SAFETY OFFICER PREPARATION SHEET

CONFINED SPACE
 Any space having a limited means of entry and exit.
 Generally which is not design for continuous human occupancy.
 Excavation more than 1.2m.
Example:- Manhole, Trench, Pipe, Pit, exaction more than 1.2m etc.
Hazar
d:-
 Oxygen Deficiency and Enrichment Entry Permit System:
 Toxic & flammable gases  Permit Requirements: Issuance of a confined space
 Poor illumination, Communication & Ventilation. entry permit before any work begins.
 Chemical hazards fire hazards.  Contents: Details of the work, identified hazards,
 Fire & Explosion controls, emergency procedures, and personnel
 Restricted movements. involved.
Pre-Entry Safety Measures:
What are the safety precautions before entry in a  Risk Assessment: Conduct a thorough risk
confined space? assessment to identify and control hazards.
 First check confined space entry work permit.  Atmospheric Testing: Check for oxygen levels, toxic
 Ventilation must be provided. gases, and explosive atmospheres using gas
 . Gas test should be frequently done. detectors.
 Oxygen level 19.5% between 23.5%  Isolation of Energy Sources: Lockout/tagout
 LEL 0%. (LOTO) procedures to isolate all energy sources.
 Shall be provide Proper light and low voltage Identifying Hazards:
electