/Vessel, Including
Safety Rules

GI 1193.001. Marine Port Information and Regulations

GI 1193.002. Navigation Warnings

GI 1194.001. Requesting, Assigning and Dispatching Pollution Control Vessels, Tugs, Launches
and Barges

GI 1196.001. Whistle Signals for Use Between Tugs and Barges or Tugs and Self-Propelled Vessels
When Berthing

GI 1198.001. Rig/Barge Moving

GI 1199.001. Safe Operation of Self-Propelled Jack-Up Barges

2.1 Other Publications

US. Coast Guard - 2.51

International Maritime Organization - Safety of Life at Sea

International Labor Office-Accident Prevention on Board Ship, at Sea, and in Port.

2.2 General
All safety precautions that are. applicable onshore. apply and must be enforced while
offshore, includiig the wearing of personal safety equipment. In addition, life vests must
be worn while working on, over or near the water. Work over water may be either
offshore or on a site camected to the shore. The hazards and the precautions for both
situations are similar.

2.3 Behavior on Floating Craft

Persormel embarked on floating craft must obey the instructions of the person in charge of
the vessel. In particular they must not obstruct his view or movements. They must travel
in the passenger designated areas. They should not enter or climb on top of the pilot house
end machinery space. are similarly out of bounds. Personnel are expected to act in a
responsible manner at all times.

2.3.1

Unexpected movements of the vessel even in good weather must be anticipated

and guarded against. Personnel should keep away from the ship’s side and make
use of handrails at all times.

2.3.2

Life vests must be available for all persamel. Each person shall wear and know
how to inflate a life vest (see Figure VI. 1).

2.4 Preparation for Transportation by Sea

2.4.1

Loose and movable parts of material and equipment must be properly secured
against movement. Such material and equipment must always be prepared as if
for very rough weather. Sea conditions can change rapidly. Even with no wind,
a swell cm produce violent movement. Lashing must be adequate. Tank
compartments being transported should be either empty or completely full.
Tarpaulins or plastic coverings must be of adequate. strength and well secured.

2.4.2

The Marine Department must be informed in advance so that they may prepare.
for the transportation of any hazardous cargo (acids, explosives gases, etc.) or
cargoes with special characteristics (e.g., sensitive to water, delicate, or
pilferage). Information on weights and measurements must be included for any
shipment that requires a manifest (Saudi Ammo Form 9063).

2.4.3

Although the actual loading may be performed by another department, the

Marine Department carries the ultimate responsibility for the safe loading and
distribution of cargo on the floating craft under its jurisdiction.
2.5 Tide and SeaEffects

During pile driving and general offshore work, allowance must be made for wave action
and the. rise and fall of the tide, especially when erecting stages and platforms. Tidal
predictions and weather forecasts are not completely accurate so a generous safety margin
must be allowed.

2.6 Care of Tools and Equipment

2.6.1

Protective coatings reduce the corrosive effects of salt water and salt-laden air on
tools and equipment. Nuts, bolts, and threads should be covered with grease or a
similar protective coating.

2.6.2

Electrical and radio equipment must not be left exposed. When not in use, they
should be protected by being retmned to their boxes or b&g covered.

2.6.3

Objects that we. dropped from any height can cause injury or damage, and they
may be impossible to recover. For this reason, small hand tools should be
secured by lanyards when working over or near water.

2.7 Housekeeping
Because of the confined space frequently encountered in Marine Operations, housekeeping
is even more important offshore than onshore.

2.7.1

Tools must not be scattered around. Any spilled grease or oil must be cleaned
up. Fire hose and rope must be coiled or flaked down clear of passageways.
Doors and drawers should be. kept closed.

2.7.2

Rags, pz~pers,cigarette butts, and scrap must be properly disposed of. Proper
disposal does not mean throwing the unwanted items overboard, thus polluting
the envim-t. Trash cans and ashtrays should be used.

Febnmy l!B3 - 2.0 Marine Opemtio~ Fage 335

 FIGURE VI.1: IF You WORK OVER, ON OR NEAR WATER

Drow,,lng fatalltles could be eltndnated Uworlor~en wore The etTectlve buoyant work vest should be operattve
eUeect,ve buoyant work vests whe” performtng their du- without mantpulatlo” by the wearer. It should sup-
ttes over. on. or “ear water locatlons. A large number of port apersonwtthhtslaceabovewatereventhough he
industries have now made the wearing of buoyant work 1s fully clothed and InJured or unconsctous.
vests mandatory lor employees who are exposed to
drowning hazards. Tests have revealed that the body tends to orlent Itself
along Its horizontal axts rather than pivot on the
“Buoyancy” ts defined as the physlcal iorce necessary to vertical axis (see Ulustratlon belowl.
support a body In a tloatlng posttlon. The clothed human
body has a negattve buoyancy. Buoyant work vests are
Intended to be worn on the body and to keep a person
alloat 11he slips or falls tnto the water. The vest should
hold the person’s face out ol the water. without any eflort
on the person’s part.

Olten. constructton contracts specify that worknlen

must wear buoyant work vests when their Jobs requtn
themtoworkover,o”.or”earwaterlocatto”sthatexpose
the”, to the tisk of posstble drowntng. However. in the
absence of’s speclnc requlrernent. It should be automa”=
that supervtsors require the wearing of a buoyant work
vest.
Due to the skeletal structure of an tnditidual. his normal The thstratlon below shows that the optbmm, flea
unasslstcd floating po~Bton would be head-down. face- trig posltto”foraFace-up body 1s 3010 60 degreeswith
down. as shown In the Illustration below. the head and face out of the water.

A” etTectlvevest will rotate a helplpssvictlm I” a race-

Up posttto” wtthln ftve seconds aRer strlktng the
The fllustrallon depicts the normal, unassisted floallng water. Weartng thevest causes onlymtnbnal tnterier-
posttton of a vtcthn with head down and face down. The ence with movement on the job and can save a
feet tend to tratl back and the ha”ds turn under. worker’s Me - should the need ever arise.
3.0 DIVING OPERATIONS
Accidents involving divers and their equipment are generally serious, because diving operations are
undertaken in an element unnatural to man. What would be considered to be a minor incident on land
could cause crippling injury or even death in a diving operation.

Due. to the extreme hazards of this occupation, divers must rely on their training, experience, and
initiative to avoid accidents. For this reason, the strictest compliance with regulations, standards, and
instructions must be observed at all times in order that everything possible is done to minimize the
possibility of an accident.

INSTRUCTIONS AND STANDARDS

Saudi Ammco General Instructions:

GI 1197.001 Procedures and Safety Rules for Diving Operations (See Appendix G)

The US. Navy Diving Manual is to be used as the standard for all Saudi Aramco diving operations.

US. Navy Diving Manual:

NAVSHIPS 0994401, March 1970

B.R. 181, 1972

United Kingdom Statutory Instruments

S.I. NO. 1229 Offshore Installations (Diving Operations) Regulations, 1981

Saudi Aramco Instructions and Standards

Saudi Aramco Bottled Gas Manual

TM 6.1 Medical Diving Emergencies (Technical Memorandum - Saudi Ammco Medical

Services Organization {SAMSO))

3.1 Employment of Qualified Divers

All divers shall be at last hventy-one (21) years old.

3.1.1

Divers must be. qualified and experienced in all aspects of underwater inspection,
constuction, repairs, and salvage works, including oxy-arc cutting, the.rmaI
lancing, and the use of pneumatic and hydraulic tools.

February 1993 - Comuucti.,,, Safety Manual: Dii Opmtie,x Page 337

 3.1.2

Divers shall be fully conversant with the use and operation of US. Navy
Decompression Tables, recompression chamben, and therapeutic decompression
p1ocedllreS.

3.1.3

Familiarity with the use of SCUBA, Hookah, and surface supplied helmets
(Swindel, Aquadyne, Kirby-Morgan, etc.) and knowledge of their maintenance
and repair is required.

3.1.4

Divers will be required to show evidence of their training and experience by

providing certificates from a competent authority.

3.1.5

All divers must be. fluent in both reading and writing the English language and
be able to depict the results of an underwater inspection by the use of sketches.

3.1.6

Evidence of medical fitness in accordance with 3.4 must be produced at the

prescribed intervals.

3.2 Diving Equipment

All equipment used in connection with diving and submarine operations shall be produced
by a reputable manufacturer. They must be of good quality and constructed of sound
material, in accordance with appropriate and accepted standards. Equipment should be
able to operate efficiently in the prevailing high temperatures of the Arabian Gulf.

3.2.1 Compressors

Compressors for supplying breathing air must be fitted with adequate filtration
and purification devices. They must be able to provide the air at a rated
pressure and capacity to cover the maximum depth required during the operation.

3.2.1.1

The air intake of compressors shall be remotely located with

reference to any exhaust system in the area to prevent contaminants
from entering the compressor intake.

3.2.1.2

All the safety devices and relief valves on high pressure compresson
must te operating properly.
 3.2.1.3

Detergent lubricating oils or oils with viscosity less than SAE 30

must not be used. Care must be taken not to overfill.

3.2.1.4

Compressed air supplied for breathing shall be certified Compressed

Gas Association grade D or better.

3.2.2 Reserve Air Supply

A reserve supply of air must be provided, maintained, and immediately available

in the event of a primary air supply failure, whether in the form of a standby
compressor or high pressure cylinders (or volume tanks) on the surface. If the
reserve is in the form of high pressure cylinders (or volume tanks), it should be
of sufficient capacity to enable the diver or divers to reach the surface safely
while carrying out any necessary decompression step on the way. Reserve
supply for recompression chambers should be sufficient to allow required surface
decompression to be carried out.

3.2.3 Bail-Out Equipment

In case there might be a ruptured, cut, or irretrievably fouled hose, each diver
should be equipped with “bailaut” equipment, either in the form of a “bail-out”
cylinder, a diver’s life vest, or a pneumo hose.

3.2.4 Maintenance

All plant (including safety) and diving equipment must be regularly maintained.
Correct records must be kept of this maintenance.

3.2.4.1

All SCUBA tanks, recompression chambers, volume tanks, high

pressure cylinders, and storage vessels must be regularly checked
and tested at the prescribed intervals in accordance with the
manufacturer’s instructions and Saudi Aramco regulations.

3.2.4.2

As indicated in the Saudi Aramco Bottled Gas Manual, air cylinders

not in sea water use are to be inspected internally and hydrostatically
tested, at intervals not to exceed five years. They should be
appropriately stamped to denote this inspection.

3.2.4.3

Each item of plant and diving equipment should be regularly

inspected by a competent person at periodic intervals, and after the
equipment has been modified. The maximum period behveen
inqxctmm should be. three months.

Febwry 1993 3.0 Diving Operation Fa.E.e 339

 3.2.4.4

All hoses used for carrying compressed air or other gases must be
checked for wear and abrasion and subjected to test pressures at least
once every three months.

Hose, fittings and connections should be of the screw thread type

and properly fitted to the hoses. Hoses used in oxygen breathing
systems must be grease and oil free.

3.2.4.5

Any pressure gauge showing an error of more than hvo and one half
percent (2.5%) must be adjusted or replaced.

3.2.4.6

Communication systems must be checked for correct operation.

Every wire must be checked for continuity and, if they are combined
with the life line, for wear.

3.2.4.7

A supply of suitable protective. clothing such as diving suits,

coveralls, gloves, and hoods must be available at all times. Insulated
gloves shall be provided to divers performing welding and burning
operations.

3.2.4.8

Gas cylinders taken under water shall be hydrostatically tested,

inspected and stamped every hvo years.

3.3 Safeguards
When divers are preparing to enter or leave the water, or are in the water, or diving
operations are underway, the International Code Flag “A” (“I have a diver down, keep
well clear of area and maintain a low speed.“) must be flown. (See Figures VI.2 and
VI.3.)

Communications - A hvo-way voice communication system shall be used between:

1. Each surface-supplied air or mixed-gas diver and a dive team member at the dive
location.

2. Two-way communication system shall be available at the dive location to obtain

emergency assistance.

In addition, special lights and day marks for “vessels engaged in surveying or underwater
operations” should be shown in accordance with Maritime Regulations (Figure V1.3).
 3.3.1

Any person involved in an activity which could he a hazard to divers in the

vicinity, such as those in charge of submarine blasting or masters of vessels
about to move, start propulsion engines, or operate. pumps, must be forewarned.

3.3.2

Adequate arrangements must be made to provide a safe means of access to and

egress from the water. It must be kept in mind that a diver may be unccnxious
as a result of an accident.

3.3.3

Proper surface support and other facilities for the safe conduct of diving
operations must be provided.

3.3.4

In all cases of emergency, the diving supervisor, the foreman diver, or the
person in charge of a diver or divers must he the sole arbiter as to action to be
taken. All personnel, whether connected with the diving operation or not,
should take instructions from him.

3.3.5 Safe Operation of Divers

3.3.5.1

Bottom time and decompression time will be controlled by the diving

supervisor or person in charge of diving.

3.3.5.2

On all work requiring four divers or more, a diving supervisor shall

be present to facilitate coordination between divers and the surface..

3.3.5.3

All diving operations requiring more than hvo divers (using air for
breathing) in water of a depth greater than 30 meters (100 feet),
require the presence of a diving supervisor.

3.3.6

At all times when a diver is in the water, a stand-by diver must be on deck with a
stand-by rig, fully dressed and ready to dive.

3.3.7

No diver working in water 9 metea (30 feet) or less shall be required to work
longer than a twelve (12) hour shift without having a proper rest except for
emergencies.

February 1993 -3.0 DivingOpcnhu Page341

3.3.8

Repetitive diving should not be. done. as a routine. If the task necessitates the use
of “repeats”, efforts should be made to obtain additional divers. When this is
impracticable, the tables must be strictly adhered to in order to avoid
decompression sickness, which could require therapeutic treatment and could
endanger the health of divers and delay operations.

3.3.9

Therapeutic decompression must take precedence over all other operational

requirements.

3.3.9.1

Divers must remain in the vicinity of a recompression chamber for a

period of hvelve (12) hours after the last dive.

3.3.9.2

In the case of therapeutic decompression the period in 3.3.9.1 shall

be extended to hventy-four (24) hours.

3.3.9.3

In mild case of decompression sickness which have been treated

under Tables 1, lA, 2, 2A and 5 (US. Navy Diving Manual), a
diver can be returned to work at tbe discretion of the diving
supervisor.

After treatment for a case of “bends” under Tables 3, 4, 6 and 6A, a

diver will not be permitted to dive again until he has been examined
and passed as tit by a physician.

3.3.9.4

Each diver will maintain a personal logbook. Entries shall include

but are not limited to the following:

. Diver’s name.
. Name and address of the employer of divers.
. Date.
. Name of the Diving Supervisor.
. Name of the vessel, barge, or installation from which the diving
operation is carried out.
. Maximum depth reached on each occasion.
. Time he spent under water on each occasion.
. Type of equipment used by the diver.
. Work carried out by him on each occasion.
. Details of decompression sickness or other illne.ss/iijury
suffered by the diver.
. Any other factor relevant to health.
 l Each daily entry will be signed by the diver and also by tbe
diving supervisor.
l Divers must retain their logbooks for a period of not less than
hvo years from the date of the last entry in the logbook.

3.3.10 Recompression Chamber

A recompression chamber must be on site during all diving operations in excess

of 18.5 meters (60 feet). Whenever a recompression chamber is not available,
only “no decompression” dives are permitted.

3.3.10.1

The maximum rate of ascent is 18.5 meters (60 feet) per minute in
the case of air decompression and 7.6 meters (25 feet) per minute in
the case of oxygen decompression.

3.3.10.2

Only necessary articles are allowed in the recompression chamber.

No tobacco or any ignition source, including electrical shall be
allowed in the chamber. Smoking shall never be permitted ia the
chamber whether under pressure or not.

3.3.10.3

The chamber shall be kept clean and dry.

3.3.10.4

Personnel in a chamber under pressure shall ensure that both they

and all loose materials are. kept clear of all atmosphere inlet and
exhaust openings. The exhaust, which is under pressure, is
especially dangerous because it subjects anything near it to a high
suction pull capable of causing extreme bodily harm

3.3.11 SCUBA Special Care

Tbe use of SCUBA equipment in water over 18 meters (60 feet) in depth should
be restricted.

3.3.11.1

SCUBA equipment shall not be used to depths greater than 45 meters

(150 feet).

3.3.11.2

SCUBA equipment should never be used for dives requiring

decompression.

February 1993 - 3.0 Diving Opcnliolu Page 343

 3.3.11.3

In open water, SCUBA divers shall always be attached to B clearly

visible float by a life line. In no case shall SCUBA divers be
allowed to swim free.

3.3.11.4

In enclosed or restricted water such as beneath structures, either a

lifeline or the “buddy” system must be used. There will be no
untethered solo diving.

3.3.11.5

When using SCUBA equipment, divers will always wear in

inflatable life jacket of the. approved type.

3.3.11.6

No SCUBA diving should be car&d out during darkness.

3.4 Physical Fitness

All divers must be physically tit for diving and have a certificate to this effect issued by a
qualified medical practitioner: one who has experience and knowledge of the medical
requirements for diving.

3.4.1

Tbe medical certificate should state “Fit for Diving” and be not more than hvelve
months old.

3.4.2

Doctors carrying out medic& for divers should be aware of the impatance of
the condition of heart, lungs, chest, ears, nose, throat, and teeth. An EKG and
chest X-ray are mandatory on an annual basis, while a long bone X-ray should be
performed every three years.

3.4.3

For British divers, a current British Diving Fitness Register is acceptable and,
Likewise, any recognized fitness register for other nationalities.

3.4.4

All divers should be. trained in First Aid/CPR, and on all diving operations,
there. should be an approved First Aid Kit suitable for use under hyperbaric
conditions on site as recommended in the US. Navy Diving Manual.
3.5 Medical Diving Emergencies: Proceduresand Responsibilities
Every incident/accident involving diving personnel shall be repoti on Saudi Aramcn
Form 3208 with the responsible supervisor submitting a follow-up report on Saudi
Aramco Form 681. Offshore emergency response procedures are given in Appendix B.
Specific responsibilities are as follows:

3.5.1 spolts Divers

All divers must have an experienced person in charge with good knowledge of
decompression sickness. He has to know the following hvo diving emergencies
numbers to call if requiring help: 678-1248 from 6 a.m. until 6 p.m. 7 days per
week; and 378-3691 from 6 p.m. until 6 a.m. 7 days per week. He should state
his exact location and follow the instructions given to him by the coordiiator
answing the number.

3.5.2 Commercial Divers

The diving supervisor will immediately arrange recompression according to the

appropriate table and report the incident to the coordinator manning the diving
emergencies numbers.

3.5.3 Coordinator, Diving Emergencies

The coordinator, on call at either of the above numbers, will receive the
information on diving medical emergencies. In the case of sports divers, he will
direct them to the nearest available recompression chamber and alert its operator.
He shall also inform the duty diving medical consultant who can be at the Saudi
Ammco Preventive Medicine Service.s Division on 877-8916 (at&r work hours
on 878-1697 or 878-0890).

In commercial diving incidents, the coordinator may elect to proceed with

treatment using the appropriate table without notifying the diving medical team
in cases of minor decompression sickness. In all type II bends and possible gas
embolism cases, the duty diving medical consultant shall be. notified
immediately.

He shall send a monthly report of all incidents involving therapeutic

decompression to the senior Occupational Medicine specialist.

3.5.4 Diving MedicaI Team

This will come under the jurisdiction of the director of Preventive Medicine
Services and will be a multidisciplinary group headed by the senior
Occupational Medicine specialist. It will be comprised of a group of physicians
with an interest and training in hyperbaric medicine who shall rotate. as duty
diving medical consultants. Nurses with special training will also be. integrated
in this group which shall constantly keep abreast with current practices. The
diving medical team will provide this service to the Marine Department.

Febnmty 1993 - 3.0 Diving Operationa Fage 345

 3.5.5 rvhineDeparlme”t
The Marine Department is responsible for the provision, maintenance, and
manning of the reuxnprcssio” chambers.

3.6 PersonnelTransfer at Sea

The following is to be wed as guidelines for the transfer of persons at sea from vessel to
vessel or from vessel to platform (or stmchxe).

A. Personal Flotation Devices. These references are pertinent items from Loss
Prevention Department GI 6.020 - Personal Flotation Devices for Work Over, On or
Near Water.

3. RequirGX”e”ts.

3.1. Wearing of personal flotation devices are required as follows:

3.1.7

When working or riding on the deck of a marine vessel or craft

during mugh seas at the discretion of the person in charge of the
vessel or craft.

3.1.11

When transferring to or from any water craft or to or from one water

craft to another.

3.1.17

At any time when deemed necessary by the boat skipper, ship

captain, supervisor, or the person in charge of the marine vessel,
installation or craft.

4.1.3

Marine craft skippers, ship captains and aircraft pilots shall enforce
the wearing of personal flotation devices in their vessels or aircraft.
Failure of an employee to heed the instructions given by the person
in charge of the marine craft or aircraft shall require the passenger to
be removed from the craft with disciplinary action to follow by the
employee’s department.

4.1.4

Supervisors or persons in charge of personnel in facilities,

installations, or work activities shall be responsible for having their
personnel follow the requirements regarding the wearing of personal
flotation devices.
 4.2.

Contractors shall provide (fully functional, no defect) personal

flotation devices for each of their perso~el. They shall also provide
their perso~el with the necessary instructions or training on the
proper way of wearing personal flotation devices. The. proponent
Saudi Ammco organization shall be responsible for ensuring that
contractors comply with the. applicable requirements of this GI
6.024X

B. Saudi Arab and contractor vessel crews shall also be issued with proper working
uniforms and personal protective equipment such as shoes, gloves, glasses and hard
hats. The Marine Department expects all Saudi Aramco and contractor persomwl
working around marine facilities to strictly adhere to Company safety rules and
regulations.

February 1993 - 3.0 Diving Operations Fagc 341

FIGURE VI2 INTERNATIONAL CODE FLAG “A”

INTERNATIONALCODE FLAG “A”

FIGURE VI.3: SIGNALS

SIGNALS
DAY NlGHT

RED BALL OR SHAPE-DAY MARKS RED L,GHT __

TO BE NOT LESS THAN
0.6 METERS (2 FEET)

DAY MARKS 8 NIGHT LIGHTS

,TO SE NOTLESSTHANlBMETERS(6FEE

WHITE DIAMOND

RED LIGHT .’
Appendix A
INDEX TO APPENDIX A

This Appendix contains the following information:

* Project Management And Contractor’s Safety Competition Site Registration Form;

* Contractor Safety Competition, Rules Of Competition;
I Contractor’s Competition Job Safety Evaluation;
* Saudi Ammco Safety, Health aad Environmental Requirements;
* Hazard Identification Plan (H.I.P.).
A.1 PROJECT MANAGEMENT AND CONTRACTOR’S
SAFETY COMPETITION SITE REGISTRATION FORM
To: Saudi Ammco Loss Prevention Department Date:

Estimated Completion Date:

B.I. Number: Peak Number Of Employees:

Signed: (Contractor’s Representative)

Job Title:

Company:

Date:

Saudi Aramco Proponent Department:

This form is to be. completed and sent to the local Saudi Aramco Loss Prevention Office with a copy to
the designated senior Project Engineer, who is a member of the proponent Project Management Team
@‘MT).

Signed:
Saudi Aramco Project Manager
A.2 CONTRACTOR SAFETY COMPETITION, RULES OF
COMPETITION

CONTRACTOR SAFETY COMPETITION JOB SAFETY EVALUATION

RULES OF COMPETITION

1. The competition shall be run over a sin-month period (January to June and July to
December) and shall be asses.& according to the requirements of Schedule ‘D’ of the
contract documents.

2. A contractor on a Budget Item (BI) who meets the following criteria shall be
registered in the competition by the responsible Proponent (PMT).

a. Contractor and related sub-contractor exceed 50 for the entire six month
period.
b. Estimated completion time exceeds the competition time period.

3. An unscheduled site inspection will be carried out by the Loss Prevention

Department once before the 25th day of every even month. A contractor shall have a
minimum of three ratings within the six month period. Tbe Saudi Aramco Loss
Prevention representative will report to the site office before. he starts his inspection.
Representatives of Project Management and the contractor shall be invited to
accompany the Loss Prevention representative during the inspection. If it is
inconvenient for a member of the Project Management Team or contractor’s
personnel to accompany the Loss Prevention representative during the inspection, the
Loss Prevention representative will conduct the inspection alone - awarding
appropriate scores. These scores shall be. final. If during the inspection there is a
difference of opinion over the points awarded, then the Loss Prevention
representative will make the final decision.

4. The Saudi Aramco Project Management Team shall revive a copy of the inspection
sheet, and they should distribute it to the appropriate contractor. Remedial steps
shall be taken to rectify faults and improve the score rating. At the end of the
competition, a copy of the six-month summary sheet will be provided to any
contractor.

5.
a. A contractor working on one BI at one location shall be evaluated, scored
sod ranked separately.
h. A contractor working on more than one BI shall have an entry in the
competition for each BI.
c. A contractor working on the same BI at separate sites shall be evaluated
by site hut the final score will be averaged.
d. Multiple contractors working on the same BI shall be entered, evaluated,
scored and ranked separately. (This also applies to consortium partners -
provided they meet requirements in 2 above.)

F&my 1993 - Conm~~tion Safuy Mti: Commctor Safuy CMlpctition Ruler Fage 332
 e. For those rare caw where there are. multiple sites and multiple contractors
on a BI, each site under the BI will be. scored separately but averaged with
all sites for that BI by contractor.

Exceptions to the above guidelines shall be reviewed by Project Management Team

and Loss Prevention during initial registrations.

6. Following each inspection by the Loss Prevention representative, the original copy of
the form SA-6710 shall be submitted to the superintendent, Central Area Loss
Prevention Division. Building 3121, Room 113, Dhahmn, not later than the 25th day
of each even month. In cases of holidays or rescheduled days off, the first work day
after the 25th is acceptable.

I. Any contractor who experiences a job related fatality, or serious incident that results
in the hospitalization of five or more. employees, and fire resulting in SR 10,OCNl
worth of damage on any one of their sites within the competition period, will cease to
be eligible for an award.

8. Should a registered contractor not retain an average of 50 or more employees for the
entire competition Period, they will be dropped from the competition.

9. Any item of concern not specitically covered on the Evaluation Form A-6710, shall
be reflected in column #18 under Special Items.

10. Should any contractor find he has completed the project before the end of the
competition period due to meritorious performance or reasons beyond his control,
then he will still be eligible to compete in the final assessment.

11. Should it be found that the contractor has not entered into the required logs details
which at a later date are determined to have occurred, e.g. restricted duty, lost work
day cases, accidents, fires, etc., then he would be deemed to have broken the rules
and forfeit the right to be included in the awards for the duration of that competition
for which he was eligible.

12. Every hazard report Saudi Aramco Form 3744 issued and not corrected within 24
hours, a penalty of 500 points shall be deducted from the total score.

13. Should a contractor incur a second hazard report, disqualification for the rest of the
competition period shall result.

14. Violations noted during 811initial inspection which have not been corr&ed by the
next general and/or follow-up inspection shall be deemed a repeat violation and a “0”
score will be given for the entire section under consideration.

SCORING:

Where a section is inapplicable to a particular site, e.g. no scaffolding, cranes, etc., then
that section will OK from the possible percentage scare.

Febnmry 1993 - A.2 Contnctor Safely Competition Rules Fage 353

POINT ASSESSMENT:

Points will be Assessedbased on the gravity/severity of violations encountered and will

range t?om 0 to 100. Points can be given from 0 to 100, depending on the judgment of the
Loss Prevention Department representative.

OVERALL PERFORMANCE RATING:

Overall percentage performance will be calculated as follows:

Points Scored x 100 = Contractor Rating:
Points Possible

Every endeavor will be made to provide an accurate assessment at each

inspection. Any questions that may arise concerning this job safety evaluation
may be submitted to the proponent department for resolution. Any contractor
who persistently retllms poor scores or violates the competition rules may be
subject to corrective action by the proponent department.

Please Nofe:
For more infomtation on the Contmctor Safety Competition, and for the
current competition rules, please contact your Area Lass Prevention Offire.
-
 F~CURE A.1: CONTRACTOR’S COMPETITION JOB SAFETYEVALUATION COKED.

I I I
WINrSscORED
wwm PossmLE I I

TOTAL POINTS SCORED TOTALPOINTSSCORED x ,w) =

TOTAL POINTS POSSIBLE

TOTAL POINTS POSSIBLE

OVERALL CONTRACTOR SCORE

A.3 SAUDI ARAMCO SAFETY, HEALTH AND
ENVIRONMENTAL REOUIREMENTS

1. Compliance With Safety Rules - Schedule ‘D’

CONTRAtYOR shall at all times comply with, and ensure that its employees, agents and
subcontrqctors comply with, applicable Saudi Arab Government Safety Regulations and all
SAUDI ARAMCO Safety and Loss Prevention rules and regulations. Specifically,
CONTRACTOR shall comply with the provisions of the SAUDI ARAMCO Construction
Safety Manual and SAUDI ARAMCO’s publication entitled “Loss Prevention
Requirements for Contractors”, Paragraphs 5 through 27 of this Schedule (which
supplement but do not limit the requirements of the Construction Safety Manual), and such
other related requirements, specifications and standards as are. made known to
CONTRACTOR by SAUDI ARAMCO. CONTRACTOR may request copies of all
applicable rules and regulations from SAUDI ARAMCO’s Loss Prevention Department.
CONTRAnOR shall also take, or cause to be taken, any additional nxasures which
Company Representative may direct to protect against injury to or death of any person or
damage to or loss of any property during CONTRACTOR’s performance of the work.
CONTRACTOR shall maintain the SAUDI ARAMCO Construction Safety Manual and
apphcable SAUDI ARAMCO GIs at the WORK Site.

2. Deviations From Safety Rules

Any deviation by CONTRACTOR from SAUDI ARAMCO’s Loss Prevention rules and
regulations must be. approved in writing in advance by Company Representative.

3. Failure To Comply

Should CONTRACTOR fail to comply with the requirements of this Schedule ‘D’, SAUDI
ARAMCO shall notify CONTRACTOR in writing. CONTRACTOR shall, upon being
advised of its noncompliance, immediately take all corrective action required to comply.
Such corrective action shall, unless provided otherwise in this Contract, be taken at
CONTRACTOR’s expense. If CONTRACTOR fails to take such corrective action
promptly, Company Representative may direct CONTRACTOR to suspend all or part of
the WORK pursuant to Schedule “A” until satisfactory corrective action has been taken.
Costs incurred by CONTRACTOR as a result of such WORK suspension shall be for
CONTRACTOR’s account and any resultant CONTRACTOR ptxfomuce delays shall not
be deemed excusable here-under.

4. Saudi Aramco Assistance

CONTRAaOR may request assistance from SAUDI ARAMCO with rep& to the
implementation of its Loss Prevention requirements. Company Representative, or such
party or parties designated by him, will assist CONTRACTOR by explaining good safety
practices, pointing out unsafe WORK Site conditions, and by applying his/their experience
and judgment in order to assist CONTRACTOR in improving WORK safety. It is
understood, however, that rendition of such assistance by SAUDI ARAMCO will in no
way relieve CONTRACTOR of its responsibilities as set forth in this Schedule ‘D’.
5. Lass Prevention Plugram

CONTRACTOR shall prepare. and submit B Loss PREVENTION Program to Company

Representative, for SAUDI ARAMCO’s approval, not later than fifteen (IS) working days
following the execution of this Contract. CONTRACTOR shall ensure full
implementation of the Program. CONTRAnOR shall appoint a qualified full-time Safety
Supervisor approved by SAUDI ARAMCO, to cooniiiate the Program. The name and
address of the Safety Supervisor shall be submitted to Company Representative no later
than the Program’s submission:

The Program shall outline specific essential measures to be taken by CONTRACTOR to

prevent injuries to persons and damage to property and to ensure compliance with this
Schedule ‘D’. The Program shall be organized and implemented by each craft or crew
supervisor. It shall include a specific plan to hold a ten minute safety discussion organized
and implemented by each craft or crew supervisor on at least one day in each workiig
week.

6. Work Pennits

CONTRACTOR shall obtain B work permit (SAUDI ARAMCO Form 924) each shift for
any WORK to be carried out during such shit3 in any SAUDI ARAMCO specified
“Restricted Area”. It shall be the CONTRACTOR’s responsibility to ascertain, in
advance, whether the WORK area is designated a Restricted Area. Company
Representative shall give guidance on Restricted Area locations. All work permit
procedures shall be carried out by CONTRACTOR in accordance with SAUDI ARAMCO
GI 2.100 (Work Permits) and GI 6.012 (Isolation, Lockout and Use of Hold Tags), which
by this reference is made part of this Contract.

I. Welding And Cutting Equipment

All welding and cutting equipment shall be of a SAUDI ARAMCO approved type and
maintained in good condition.

8. Personal Protective Equipment

CONTRACTOR shall, as a minimum, provide, maintain and enforce the use of the items
of personal protective equipment listed in SAUDI ARAMCO’s Construction Safety
Manual, other applicable Gls and Operator Instruction Manuals (OIMs).

9. Tools And Portable Power Tools

CONTRACTOR shall ensure that all tools provided by CONTRACTOR are of the best
quality with proper safeguards and are suitable for the use intended. Electrical hand tools
shall be properly grounded or be of the double insulated type. All tools shall be free from
defects and maintained in good condition. Saudi Ammco will reject tools which are found
to be defective.
10. Cartridge Operated Took

Cartridge operated tools shall be wed only with the prior written approval of Company
Representative. Furthermore, CONTRACTOR shall ensure that only SAUDI ARAMCO
approved tools shall be used and that they shall be maintained in good condition in
compliance with tbe SAUDI ARAMCO Construction Safety Manual.

11. Ladders

CONTRAaOR shall ensure that only metal or timber ladders of SAUDI ARAMCO
approved type are provided end wed for ingress to and egress from WORK places where
other means of ingress and egress are not available.

12. ScaITolding

CONTRACTOR shall provide and cause to be used scaffolding, platforms or temporary

floors for all WORK which cannot be done safely from the ground, from a ladder or from
a boatswain’s chair. All scaffolding shall be constructed of SAUDI ARAMCO approved
metal components aad erected to comply with the requirements of the SAUDI ARAMCO
Construction Safety Manual.

13. El&ricaI Installations And Equipment

All material and equipment used in temporary electrical installations shall be of SAUDI
ARAMCO approved type and maintained in good condition.

CONTRACTOR shall ensure that all 120 volt single phase 15 and 20 ampere receptacle
outlets which are not a part of the permanent wiring of any building or structure shall have
ground fault circuit intemtpters for personal protection.

14. Cranes And Rigging Equipment

CONTRACTOR shall ensure. that all liftiig appliances and every part thereof, including all
working gear, and all other plant or equipment for anchoring or fixing such appliances
shall be of good mechanical construction, sound material, adequate strength and free from
defect and are. properly inspected and maintained. All chains, hooks, slings, shackles and
other equipment used for raising or lowering on B lifting appliance shall be. of a SAUDI
ARAMCO approved type and maintained in good condition. All mobile heavy equipment
and crane operators must possess a valid Kingdom of Saudi Arabia heavy equipment
operator’s license and be certified by SAUDI ARAMCO to operate such equipment (GI
7.025). AI1 cranes and lifting equipment must be inspected and certified by SAUDI
ARAMCO before beiig permitted to operate. on SAUDI ARAMCO property (GI. 7.030).
Certified riggers shall be provided (GI. 7.030).

15. Mechanical Equipnent

CONTRAaOR shall ensure that all mechanical equipment provided is of a SAUDI

ARAhfCO approved type. and maintained in good condition.
 All moving parts of any equipment shall k securely guarded so as to prevent access to the
moving parts by persons working on or passing through the WORK Site.

16. Saudi Armnco Flant Opemtiom

CONTRACTOR shall ensure that CONTRACTOR’s personnel and the personnel of its
subcontractors do not open or close any valves or electrical switches, or operate any other
piece of SAUDI ARAMCO plant without the prior approval of SAUDI ARAMCO and
then only under the direct supervision of the supervising operator or plant foreman.

17. TlXllSpOrtatiOll

CONTRACTOR shall ensure that passengers shall travel only in vehicles that are provided
with SAUDI ARAMCO approved passenger seats. This requirement shall apply while
traveling to and from the WORK Site and during travel on the WORK Site. Seat kits
shall k installed and used in all vehicles carrying personnel (except in the case of buses
where seat belts are. mandatory only for the driver).

18. Ifijury And Damage Reporting

CONTRACTOR shall ensure that an immediate oral report is made to Company

Representative in the case of all:

. Fatal injuries;
. Injuries requiring medical attention which result in lost time;
. Damage over SR 10,000 to CONTRACTOR’s plant or equipment;
. Damage, in any amount, to SAUDI ARAMCO’s equipment or property;
. Fire;
. Damage and near misses to cranes and heavy equipment (GI. 7.026).

For accidents involving CONTRACTOR employee fatalities, serious injury to five or more.
CONTRACTOR employees, or damage to SAUDI ARAMCO equipment or property, B
written report shall k submitted promptly to Company Representative. In addition,
SAUDI ARAMCO may convene an engineering review or investigation committee in
accordance with the requirements of GI 6.001 and GI 6.003..

CONTRACTOR shall maintain, in a format approved by Company Representative, a

current record showing all:

. WORK injuries
. Fires
. Incidents of property damage over SR10,009
. Motor vehicle collisions
. Incidents involving damage to SAUDI ARAMCO equipment and property
. Damage and near misses to cranes and heavy equipment (GI 7.026)

This record shall k available for inspection at all reasonable times and shall k submitted
to SAUDI ARAMCO on request.
19. EXtXV&iOILV

CONTRACTOR shall ensure that any excavation work carried out during the course. of the
WORK is done according to the requirements of SAUDI ARAMCO GI 1021.010 and
OIM. 1.108 which are by this reference made part of this Contract.

20. Work Over Or Acijacent To Water

Adequate lifesaving and rescue equipment shall be provided by CONTRACTOR on every

seagoing vessel, and at every work station where. WORK is beiig carried out over or
adjacent to water. Life vests shall be worn by CONTRACTOR’s personnel when working
over water as prescribed in SAUDI ARAMCO GI 6.020, which by this reference is made
part of this Contract.

21. Fire Prevention

CONTRACTOR shall provide and maintain in good working order adequate fire fighting
equipment. All CONTRACTOR’s personnel shall be properly trained in the use of such
equipment. Store yards shall be laid out in accordance with SAUDI ARAMCO Standards
(SAES-B-7A, SAES-B-7C) and NFPA 231 A with respect to spacing of rows, tire lamx
and compatibility of materials.

22. Formwork

CONTRACTOR shall ensure that all fomwork supports are constructed to SAUDI
ARAMCO approved standards. As far as practicable, steel units shall be used.

Where the WORK requires a timber supporting struchlre, the timber shall be of suitable
quality and of adequate strength. CONTRACTOR shall obtain prior written approval from
Company Representative before any timber supporting struchwe is erected.

CONTRACTOR shall ensure that prior to any concrete being poured into any supported
formwork structure, approval is obtained from Company Representative.

23. Ionizing Radiation

CONTRACTOR shall ensure that radioactive sources shall be used in compliance with the
“General Rules and Regulations for the Use and Handling of Radioactivity and
Radioisotopes” as promulgated by the Saudi Arabian Atomic Energy Department and with
prior written approval of SAUDI ARAMCO. Where the WORK requires the use of
ionizing radiation either by the CONTRACTOR or by some other organization approved
by SAUDI ARAMCO, CONTRACTOR shall ensure that all employees are made aware of
the precautions to be taken.

24. First-Aid Facilities

The CONTRACTOR shall provide and maintain first-aid facilities at the WORK Site in
accordance with Articles 134 and 135 of the Saudi Labor Laws. when a CONTRACTOR
employs 50 or more workmen at a WORK Site the CONTRACTOR shall provide. a
 qualified nurse and a dedicated emergency vehicle (ambulance), properly supplied and
marked, to transport injured personnel to the. nearest health care. facility.

25. Handling, Transportation And Disposal Of Hazardous Materials And Waste

25.1

When a CONTRACTOR, in the course of performing his obligations under the

Contract, handles hazardous materials, the CONTRACTOR shall ensure. that the
handling of such materials is performed in accordance with currently accepted
industry practices for the handling of such material. CONTRACTOR shall
ensure. that in handling of hazardous materials, especially liquids, such material
is properly containerized and labeled in accordance with SAUDI ARAMCO GI
355.001.

25.2

Subject to any specific requirements in Schedule “B”, CONTRACTOR shall

include in its Loss Prevention Program its procedure for the disposal of solid and
liquid wastes. The procedure shall detail specific locations for the disposal of
each type of waste (construction, chemical, sludge, sanitary, scrap and sewage)
and shall also identify the steps to be taken to treat the wastes or otherwise
prevent them from polluting the ground water or the sea or from beaming a
public nuisance. SAUDI ARAMCO shall approve such procedure before
disposal of any waste by CONTRACTOR.

25.3

In addition to the requirements of sub-paragraph 25.2 above, where the

CONTRACTOR is required to dispose of wastes determined to be hazardous, the
CONTRACTOR shall:

25.3.1

Follow Saudi Arab Government regulations in disposing of

hazardous waste materials. CONTRACTOR must provide SAUDI
ARAMCO proof that the hazardous wastes have been properly
disposed of at a licensed hazardous waste disposal facility.

25.3.2

CONTRACTOR shall also provide SAUDI ARAMCO proof of an

established land treatment/disposal program which is designed to
ensure that hazardous constituents placed in or on the
treatment/disposal zone. are degraded, transformed or immobilized
within the treatment zone. to prevent migration to ground and/or
surface waters. The CONTRACTOR shall submit this program to
SAUDI ARAMCO for approval prior to the disposal of any
hazardous material by the CONTRACTOR.
26. Explosives

CONTRACTOR shall pmmptly advise Company Representative of any requirements for

explosives and only use such explosives after the written approval of Company
Representative. Contractor shall comply with the general rules and requirements for the
handling and use of explosives issued by the Ministry of the Interior and all Saudi Aramco
requirements per the Saudi Aramw Construction Safety Manual for the storage,
transportation and use.of explosives.

21. Sandblasting

CONTRACTOR shall comply with SAUDI ARAMCO GI 6.021 and Construction Safety
Manual requirements on sandblasting.
A.4 HAZARD IDENTIFICATION PLAN (HIP)

INTRODUCTION
In reviewing the safety requirements for our design and construction activities (i.e. new,
modified or rebuilt plants or facilities), it is difficult for even the most experienced
engineer and/or contractor to identify all the potential safety hazards that may be
encountered U&S a systematic potential-hazard review is conducted as a part of a Hazard
Identification Plan (HIP).

The attached Hazard Identification Plan (HIP) provides the method for conducting such a
review. The ham& identified are classified as A, B or C according to their degree of
potential human impact considering severity and probability (i.e. from most severe and
probable to least severe. and probable) during the initial design phase. Tbis allows for a
change. in the methodology or operating procedure in the direction of reducing the risk
associated with the hazard to an acceptable level, or eliminating it altogether.
HAZARD IDENTIFICATION PLAN:

Brief description of work to be accomplished.

I. Conduct Hazards ldtmtification Review.

(To include on-site tour)

Record hazards identified on location map.

II. List Potential Hazards

. Each hazard will be classified A, B, or C.

. Statement of corrective action to be taken.
. Hazard areas identified on a location map and color coded.
. Contractor will submit this list to Saudi Ammo representative.

Consideration will be given to the following potential hazards:

. Potential hazards to P.M.T. and contractor personnel.

. Potential hazards to the general public.
. Incompatible interface with existing plants, facilities, procedures,
regulations, engineering specifications, ground condition, etc.
. Potential hazards that may be. encountered from outside sources.
. Hazardous materials identification/handling/storage.
. Potential fire / electrical hazards.

III. Hazard Classification

Once the hazards are. identified, they are classified as Class A, B, or C.

. Class “A” Hazards:

A condition or practice likely to cause permanent disability, loss of

life or body part and/or extensive loss of stnwhlre, equipment or
material.

. Class “B” Hazards:

A condition or practice likely to cause serious injury or illness

(resulting in temporary disability) or property damage that is
dismptive, but less severe than Class “A”.

. Class “C” Hazards:

A condition or practice likely to cause minor (non-disabling) injury

or illness or nondisruptive property damage.
N. Corrective Action

List all hazards identified in the HIP outline, and determine what comctive
action should be taken.

bdmtde: “A” Hazards

Overhead electrical power lines over building site

l Electrical power rating, (KV)

. Sbow power lines on location map.

Corrective Action

E~ot~~ole: “A” Hazard. “Overhead Power Lines”

Conective Action:

. Obtain work petit before starting any work under or near

electrical power lines.
l No activity in area under power line until power lines have been
disconnected and/or relocated.

Following are examples of typical hazards that cm be encountered:

1) Above Ground Potential Hazards

. Overhead power lines, list KV rating

. Bridges, by-passes
. Micro wave I communication towers
. Houses
. Traffic flow
. Facilities close-by
. Aircraft flight path
. Trees, poles
. High cliffs I dangerous overhangs
. Fuel I chemical / pressure vessels and systems

2) Ground Level Potential Hazards

. Electrical wires
. Roadways
. Ditches
. High water table.
. Tie-downs
. Obstruction
. Unstable soil
. FelUS/WallS
. Traffic flow
. Guide wires
. Nearby buildings, schools, houses
. Possible flood or wash out areas
 l Adverse weather conditions
l Hazards from nearby plants or operations, etc.

3) Underground Potential Hazards

Buried utilities
High water table
Building foundations
Underground water waste
Unstable soil
Chemical I trash dump area
Voids in the earth (caves)
Underground fuel I chemical / pressure systems and vessels

4) Interface Potential Hazards

. Existing emergency evacuation plans

. Emergency communication system
. Traffic flow
. Special personnel
. Protective equipment requirements
. Hazardous waste disposal
. Hazards from other outside operations
. Escape routes
. Evacuation alarms
. Access control
. Flammable liquid I chemical / pressure vessel storage
. Gas release into proposed area

5) Off-Shore Potential Hazards

l High wind / sea conditions

l Night time operations
l Inclement weather conditions
. Fog
. Rain
. Lightning
. Marine vessels and materials adrift
. Electrical hazards
Appendix B: Emergency/Disaster
Planning And Response
B.l SEARCH AND RESCUE PROCEDURES
This Appendix outlines Saudi Ammw search and rescue procedures for on- and off-shore facilities.
Included in this appendix are the following:

l Control of Remote Area Travel And Search And Rescue Procedures (Cl 6.025);

l Offshore Emergency Response;

l Fire. and Other Serious Emergency Response Procedures (Supplement No. 1-503-l).

Any fwtber questions on search and rescue procedures should be. forwarded to your area Loss
Prevention Department office or the Saudi Ammco contract proponent.

Effective emergency planning requires that employees be familiar with emergency procedures before a
crisis. It is the responsibility of management to ensure. that all employees are familiar with the proper
response to fire and other serious emergencies.
B.2 EMERGENCY/DISASTER PLANNING AND RE!SONSE
It is the responsibility of every contractor employee to become familiar with emergency response
procedures for both offshore and onshore operating facilities.

The following Operating Instructions Manuals (OlMs) give facility-specific emergency response
guidance/pnxaiures:

Saudi Aramco Operating Instruction Manual (OIM):

01 1.501 Overall Disaster Control Procedure - SafaniyalTanajib Area

or 1.501-l Tanajib Disaster Control Center Commander

011.501-2 Safaniya Support Personnel Assignment

011.501-3 Disaster Control Command Center - Tanajib Personnel Assignment

011.502 Onshore Control Unit - Safaniya Producing

OIl.503 Offshore Disaster Control Plan - Safaniya Producing

011.503-1 Offshore Emergency Response

01 1.503-2 Offshore Emergencies Only

011.503-3 Safaniya Offshore Jack-Up Test Barge/Well Platform Disaster Control Plan

011.503-4 Safaniya Offshore - Offshore Casualty Evacuation

011.503-5 Personnel Accountability Offshore Facilities

011.527 Safety Zones and Safety of Navigation Around Offshore Installation

0110.011 Work Around Offshore Producing Facilities

General guidelines for preparing emergency response plans can be found in the following Saudi
Aramco Loss Prevention Department publication:

GI 70.500 Disaster Contingency Plan, Dhahran Area

Guidelines for Preparing Emergency Response Plans, October 1989

Other references include:

Saudi Anunw Corporate. Loss Prevention Manual (CLPM)

Mobil Oil Corporation - Guidelines for Emergency Response and Disaster Contingency Planning for
Saudi Ammco, May 1991
The potential for emergencies and disasters exists at all construction sites and facilities and their
associated costs can be devastating in terms of employee casualties, business interruption, loss of
capital investment, etc. These events cannot be avoided but the contractor can reduce their frequency
of occurrence and severity of damage with effective preparationlplanniog. This cam be accomplished
by developing emergency response plans that address immediate concerns within the contractor’s
operations and which also interface, as required, with emergency response procedures developed by
Saudi Aramco organizations.

The following guidelines (B 3.1 and B 3.3 nod Figures) are extracted from the publication “Guidelines
For Preparing Emergency Response Plans”. These are generally used by Saudi Aramca operations as a
framework for plan development. Contractors should refer to these guidelines for developing their
own plans as appropriate, paying particular attention to the need for interfacing with local Saudi
Aramco emergency planning procedures. Contractor’s plans will need to be tailored to their specific
operations and resource.s and the nature of their work with Saudi Ammco.

B.2.1 General Provisions

1. The purpose of the emergency plan is to provide guidance on the following:

. A facility/site emergency response organization’s stmchlre and responsibilities

. Development of credible emergency/disaster scenarios and their consequeoces
. Establishment of emergency control resources (human, equipment, etc.) and
pV3lXdU~eS
. Emergency response training and drills

2. Ensure that the emergency plan with the latest issue date is beiig used and it
incorporates all amendments to date. It must have provision for any future
amendments as addendum or reissues.
3. Tbe emergency reporting instructions must be. provided in the front of the plan.
4. The emergency telephone numbers must be provided in the front of the plan.
5. The disaster preparedness policy must be provided in the front of the plan.

B.2.2 Definitions

1. Emergency:

An emergency is an abnormal incident posing a threat to the safety of workers,

residents, the environment or property at a facility or site and which g be
brought under control using tbe resources and procedures for emergency
response in place for the facility or site.

2. Disaster:

A disaster is an emergency which poses a more serious threat to the safety of

workers, residents, tbe environment or property at a facility or site and which
CannOt be brought under control using the rexwrces and procedures for
emergency response in place for the facility or site. Whether an emergency
becomes a disaster depends cm the following:

. the type of facility;

. the hazards of the facility operations;
 . the proximity of neighboring communities or other facilities;
. the capabilities of emergency pef~~~~~el;and
. muhtal aid capabilities of outside agencies.

3. Emergency Planning:

This involves the development of a specific plan which details actions to be taken
by trained personnel during au emergency in an effort to efficiently control it and
minimize its net negative impact on workers, residents, the environment or
property at a facility or site. This type of planning also extends to developing
emergency control strategies and instituting training and drills for all facility
personnel.

4. Disaster Command Center @CC):

The location where the Emergency Manager and support staff assemble to
respond to an emergency. It is a centralized location for monitoring the facility
response and also serves as a command center for coordinating all
communications, including the allocation and distribution of information. (This
will also remain an onshore centralized location for an offshore emergency
response episode.) During an offshore search and rescue (SAR) operation, this
will become the SAR control center. A designated helicopter pilot will report to
SAR control center to act as a search coordinator. Staffing from pertinent
technical and support groups assures accessibility to all required resourcea for an
overall effective emergency response.

5. Diiter Command Post @CP):

A designated safe location near the emergency site from which the Incident
Commander directs emergency control efforts. He directs operations and
coordinates tire fighting, rescue and medical treatment activities during the
emergency episode.

At some onshore. facilities, the DCP is a specially equipped vehicle outfitted with
facility maps, communication equipment and support information similar to a
DCC. This equipment provides the means for contact with the DCC and for
field coordination. At offshore facilities, the DCP would be a safe location
designated by the Incident Commander which should be equipped with a
telephone, radio communication and personal protective/identification
equipment, at a minimum.

6. Table Top Exerciw

This is a disaster management simulation where key personnel face a

hypothetical disaster situation developed by a skilled moderator. Weaknesses are
identified by evaluating the results of the exercise and corrected by revising the
ph.
I. Ilaming Committee

A planning committee is B body comprising of members from key functional

groups within the organization. This is set up to develop an emergency plan
using the broad expertise of its members.

8. PllJnni”g Coordinator:

An individual who is qualified to develop an emergency plan to direct its

development through a planning committee. This individual is required to
process great depth of knowledge of emergency response and disaster control
practices and procedures, and manpower organizational capabilities for his
facility or site. He can review and use Saudi Aramco approved emergency plans
from other similar facilities or sites in the development or modification of his
facility/site plan.

9. Emergency/Disaster Respolw Organization:

The Emergency/Disaster Response Organization is a struchlred working group

whose function is to control an emergency or disaster. The stmchlre of this
group is typified in Figure B. 1. The organization is basically comprised of the
following positions with their delegated responsibilities.

A. Key Positions

(a) Emergency Manager

The Emergency Manager is responsible for the overall organization

and strategy of the emergency response, coordinates logistical efforts
and has the authority for the final decision in any emergency action.
He is usually, but not always, the senior management person at the
facility. His specitic responsibilities are to:

(1) assume control of the DCC

(2) implement the Emergency Plan
(3) receive updates on control measures taken by the Incident
Commander
(4) assess the situation and direct actions to minim& damage
and loss of life
(5) maintain contact with upper management
(6) declare the emergency “under control” and authorize the
“all clear” signal

(b) Incident Commander

The Incident Co mmander is responsible. for suppression and control

tactics at the site. The Shift Superintendent usually tills this position
and provides direction to all personnel at the scene, including the
senior fire officer. His specific responsibilities are to:

(1.) establish the Disaster Control Post (DCP) at a safe location

near the emergency site
 (2) develop and implement control tactics
(3) approve use of all enle.rge”cy related resources
(4) keep the Emergency Manager informed
(5) evaluate. mutual aid needs, and request assistance through
the Emergency Manager
(6) coordinate mutual aid personnel and equipment
(7) determine the need for evacuation

AI1 normal plant functions and emergency support services report

directly to s of the above positions according to their reporting
relationships given in Figure B. 1.

B. EmeYypcy/Diiter support stafT/Teams

(a) Fire Protection/Rescue

This function is usually performed by a combined team of

facility/site fire protection personnel. They take directions from the
Incident Commander through the appointed senior tire officer at the
DCP. The responsibilities of the senior tire officer are as follows:

. Fire-Fighting

(1) provide initial evaluation to the Incident Commander

(2) deploy fire fighting personnel and equipment
(3) advise Incident Comman der of the need for outside
ESO”~CeS
(4) keep Incident ‘Amman der current on tire control status
(5) direct outside fire fighting organizations
(6) clean-up and restore. fire protection equipment and supplies

. RfSCW

(1) locate and rescue missing persons

(2) render essential first aid and life support
(3) remove victims to designated safe locations for medical
treatment

(b) Process

This function is usually performed by an operations representative

who is responsible for advising the Emergency Manager in the
following awas:

(1) operations, hydrocarbon movement, unit isolation and

emergency shutdown activities
(2) special fire protection needs
(3) materials or pnxess in the affected area
(4) actions taken affecting the process
(5) process equipment involved in the control of the incident

(c) Maintenance
Tbis function is usually performed by B maintenance representative
who is responsible to:

(1) assemble maintenance manpower io tbe maintenance shops

(2) assist operators in isolating and shutting down units as
directed
(3) repair of emergency equipment
(4) assist utilities personnel in bypassing or repairing critical
utility components
(5) provide fuel for emergency vehicles and firewater pump
engines
(6) transport foam and other emergency supplies

(d) Engineering

This function is usually performed by an operations engineering

representative whose responsibilities are as follows:

(1) provide mechanical and process related information

(2) keep the Emergency Manager, Incident Commander, and
Process Cwrdiiator advised of factors influencing
emergency activities.
(3) assign an engineer to serve as an emergency events
recorder
(4) prepare damage assessment reports
(5) collect and preserve evidence for tbe incident investigators
(6) perform post-incident engineering for repair work

(e) Sexwity

This function is usually performed by the facility Security Supervisor

whose responsibilities are as follows:

(1) ensure integrity of tbe plant perimeter

(2) provide necessary staffing to control use of emergeocy
gates
(3) prevent entry of unauthorized personnel
(4) direct the flow of traffic away from the disaster scene
(5) direct emergency resources to the appropriate staging area
(6) provide escorts for emergency v&i&s when reque.sted
(7) advise Incident Commander on security matters
(8) act as liaison between the Frontier Force, the. Incident
Commander and Government Affairs

(f) Loss Prevention

Tbis function is usually perfomvzd by tbe Loss Prevention

Advisor/Engineer whose responslbd~tles are as follows:

(1) help evaluate hazardous sihlations and materials

(2) recommend actions and equipment mxesswy to protect
pels0Me.l
 (3) direct Loss Prevention staff to perform gas testing or other
emergency/disaster services and interface. as needed with
Industrial Hygiene
(4) assign Loss Prevention staff to record or log
emergency/disaster activities for future we
(5) coordinate with services as necessary regarding safety
equipment

(g) Services

This fimction is usually performed by a staff engineer who

coordinates support services and obtains a cost code from the area
Finance representative to account for all financial, purchasing, and
cost analysis aspects of the incident. His responsibilities are as
follows:

(1) contact the on-call Area Representative who will provide

safe and sanitary food, potable water, and field sanitation
facilities on request of the Incident Commander
(2) purchasing and contracting requirements
(3) coordinating claims actions
(4) providing necessary accommodations for emergency
respo”se personnel

(h) Medical

This function is usually performed by district medical personnel

whose responsibilities are as follows:

(1) establish a triage area at the scene

(2) provide on-site emergency medical care
(3) advise the Emergency Manager of the number of injured
and any need for additional medical assistance
(4) notify appropriate hospitals and clinics of the anticipated
number of casualties
(5) advise the Emergency Manager of special medical
transportation needs
(6) keep records of victims and their treatment

(i) External Relations

This function is usually performed by the area Government Affairs

representative whose responsibilities are as follows:

(1) establish and maintain communications with civil

authorities
(2) communicate the incident status to government
organizations as appropriate.
(3) request approval from the Emergency Manager for any
government inspections and/or investigations during the
emergency
 (4) inform community leaders of incident stahw, potential
dangers which might require. evacuation and recovery
efforts

(j) Operations/Utilities

Tbis function is usually filled by plant/site foremen who direct the

activities of plant operators. Their responsibilities are as follows:

(1) account for personnel by head count procedures

(2) report missing persons
(3) implement tbe facility emergency operating plan for a
specific sihlation (i.e. isolation and shutdown unit(s) as
ia~tructed and stabilize units not involved)
(4) await futber orders after the units have been shutdown and
secured
(5) assign an operator to check firewater mains pressure and
start fire pumps
(6) control the plant air systems, steam systems, and other
utilities and advise tbe Incident Commander on their status
(7) inform the Incident Commander and Maintenance of
system failures
(8) evacuate personnel if instructed by the Incident
Commander

(k) Communications

This function is usually performed by an operations employee who

rqmt.s to the DCC to manage radio transmissions, telephone lines,
operate special equipment such as DVD, EARS, etc., and record all
message traffic.

(I) Environmental

This function is usually performed by an assigned environmental

specialist whose responsibilities include providing environmental
monitoring services and spill containment/recovery advice to the
Emergency Manager and Incident Commander.

B.2.3 Plan Development Action Items

Task 1: Assiin (or Establish) Pkmiq Coordinator (or Team)

1. A planning coordinator must be assigned; or

2. A planning committee/coordinator team must be established

Task 2: Establish Scope and Objectives

3. A scope and writtea objectives must be developed for tbe site.

Task 3: Identify Emergeney/Diispstw Scenarim

4. Develop emergency/disaster scenarios specific to the facility or site as

follows. (Use Figure B.2 for scenario development):

. Planning Coordinator/team to identify emergency/disaster

sihrations.
. Group these situations into generic scenarios (e.g. tank fires, pump
tires, liquid release, vapor releases, explosions, natural disasters,
etc.)
. For each generic scenario, select the credible. worst case
emergency/disaster situation to represent that scenario (e.g. the
largest tank fire) and till out Part A (Description) and Part B
(Possible Causes) of the Scenario Analysis Sheet (Figure 8.2).
Similarly, describe all scenarios on separate sheets and assign a
rank order to each in Part E (Evaluation) based on likelihood of
occurre0ce. (The. “consequences” of Part E will be developed as
part of Task 4, “Assess the Consequences of Scenarios”.)

The following information is useful in identifying emergency/disaster situations

(initiated on-site. or off-site) within each generic scenario:

. Fire.
-

Fires are generally caused as a result of ignition of a gas (or liquid)

hydrocarbon leak under pressure. Unburned liquid hydrocarbon pools in
the ground and fuel the tire to increase. its intensity and spread. All
situations within this scenario can lead to disasters if fire. spreads beyond
the capabilities of the fire. fighting systems/personnel in place. Generally,
this occurs if the response is not quick to contain the fire to a manageable
limit before it approaches a disaster level. Some examples of potential
emergency/disaster sihutiationsfor the fire scenario are.:

. congested multiple process unit area tire

. flammable liquid tank storage. area tire
. wharf loading and unloading area fire

. Exolosion

Flammable vapor releases are one of the most significant sources of

explosions and the potential for casualties and property damage is high.
Some examples of potential emergency/disaster sihrations for the explosion
scenario are:

. boiling liquid expandiig vapor explosion (BLEVE) of storage,

sphere, bullet or process vessel
. runaway (exothennic) process chemical reaction
. gas explosion from * large volume. release of refrigerated LPG
. uncontined vapor cloud explosion (UVCE) from a flammable vapor
lYleaSe

. Flammable Vawr Release (FVR)

 In the petroleum industry, the possibility of release of flammable vapor
poses * great risk. Some examples of potential emergency/disaster
situations for tbe FVR scenario are:

. failure of piping connection to pressurized storage sphere (or

bullet), or refrigerated tank
. tank overtill
. LPG tanker accident resulting in containment failure.
. high pressure gas pipeline rupture

. Toxic Vapor Release CrvR)

Toxic materials may or may not be flammable but could be in a high

enough concentration to pose P health risk when released as a vapor. Some
examples of potential emergency/disaster situations for the TVR scenario
WC

. rupture of pipeline or well blowout releasing H2S vapor

. rupture of storage container releasing chkwinelammonia vapor
. rupture or leak of amine regenerator overhead accumulator
piping/flange to release H2S vapor
. failure of H2S compressor seal releasing the vapor

. Hazardous Materials SDill

Hazardous materials are used as solvents, reagents, and catalysts in various

processes. A likely s&ration for a hazardous material spill is from the
tanker vehicle transporting it to tbe facility or during its transfer from the
tanker vehicle to its process usage or storage point. Other examples of
potential emergency/disaster sihlations for the Hazardous Materials
Release/spill scenario are:

. TEL/TML gasoline antiknock compound liquid release

. rupture of storage container or associated piping releasing
chbxine/amnwnia liquid
. rupture of storage container or associated piping releasing sulfuric
acid liquid

. Nahlral Disaster

Each facility or site is susceptible to nahmal disasters (e.g. high winds,

flooding, etc.). The impact of natural disasters to cause other related
process disasters should be recognized in the. planning stage. Historical
data on disasters at similar facilities or sites coupled with weather data can
help in predicting the frequency of natural disasters for the area. Another
source of such information is the Saudi Ammco Risk Analysis Manual.

Task 4: Assea the Consequences

5. Complete each scenario analysis sheet started in Task 3 by describing the

incident size, duration nod effect on operations.
 6. Eater an estimate of the magnitie of potential consequences in Part E
(Evacuation) of the Scenario Analysis Sheet (Figure B.2) after
considering the following factors for &J scenario:

. Sire (including explosive potential, maximum fire areas, maximum

spill volume and area, maximum vapor cloud volume).
. Growth spread of impact area resulting from the spread of a tire,
toxic vapor cloud, or other undesirable product of the
emergency/disaster episode.
. Amount of advance warning.
. Impact (m severity of potential damage, potential casualties,
effect on surrounding population, domino effect of sequential
explosions, and total duration).
. Controllability of incident based on level of emergency/disaster
training of personnel and adequacy of equipment available within a
facility or site.
. Reaction (or response) time and effectiveness of facility resources to
control incident.

After the Scenario Analysis sheets have been completed for each
scenario, assign a rank order in Part E based on consequences. The plan
coordinator selects the scenario which represents the most likely event
with the severest consequence(s) as the basis for developing the
emergency respaw plan. This choice should be approved by Contractor
management.

Task 5: Review Emergency Control Needs

I. Use the Disaster Control Tasks Checklist to determine all tasks required
(see Figure B.3).

8. Assign a team member to develop the facility’s response.

9. Develop and document the assigned response.

Task 6: Available/Needed Resources

10. The metbcds to identify, estimate, and establish available needed

re.w”rc.% are a.9follows:

(a) Develop an inventory list of critical supplies and equipment needed

to control the emergency disaster scenarios in Tasks 3 and 4.

(b) Ensure that these critical items are stored together at one easily
accessible location (or the critical items store itself if accessible).

(c) Display the list of critical items on the entrance to the critical items
store.

11. Identify and list the entities responsible for supplying food, water, shelter,
transportation, emergency equipment, additional manpower, external
mutual aid, medical support and cost accounting.
12. Determine that the source needs in item number 10. (above) have been
met List contingencies to cover failure of any of those entities indicated
in item 11. to supply the needed items.

13. Survey alternate outside sources to determine their ability to supply

n%o”rces which “lay be in short supply.

14. If a mutual aid agreement has been established, develop an inventory of

equipment and supplies that any mutual aid entity is expected to bring
with them when they respond.

15. Establish a telephone and personnel list of 24-hour contacts at all mutual
aid entities.

16. Determine and document that the equipment and supplies provided
through mutual aid are compatible with emergency/tire protection
equipment at the site.

11. Measure the response/travel time needed by all mutual aid entities to
respond to an emergency/disaster at the site. Establish the needed time
range for all outside resources to reach the site.

18. List and detail all high cost items and their corresponding authorization
levels.

19. List emergency response. skills required to control all scenarios selected
in Tasks 3 and 4.

20. Compare & skills with available skills of construction/site

perso”“el.

21. Establish a Disaster Co mmand Center (DCC).

22. Consider the need to provide an alternate location for the DCC in case
the original location is rendered unusable.

23. Supply the DCC (and alternate) with:

. telephone, fax, and other radio communication/alarm equipment

. emergency power and lighting
. reference materials (e.g. emergency response manuals, call out lists,
Material Safety Data Sheets (MSDSs), drawings, photographs,
maps, etc.) and emergency equipment (e.g. flashlights, spare
batteries, camera, battery powered megaphones, etc.
. oftice equipment (e.g. dictating machines, tapes, flip charts,
stationery items, etc.)

24. Establish a Disaster Command Post (DCP) vehicle/safe location near the
emergency site..
 25. Ensure that the DCP is set up with supplies similar to the DCC (except
on offshore facilities where tbe DCP may only have a telephone, radio
communication and personal protective/identification equipment).

26. Additionally, ensure that the DCP also has the following:

. self-contained breathing air

. megaphone
. binoculars
. safety/environmental monitoring equipment
. means of identification (vest, hat)

Task 7: Emergency Response Organization

21. Establish an emergency/disaster response organization.

28. Ensure there are sufficient perso~el to till all assigned positions and
alternates/substitute identified and on standby to till critical positions
should it become necessary.

29. Ensure that each assigned position has a documented detailed description
of its responsibilities. Such a description must include:

. duties of the position

. reporting relationship
. reporting location

30. Verify and document that all assigned individuals are aware of their
responsibilities.

31. Develop a physical method to identify each individual in the organization

chart by position (ID. badges, vests).

Task 8: Develop Emergency Response Procedures

32. Ensure that the planned facility/site emergency response procedures are
structured according to the logical progression of action items given in
Figure B.4.

64 Reporting Emergencies:

(1.) Report to senior operations person in control roan using

radios, telephones, manual pull box alarms, or public address
systems. (Emergency telephone numbers or local 110
instructions should be posted near or on all telephones.)

(2.) Determine how significant does an incident have to be to be

reportable.

(3.) Suggested wording for reporting emergencies (or drills) is

shown in Figure B.5 (Emergency Reporting Instructions).
 Also see section VI1.A (Reporting Emergencies) of the plan
(see Task 9: Write the Plan).

(4.) Details of the telephone and radio systems (i.e. different

dialing and radio frequencies) should be in the appendix of the
ph”.

(b.) Initiate The Alarm:

All emergency related signals (i.e. “stop-work”, “evacuation”, and

“all clear”) and expected actions relating to each signal alarm must
be established and followed.

Authority and criteria for sounding the different alarms must be

clearly stated in the plan.

(4 Assess The Situation:

The Incident Commander must follow-up on every emergency

declared by reporting to the incident site to assess:

. the emergency response actions taken or being taken

. additional actions and re.sources required to control the
situation
. extent of damage to property and harm or negative impact to
life.
. existing hazardous conditions and their likelihood to escalate.

Cd.) Mobilization Of Remwces:

1. Actions are taken by facility/site personnel to mobilize the

facility’s internal resources (human, equipment, etc.) and, if
needed, contact external groups to mobilize. their resources to
the scene as developed in Task 6 (Available/Needed
Resources).

2. Plant personnel assigned to the emergency response

organization are to proceed to their preassigned locations and
await instructions from the Emergency Manager or Incident
Commander, as applicable.

3. Non-essential plant personnel are to be evacuated to

preassigned assembly areas at a safe distance from the incident
scene. Supervisory or assigned personnel are. to take head
count and DCC is to organize search and rescue for any
missing personnel.

4. Support groups such as Security, Medical and Fire. Protection

arc. to report to their preassigned locations and must commence
any preauthorized emergency response related actions.
 5. At least hvo methods of in-plant communication should be
available (e.g. radio sod telephone). One in-plant radio
channel is reserved as the main communication link behveen
the Emergency Manager and Incident Commander. At least
two methods of communication are necessary for external
contacts (e.g. telephone, radio, Direct Voice Dispatch - DVD,
Emergency Alert and Response System - EARS, etc.).

A telephone number with a pre-recorded message providing

essential up-to-date information on the incident (e.g. 113 in
Dhahran) will be established.

(4 Suppression/Control Of Incident:

A separate control procedure must be written for each generic

incident scenario developed in Task 3 (Identify Emergency
Scenarios). This procedure is based on facility operating
instnrctions detailing the rapid and safe sequential shut down of
process unitslequipment involved or affected by the particular
incident scenarios.

WI Post Incident Actions:

There are follow-up actions needed once an emergency is

declared under control by the Emergency Manager. These
actions are:

1. Stand Down And Fire Watch

The Emergency Manager gives the “stand down” order to

emergency response personnel. At this time, same personnel
are released from duty, some are assigned to gather evidence,
on the emergency episode and others are to maintain a fire
watch if there is danger of reignition. The fire. watch is set up
by Fire Protection following consultation with the Emergency
Manager.

2. Investigate And Report

Incident investigation of causes and reporting can be made

according to prescribed procedures. GI. 6.001 (Notification
Requirements For Incidents) and GI 6.003 (Guide For
Committees Investigating Major Incidents) are hvo ~lurces
which provide guidance for developing such procedures.

3. Restore Operations

This coven all post-emergency control actions which must be

followed to restore normal operations at the facility. This
includes, but is not limited to:

l demands of caring for injured and homeless

 . repaitig damaged equipment to bring proces.s equipment
on-line
. collecting evidence for the reporting requirement
l determining secondary hazards that may have developed

4. Revise The Plan

All new information gained as a result of the incident should be

analyzed to determine what impmvements could be made to the
facility’s Emergency Response Plan. These improvements
should be integrated into the Plan and all emergency response
personnel should be retrained and drilled to ensure that they are
familiar with and proficient in following upgraded procedures.

33. Develop procedures for the following emergencies/disaster

(onshore/offshore as applicable):

. emergency unit shutdown

. individual equipment isolation
. process unit tire
. tank farm tire
. marine dock fire
. off-site pipeline leak
. personnel rescue
. medical emergencies
. toxic/flammable/corrosive gas leak
. evacuation from units and buildings
. process upsets
. breaches of security (includine terrorism or sabotage)
. For more information refer to the Saudi Aramw Loss Prevention
Department “Guidelines for Preparing Emergency Response Plans”
manual.

34. Complete the emergency reporting form given in Figure B.5 and follow
the instructions contained therein to report such event(s).

Task 9 - Write the Plan

35. Ensure. that the plan has a Corporate Policy Statement on

emergency/disaster preparedness, and is prepared in conformance with
the format and instructions presented in the Saudi Aramco Loss
Prevention Department “Guidelines for Preparing Emergency Response
Plans” manual.

A typical Emergency Response Plan will follow the outline given in

Figure B.6.

36. The plan manual must be reviewed and signed off by all outside mutual
aid entities expected to respond to an emergency at this site.
Task 10 - Emergency Response Training and Drills

31. Develop, document and follow the emergency response training/drill

items given below to ensure that all personnel expected to participate in
emergency response are proficient in its theory and practice.

. table top exercise

. classroom training of personnel
. simulation of DCC operations during an emergency
. field simulations/drills of credible scenarios

38. Ensure that alternates (or standby) personnel are also trained and drilled
on emergency response

39. Train and familiarize all personnel with the provisions of your emergency
re.9po”se manual.

40. (a) develop a document and drill schedule in your manual

(b) ensure that these include full scale disaster simulations

41. Hold and document critique sessions following all drills, simulations
and/or actual incidents.

42. Establish a procedure to ensure that all suggestions from the critique
sessions are incorporated into your manual.

Task 11 - Review and Revise the Plan

43. Provide for regular reviews (e.g. documented tickler date) and update the
plan at least once a year through the plan coordinator.

44. Keep a record of all amendments and maintain it in the front of the plan
document manual.

45. Keep a current list of all document manual holders and periodically
fcmvard them copies of any amendments.
FIGURE B.l: TYPICAL EMERGENCY ORGANIZATION CHART

. p&y
 I

FIGURE B.2: SCENARIO ANALYSIS SHEETFOR (LOCATION)

0 Unit/Equipment: Scenario No.:

Type of Emergency:
. -Fire
. -Explosion
. -Flammable Gas
. -Toxic Gas
. -Hazardous Materials Spill
. -Natural Disaster

A. Description of the Scenario:

B. Possible Causes:

C. Expected Size or Duration:

l D. Effect on Operations:

E. Evaluation and Ranking:

. Likelihood: (1 = most likely)

l No. of scenarios

. Consequences: (1 = most severe)

l No. -- of scenarios

F. Location/equipment-specific notes:

Reviewed by: Date:

Page 388
FIGURE B.3: EMERGENCYIDISASTERCONTROL TASKS CHECKLIST

1. Warning

. Alarm/communication systems to alert employees and local community of an

emergency/disaster.

. “Alert”, “Evacuation” and “All-Clear” signals must be recognized by all affected

population, and they must know how to proceed in each case.

2. Pre-impact Preparation

If time pennits, facility personnel must do the following to minimize negative impact of an
emergency/disaster:

. Notify emergency response organization.

. Call for all available material reserves and resources.

l Contact appropriate resource for weather data and other emergency/disaster

information

. Evacuate all affected areas,

3. Evacuation

l Evacuation of persons from affected areas and non-essential workers from adjacent
areas lowen the risk of casualties.

l Evacuation system testing and training.

l Control of access and exit points.

l Dead count requirements.

4. Mobilization and Utilization of Human and Material Resources

The effectiveness of an emergency response depends on the quality and supply of human
and material resources. These resources must be:

l Known in advance.

. Available on demand.

. Compatible with each other.

. Used in an organized and controlled manner.

5. Incident Suppression/Control

l Selective use of assembled resaurces.

l Training and experience of emergency response team (esuecially Incident

Commander).

6. Search and Rescue

l Identify likely search aud rescue situations from generic scenarios.

l Establish resources (qualified personnel and equipment) and procedures to locate

victims - and transport them to safety.

I. Care for Casualties

Factors to be addressed in the care, treatment and relocation of casualties are:

. Access of medical personnel to site.

l Temporary hospital facilities and equipment.

l Transportation to move casualties to such facilities.

8. Communications

Efficient and accurate communications are a necessary part of effective emergency

response actions.

. Communication equipment/system in place.

l Back-up communications equipment/system.

l Compatibility of facility communication equipment with that used by mutual aid

organizations.

9. Continuing Assessment

l Continuing assessment of the situation by knowledgeable observers to redirect

emergency/disaster response actions as needed.

10. Coordination

l Coordination of call-out personnel and staging of resources to ensure proper level of

support is available where needed.

11. Control and Authority

. System of overall control and distribution of authority by chain of command.

 l Call-out list for management personnel.

. Personnel responsible to contact outside agencies and/or mutual aid organizations.

12. Security

Adequate security personnel/system be in place to:

. Co”trol traffic.

l Control access to scene of emergency/disaster.

13. Continuity of Operations

l Plan to continue operations unaffected by emergency/disaster by manpower

reassignment.

. Ensure that sufficient manpower/equipment is on standby to handle escalation of

emergency/disaster to other units.

14. Outside Community Order

Request Government Affairs representative to contact appropriate law enforcement

authorities and community leaders to address the following:

. Evacuation, traffic and crowd control, guarding property and patrolling dangerous
areas.

15. Secondary Hazards

. The plan should identify hazards created as a result of the emergency/disaster (e.g.
structural damage to buildings, isolated tires from explosions, downed electrical lines,
etc.)

l Determine and plan to provide additional re.wwces needed to control these hazards.

16. Restore Normal Operations

l Maintenance personnel should maintain a current stahls list of plant utilities and
services lost during the emergency/disaster and the estimated time to restore them.

17. Emergency Teams and Equipment Recovery

l System to check and replace emergency equipment damaged during or immediately

after the emergency/disaster.

l System to provide shift relief to emergency/fire fighting crews and replenishment of

tire fighting materials and other consumables.
a 18. Personnel Needs

l Plan to provide emergency/disaster workers and other affected personnel with sanitary
food, water, clothing, shelter and financial assistance as needed.
FIGLIRE 8.4: nOw DIAGRAM OF TWICAL OFFSHOREEMERGENCY RMONSE

EMERGENCY INCIDENT

I. INITIATE THE ALARM

2. REPORT THE EMERGENCY

3. ASSESS THE SITUATION

4. MOBILIZE RESOURCES

5. CONTROL THE INCIDENT

6. POST-INCIDENT ACTIONS
Flcm B.5: EMERGENCY REPORTING INSTRUCTIONS

TELEPHONE: XXX-xXxX (if busy see below)

I have no emergeocy to report:

I *m calling from

My name is My badge number is

ISWa at
(fire, gas leak, etc.) (north/south/east/west)

There are (no.) of people hurt and requiring medical assistance.

DO NOT BANG UP. ENSURE THAT YOU HAYE A RESPONSE THEN IF

NECESSARY REPEAT THE ABOVE INFORMATION AND ANSWER
QUESTIONS.

1. If the number is busy or unavailable, try the following in the order listed:

2. telephone xxx-zizz

3. radio frequency xxx.xx

4. (other for the facility)

After the message has been given successfully, the reporting individual, if an operator, should return
immediately to tbe emergency site. to do whatever he can safely do to improve the emergency sitoation.
FIGURE B.6: EMF%GENCYPLAN-SAMPLETABLEOF CONTENTS

Suggestedheadiigs are shownbelow. Sectionsshouldbe separated

by dividers with extendedtabs
namingeachsection.

I. Title Page
II. RepottingEmergencies
II. EmergencyResponse
PersonnelRoster
IV. TableOf Contents
V. Introduction
A. Scope
B. WhenTo Implement
C. Definitions
VI. EmergencyResponseOrganization
A. ChainOf Command
B. FunctionalResponsibilities
VII. EmergencyResponse Actions
A. RepottingEmergencies
B. InitiatingThe Alarm
C. AssessThe Situation
D. MobilizationOf Resources
1, InternalResources
a. PlantPersonnel
b. SupportGroups
c. Contractors
2. ExternalResources
a. SaudiAramco
b. Non-SaudiAramco
E. Suppression/Control of Incident
I. VaporRelease
2. Toxic VaporRelease
3. Fire
4. Explosion
5. HazardousMaterialsRelease
6. NaturalDisaster
7. OtherSite SpecificIncidents
VIII. Post-IncidentActions
A. StandDownAnd Fire Watch
B. InvestigateAnd Report
C. RestoreOperations
D. ReviseThe Plan
IX. Appendices
A. MaterialsAnd EquipmentInventory
I, EmergencyEquipment
2. Fire FightingSupplies
3. Facility Maps,Plans,Drawings
4. CommtmicationEquipment
5. MutualAid
 a. Saudi Arsmco
b. Non-Saudi Ammo
B. Exceptions To Generic Scenarios
C. Operating Instruction hkmals (OIMs) And Other References
 a. Saudi Ammco
b. Non-Saudi Aramco
B. Exceptions To Generic Scenarios
C. Operating Iostmction MamaIs (OIMs) And Other References
Appendix C: Fire Safety Checklist For
Evaluating Construction
Materials Store Yard
C.l FIRE SAFETY CHECKLIST FOR EVALUATING
CONSTRUCTION MATERIALS STORE YARD

(Based on NFPA 231-APPENDIX C)

PROTECTION OF OUTDOOR STORAGE

I. SELECTION OF A SITE

A. Adequate fire department protection.

1. Travel time to site, primary factor.

B. All-weather roads adequate to carry fire department apparahls.

1. Kept clear at all times.

C. Available water supply of sufiicient pressure and quantity.

D. Sufficient clear space from combustible structures or other storage which could be an
exposure hazard.

E. No danger of flooding.

1. Run-off from fire fighting water should be considered.

2. Drainage from fuel spills should travel away from all storage.

F. Enough clearance from storage site to highways or major roads.

II. FENCING SITE

A. Entire site should be fenced to control access.

B. Two 15’ gates, directly opposite each other (180°) are required to petit ready
access of fire apparahrs to any part of the storage area regardless of wind direction and
location of fire.

III. PILING OF MATERIALS

A. LOW HEIGHT and SMALL AREA are the ideal conditions.

I. Reasons for this are -

(a) stability of the pile under normal and tire conditions (containers
maximum: 2 high).

(b) access to the seat of the tire with hose streams from the ground.

B. &J&j must be maintained behveen individual piles; between piles and buildings,
and behveen piles and the boundary line fence for the storage site, to allow access to
all sides of the piles.
 1. Aisles minimum of 10 feet wide.

C. DRIVEWAYS of minimum 15 feet width are required to petit travel of fire

apparatus to all parts of the storage area.

1. Driveway and aisle widths should be increased to at least equal the height
of piles of goods, since they also act as firebreaks to limit the spread of
tire.

D. ARRANGEMENT OF MATERIALS is important to reduce the speed of the spread

of fire.

1. Generally less hazardous materials should be stored upwind and more

hazardous materials downwind.

2. Piles or “blocks” of small piles are arranged with combustibles and non-
combustibles in alternate locations -

(a) This technique tends to isolate a tire, allowing greater chance to

contain it within the pile or “block” of origin.

(b) This checker board pattern of materials also helps reduce

reliance on wind direction to control the spread of a fire.

N. BUILDINGS

A. Buildings within storage yards should be at least 50 feet from the nearest storage pile.

1. This space should remain clear and free of combustible materials, at all
times.

B. ARRANGEMENT OF BUILDINGS should also consider the effects of wind on the

spread of fire.

1. One approach is to have less hazardous shops and sheltered activities

upend, more hazardous ones downwind.

2. In addition to the above, leave plenty of clear tire- break space behveen
buildings (50 feet minimum), and alternate hazardous shops or stored
goods with those structures housing less hazardous goods or activities.
Again, this will help counteract unfavorable winds.

V. FIRE PROTECTION

A. Communications -- a reliable means of communication with the Saudi Aramco Fire

Protection Department shall be provided. Normally this will be a Saudi Aramco
system telephone.

WARNING: Prompt NOTIFICATION of the Fire Protection Department is

mandatory and absolutely necessary to prevent out-of-control fires.
B. Portable fire extinrmisbers shall be provided throughout the storage ares and the
buildings located as to be quickly available for use at any point.

C. Standard Live Hose Reels shall be provided throughout the storage areas to allow fast
application of firewater onto any location within the store yard. These hoses are
easily handled by one man and can deliver significant quantities of water. Full
coverage of the interiors of all buildings must also be provided.

WARNING:

1. Tbe need to notify the Fire Protection Department and man these live hose
reels as fast as possible cannot be over-emphasized.

(a) Fire areas increase as an increasing multiple of time, not at a

constant rate. The longer you wait to apply water on a small fire, the
more you will be surprised at the size the fire has attained.

(b) These l-114” diameter hoses allow one person to apply about 100
gallons/minute without difficulty.

2. Two inch steel (galvanized) lines shall be used to feed these hoses. Each
hose reel will have a valve at the tie-in to the 6” Iwp.

D. Standard Fire Hydrants - Saudi Aramco Engineering Standard B-7C requires type
509-G hydrants for protection of outdoor storage. Depending on system pressure,
the 2-I/2” hoses used by the Fire Protection Department can require 4 to 5 trained
men to handle. It is for this reason that tire hydrants are not normally provided with
hose or used by construction yard personnel.

1. In areas where there is no Fire Protection Department within reasonable

distance, sufficient 2-112” hose, and other equipment such as nozzles,
hydrant wrenches, etc. shall be kept on the site, suitably located, housed,
and maintained ready for use.

2. Hydrants and all tire fighting equipment shall be accessible for use at all
times. No temporary storage will be allowed to obstruct access for tire
fighting.

E. Details of Water Supply

Connect to main with gate valve.

Provide a looped system valved to feed hydrants from either direction.

(Block valve(s) to isolate either 50% of the piping and hydrants.)

Materials - carbon steel pipe, okay for temporary yards.

(Good mechanical strength, repairable.)

Size of loop piping, 6” diameter minimum.

VI. GUARD SERVICE

A. Guards trained in the use of live tire hose reels, fire extinguishers and the fire
warning system shall be on site at all times when the yard is otherwise unoccupied.

1. Supenkd rounds are mgg&ed to verify the entire property is

periodically observed.
2. Means of communication nexssary to summon assistance during
emergency situations shall be provided.

VII. YARD MAINTENANCE AND OPERATIONS

A. The site shall be kept free from accumulation of unnecessary combustible materials
such as empty cartons or other packing or packaging materials.

B. All electrical equipment and installations to comply with National Electrical Code.

C. Employees’ smoking areas shall be clearly designated and no smoking strictly

enforced outside these “safe” areas.

D. Motor vehicles shall be garaged and repaired outside the yard area, in a non-
combustible structure or unsheltered. Fuel handling shall comply with NFPA 30,
Flammable and Combustible Liquids Code., at 8 safe distance from the storage yard.

A site layout plan of the materials storage yards shall be submitted to the Loss Prevention
Department Area Fire Prevention Engineer for review. All essential features of this
“Checklist’ shall be clearly illustrated on a site drawing of the proposed yard. Two copies
of this drawing (done accurately to scale) will be submitted and once approved, one signed
copy shall be kept at the site for periodic review. Changes to the original storage yard
layout must be reviewed and concurred by Loss Prevention Department.
Appendix D: Saudi Aramco Crane
Safety Handbook
D.l CRANE SAFETY HANDBOOK

Notice:

For utility, the crane safety handbook is bound under separate cover. One copy will be
distributed to each holder of tbe Construction Safety Manual. Additional copies may be
acquired by contacting the Support Services Unit, Loss Prevention Department, E-1660,
Dhahran.
Appendix E: Suggestion Form
 SUGGESTIONS FOR THE SAUDI ARAMCO
CONSTRUCX’ION SAFETY MANUAL

MANAGER, Loss Prevention Department

Saudi Arabian American Oil Company
E-1770
Dh~bma, Saudi Arabia

Please consider the following suggestion(s) relative to the Saudi Aramco Construction Safety
Mnouol:

(Signature)

(Date)

(Address)

Contact Telephone Number

Contact FAX Number

Appendix F: Distribution Form

Fcbnwy 1993 - Constluetioo Safety Manual - Appmdir F: Distibtuim Form Fags 406
MANAGER
Address For Distribution
Construction Safety Manual
a
Loss Prevention Department
Saudi Arabian Oil Company
E-1770
DInbran, Saudi Arabia

Please continue. to send me changes or additions to the Saudi Ammco Construction Safety Manual.

My present address is:

company:

Address:

(Signature)

(Da@)

Contact Telephone Number

Contact FAX Number

Appendix G: Sanitary Code
IMPLEMENTING THE SAUDI ARAMCO SANITARY CODE - GI
151.006

SASC-A-010 INDOOR AND OUTDOOR RECREATION AREAS

AND FACILITIES, INCLUDING BEACHES,
CAMPGROUNDS AND MARINAS

SASC-C-010 CAMPS AND COMMUNAL LIVING FACILITIES

SASC-F-010 FOOD ESTABLISHMENTS

SASC-P-010 SWIMMING POOLS, WADING POOL2 AND SPAS

SASC-RBlO SOLID WASTE MANAGEMENT

SASC-S-010 WASTE WATER AND SEWERAGE SYSTEMS

SASC-W-010 WATER

Fcbnuq 1993-Appendix 0: Smimy Code Page409

Appendix H: General Instructions
Master Index
GENERAL INSTRUCTIONS (GI) MASTER INDEX

GI Number

2.100 IWork Petit System

2.102 Pressure Testing Safely

2.702 Electrical Safety for Boom or Derrick Type Hoisting Equipment

2.708 Gas Testing Procedures

2.710 Mechanical Completion & Performance Acceptance of Plant/Unit

2.711 Fire and Safety Watch

2.718 Contractor Sites Allotment Procedure

5.002 Loss Prevention Policy Implementation

6.001 Notification Requirements for Incidents (Including Fires)

6.003 Guide for Committees Investigating Major Incidents or Engineering Reviews of

Other Incidents

6.012 Isolation, Lockout and Use of Hold Tags

6.020 Personal Flotation Devices for Work Over, On or Near Water

6.021 Safety Requirements for Abrasive Blast Cleaning

6.025 Control of Remote Area Travel and Search/Rescue Procedures

6.029 Reporting and Recording of Motor Vehicle Accidents

6.030 Traffic and Vehicle Safety

7.025 Mobile Heavy Equipment Operator Testing and Certification

7.026 Lifting/Elevating and Mobile Equipment Accident Reporting Procedures

7.027 Personnel Work Platform Operations

7.028 Heavy Crane Lift, Multiple/Tandem, Critical Crane Lifts

7.029 Inspection, Testing and Maintenance of Wire Rope Slings

7.030 Inspection and Testing of Cranes, Elevators, Powered Platforms, and Mobile
Aerial Baskets
8.001 Safety Requirements for Scaffolding

8.002 Prescription Safety Glasses

8.003 Air-Supplied Breathing Apparatus

8.005 Protective (Safety) Foohvear

70.500 Disaster Contingency Plan - Dhahnm Area

80.500 Disaster Control - Refinery and Terminal - Ras Tanura

150.001 Asbestos Regulations

150.002 First AidlCPR Training and First Aid Kits - Remote Areas

150.003 Ionizing Radiation

151.006 Implementing the Saudi Aramco Sanitation Code

330.87 Bulk Deliveries of Oil Field Treatment Chemicals from Local Vendors

355.001 Identifying, Cataloging, Ordering and Tracking Hazardous Materials

355.002 Receiving, Storing and Issuing Hazardous Material

355.003 Disposing of Hazardous Material

355.004 Handling and Disposing of Polychlorinated Biphenyls (PCBs)

355.015 Requisitioning, Receiving, Storing and Issuing Explosives

355.015-01 Deterioration and Disposal of Explosives

355.020 Control of Compressed Gas Cylinders

401.081 Performance Qualifications For Welders and Welding Operators

402.001 Operational Chemical Cleaning of Boilers

432.00 Pipeline Hydrotest Water Disposal

434.00 Pipeline Repair and Maintenance

441.014 Repair Procedures on Hydrocarbon Pipelines

447.002 Pressure Relief Valves - New Installation, Change in Set Pressure, Replacement
or Retirement from Service

447.003 Pressure Relief Valves - Routine Tests, Inspection, Quality Assurance and
Regulation
475.001 Blasting Near Existing Facilities

475.002 Use of Explosive-s in Construction

520.001 Confined Space Entry Procedure

618.001 Special Regulations for the Use of Explosives in Seismic Operations

1021.000 Street and Road Closure, Excavation, Reinstatement and Traffic Controls

1127.700 Transportatioo Engineering Procedures for Heavy-Lift/Over-Sized Equipment

1130.013 Vehicle Loading

1131.165 Use of Trailer Brakes

1131.921 Use of Trailer Safety Chains

1183.215 Transporting Explosives in Company Owned/Leased/Rented Motor Transport

Vehicles

1185.003 Death or Injury Aboard Seagoing Vessels

1186.502 Marine Craft Fueling, Tanajib or West Pier

1186.504 SAG Regulations and Practice as Applied to All Types of Marine Craft at the
Port of Ras Tanura

1187.001 Collision & Damage By or To Marine Equipment or Craft

1192.001 Operating Practices for Harbor Tugs, Offshore Vessels and Launches, Including
Safety Rules

1192.002 Operating Procedures for Barges Including Safety Rules

1192.502 Operating Procedures for Marine Oil Recovery and Storage Barge/Vessel,
Including Safety Rules

1193.001 Marine Port Information and Regulations

1193.002 Navigation Warnings

1194.001 Requesting, Assigning and Dispatcbiig Pollution Control Vessels, Tugs,

Launches and Barges

ll%.OOl Whistle Signals for Use Behveen Tugs and Barges or Tugs and Self-Propelled
Vessels when &thing

1197.001 Pnxedures and Safety Rules for Diving Operations

1198.001 Rig/Barge Moving

 1199.001 Safe Operation of Self-Propelled Jack-Up Barges

w1o.ooo Transportation of Dangerous Articles Onboard Saudi Aramco Aircraft

1321.015 Request for Air Medical Evacuation

16Qo.003 Destruction of Obsolete/Damaged, Unneeded Communication Equipment

1601.002 Radio Asset Control And Accountability Program (RACAP)

1602.001 Residential Telephone Service

1602.002 Business Telephone Service Inside Aramco Communities and Facilities

1602.003 Business Telephone Service Outside Aramca Communities and Facilities

1603.001 Data Circuits, Message Switch And Facsimile Terminals

1781.001-1 Inspection/Maintenance - Fire Protection Equipment

1787.00-l Fire Reports

Febmury 1993 - Appendix Ii: 01 Master Index Fage 414

Appendix I: List Of Figures
LISr OF FIGURES

I. Administration:
Figure I.1 Preliminary Accident Report 14
Figure I.2 Contractor Monthly Safety Report I.5
Figure 1.3 Injury Summary 42
Figure I.4 Protective Goggle, Spectacles, Face Shields And Helmets 48
Figure 1.4A Protection Against Radiant Energy 49
Figure 1.5 Specialized Hand Pmtectors 50
Figure I.6 Typical Self-Powered Platform For Building Maintenance 51
Figure I.7 Respiratory Protection 58
Figure I.8 CIeanmce Considerations For Safety Equipment 59
Figure I.9 Know Your Fire Extinguisher 66

II. General And Civil:

Figure II. 1 Hold Tag 94
Figure II.2 Lockout Clip qypical) 95
Figure II.3 Excavations Made In Type A Soil 106
Figure 11.3A Simple/Multiple. Bench 107
Figure 11.3B Unsupported Vatically Sided I08
Figure II.4 Excavations Made In Type B Soil 109
Figure 11.4A Single/Multiple Bench 110
Figure 11.5 Excavations Made In Type C Soils Ill
Figure II.6 Excavations Made In Layered Soils 112
Figure 11.6A Excavations Made In Layered Soils 113
Figure II.7 Examples Of Trench Shields 114
Figure II.8 Guide To Safe Distance Back From Top Of Slope For 115
Storage Of Materials Or Placing Equipment
Figure II.9 Examples Of Screw Trench Jacks 116
Figure II. 10 Aluminum Hydraulic Shoring Typical Installations 117
Figure. II. 11 Aluminum Hydraulic Shoring 118
Figure II. 12 Aluminum Hydraulic Shoring Waler Systems For Soil 119
Spe B
Figure II. 13 Example Of Timber Shoring Protective Systems 120
Figure II. 14 Timber Trench Shoring - Minimum Timber Requirements 121
Figure II. 15 Timber Trench Shoring - Minimum Timber Requirements 122
Figure II. 16 Timber Trench Shoring - Minimum Timber Requirements 123
Figure II. 17 Standard Coupler 167
Figure II. 18 Adjustable Coupler 167
Figure II. 19 Typical End To End Coupler 167
Figure 11.20 Screwjack 167
Figure II.21 Typical Reveal Pi 167
Figure II.22 Typical Base Plate 167
Figure II.23 A Typical Independent Tied Scaffold Constructed Using 185
Tube And Coupler Scaffolding
Figure II.24 A Typical Tube And Coupler Scaffold 186
Figure II.25 Plan View Of Two-Way Tie 187
Figure II.26 Plan View Of Column Box Tie 187
Figure II.27 Plan View Of Reveal Tie 187

Febnuy I993 - Appendix I: Lid Of F~gurcg Page 416

 Figure 11.28 A Typical System Scaffold 188
Figure II.29 A Typical System Scaffold Being Assembled 189
Figure 11.30 A Typical System Scaffold Base In The Process Of Being 189
Assembled And Leveled
Figure II.31 A Typical Fabricated Tubular Frame Manually Propelled 190
Mobile Scaffold
Figure II.32 A Typical Tube And Coupler Mobile Access Tower 191
Figure II.33 Cross Tube Anchor 192
Figure II.34 outriggers In use 192
Figure II.35 Driven Tube Anchor 192
Figure. II.36 Abrasive/Grinding Wheel 200
Figure II.37 Grinder Guards 201
Figure II.38 Bench Grinder - Machine Guarding 202
Figure II.39 Ring Test 211
Figure 11.40 Correctly Mounted Wheel 212
Figure II.41 Wire Conversion Chart 213
Figure II.42 Self Adjusted Guard 214
Figure. II.43 Table Saws 215
Figure II.44 Table Saw - Machine Guarding 216
Figure II.45 Radial Saws 217
Figure II.46 The Woodworking Machine Regulations 218
Figure 11.47 Cartridge/Tool Issuance Control 219

m. Mechanical Equipment And Materials:

Figure III. I Pre-Lift Operation Checklist 241-242

Figure III.2 Lift Plan For Cranes 243
Figure. III.3 Identification Tags 252
Figure III.4 Installing A Wedge Socket On A Rope 253
Figure. III.5 Two-Legged Chain Sling: Major Components 253
Figure III.6 Sling Fixings 253
Figure III.7 Synthetic Webbing Slings 254
Figure. III.8 Sling Loading 255
Figure III.9 Eyebolts 2.55
Figure III. 10 Crane Hooks 255
Figure. III. 11 Shackles 2.55
Figure III. 12 Wire Rope Sling Inspection Log 256
Figure III. 13 Typical Construction Materials Store Yard 272

N. Electrical And Radiation:

Figure IV. 1 Temporary Crossing For Construction Equipment 293
Figure IV.2 Proper Use Of Insulating Tools And Protective Apparel 294
Figure IV.3 Standard Sign - Radiation 299

V. ChemicalsAnd Operations:
Figure V. 1 Identification Of Materials By Hazard Signal 326
Dimensions And Arrangement
Figure V.2 Explanation Of Hazard Rating Codes 327
Figure V.3 Identification Of Health Hazard, Flammabiiity And 328
Reactivity
VI. Marine:
Figure VI. 1 If You Work Over, On Or Near Water 336
Figure VI.2 International Code Flag “A” 348
Figure VI.3 Signals 348

Appendix A:
Figure A. 1 Contractor’s Competition Job Safety 355-356
Evaluation

Appendix B:
Figure B. 1 Typical Emergency Organization Chart 387
Figure B.2 Scenario Analysis Sheet For (Location) 388
Figure B.3 Emergency/Disaster Control Tasks Checklist 389
Figure B.4 Flow Diagram Of Typical Offshore Emergency Response 393
Figure B.5 Emergency Reporting Instructions 394
Figure B.6 Emergency Plan - Sample Table Of Contents 395-396
Appendix J: List Of Tables
LIST OF TABLES

1. Administration:
Table I. 1 Basic Personal Protective Equipment 48

II. General And Civil:

Table II. 1 Maximum Allowable Slopes 105
Table II.2 Wood Scaffold Plank Loading 166
Table II.3 Tube And Coupler Scaffolds - Light Duty 116
Table Il.4 Tube And Coupler Scaffolds - Medium Duty 177
Table Il.5 Tube And Coupler Scaffolds - Heavy Duty 178
Table II.6 Ventilation Requirements For Confined Spaces 223
Table II.7 Personal Protective Equipment To Be Worn Or Used 227
During Surface Preparation And Paint Application

III. Mechanical Equipment And Materials

Table III. 1 Wind Speed (Miles Per Hour) vs. Force Of Wind In 244
Pounds Per Square Foot
Table 111.2 Wind Speed Definition 244
Appendix K: Forms
&WI&X K contains originals of many of the forms which have appearedas
figures throughoutthe Manual. Pleasecopy thesefor usein your safetyprogram. l

February 1993 Appendix K: Fom Page 422

PRELIMINARYACCIDENTREPORT:

Detailed Repott Required Within 3 Days Cootml No

Accident Location: Date Of Aeeideot: Time Of Accident:

COltp~~: Perwaoel Injured: Badge Number:

Type Of Injuries: F’roperty Damage And Estimatkd Cost Damage:

Description Of Accident:

Witiess Statement(s)

What Caused The Accident:

What Corrective Action Has Been Taken

Signed:

Date Of Report:

Name (Printed):

Company:
CONTRACTOR MONTHLY SAFETYREWRT

BUDGET lTEh4 No:. CONTRACI No.: JOB No:-

1. WorkI@ies:

2. Fires:

3. IncidentsOr PropertyDamage
(OverSR10,000):

4. MotorVehicle
Accidents:

5. IncidentsInvolvingDamage
ToSaudiAramcoEquipment:

6. Crane,HeavyEquipment
& ManliftAccidents:

7. SafetyMeeting:

(A) TopicsDiscussed:
1.
2.
3.
4.
5.
(B) Attendance:

,
(C) Instructor(s):
INJURY &JMMARY (PAGE 0~ )
Project: Project No.: Month & Year:
Contractor: File No.:

I I I I I I I I

I I I I I I I I I I

I I I I I I I I

I I I I I I I I

I I I I I I I I I

I I I I I I I I I I

I I I I I I I I

I I I I I I I I
I I
Total Lost Time Injuries Total Days Total Man-hours Worked This
This Month: Lost: Month:

Report Prepared By:

Signahue:

Title And Telephone:

LIFT PLAN FOR CRANES
1. Co”tmctor: J.O. No.:
2. Crane Inspection Sticker valid: Yes:0 No:0 Date of expiry:
3. Operator Saudi Aramco certified: Yes: 0 No: 0 4. ~escriptio” of load:
5. *Type of crane to be used stowed Erected NIA (lbsntgs)
*Boom length (total) ftlm Jib: 0 0 0
*Jib length ftlm Extension: 0 0 0
Hookblock (Main): - - - -
Aux. Boom Head: cl 0
Headache Ball: 0 0
Slings, Shackles, etc.: - ~ - -
Others:

I Total (Gross Load Weight):

6. l Weight of load -lbs/kgs l Effective weight of jib - Ibsikgs (see.jib chart)

l Effective weight ofjib headache ball - lbsikgs l Weight of load block ~ lbsikgs
l Weight of hoist rope below boom tip- Ibs/kgs l Weight of spreader bar plbsikgs
. Weight of other rigging - lbsikgs
Total load weight lbsikgs
7. Hoisting clearance film. 8. Lift quadrant zone 9. Dperating radius H/m.
10. Crane capacity at operating radius (Note: Do not make lift if total load is greater than crane capacity show” in ltem 10. Refer to GI 7.028
for appropriate derating based on type of lift.)
II. Crane capacity for jib configuration: 12. Ground and site conditions:
13. Wind speed: mph (Maximum 20 mph)
14. Work permit required: Yes0 No: 0
15. Load moment indicator: Yes:0 No: 0 Type:
16. Sketch and supplementary information for crane lift is required to be attached to this plan. (Note: The sketch of the crane should include the following
rigging information: size of each component; safe working load (SWL,) capacity; length of slings; type of component; component diameter; weight
of component and sling angles).
Contractor: Date: Crane operator: Date:
Approved: Date: Reviewed by: Date:
(Competent Person) (Saudi Aramco Site Representative)
Approved: Date:
(Heavy Haul/Rig Move Unit, Transportation Dept., Abqaiq)
Footnote: This fona is to be filled out for the following lifts: 1. At all construction sites and opemting plants; 2. Associated with offshore and marine
sites aad opemdons; 3. Within safety zones of power lines; 4. Involving personnel plntfomts (as per GI 7.027, 7.028 aad 7.030).
 EMERGENCY
REF~RTINCINSTRUCTIONS
TELEPHONE: XXX-XXXX (if buy see below)

I have an emergency to report:

I am calling from

My name is My badge number is

I.S=a at
(tire, gas leak, etc.) (north/south/east/west)

There are (no.) of people hurt and requiring medical assistance.

DO NOT HANG UP. ENSURE THAT YOU HAVE A RESPONSE THEN IF NECESSARY
REPEAT THE ABOVE INFORMATION AND ANSWER QUESTIONS.

1. If the number is busy or unavailable, try the following in the order listed:

2. telephone xxx-zzzz

3. radio frequency XXLXX

4. (other for the facility)

After the m&age has been given successfully, the reporting individual, if an operator. should return immediately to
the emergency site to do whatever he can safely do to improve the emergency situation.
PROJECT MANAGEMENT AND CONTRACTOR’S SAFETY
COMPETITION SITE REGISTRATION FORM

To: Saudi Aramco Loss Prevention Department Date:

Name Of Contractor: Contractor’s Address: Contractor’s Phone Number:

Job Description: Job Number: Starting Date:

Estimated Completion Date:

B.I. Number: Peak Number Of Employees:

“ontractor Site Representative: Saudi Aramco Site (PMT) Project Mgmt. Department:
Engineer:

Telephone Number: Telephone Number: org. code:

Name Of Contractor’s Safety Contractor’s Site Phone Site Location:

Representative: Number:

Signed: (Contractor’s Representative)

Job Title:

Company:

Saudi Aramco Proponent Department:

This form is to be completed and sent to the local Saudi Aramco Loss Prevention Office with a copy to
the designated senior Project Engineer, who is a member of the proponent Project Management Team
(PMT).

Signed:
Saudi Aramco Project Manager
WIRE ROPE SLING INSPECTION LOG

contractor: Location:

BI/JO Number: Project Title:

Inspector Signature (Date)

I I
CARTRIDGE/T• OLISSUANCECONTROL

Received By
Cert No. NC%lW/ Issued By
Signature
I I I

I I I I I

I I I I I

I I I I I

Warning: Above items can only be issued to workers with valid training certificate Storekeeper:
Safety Offkxr:

l 0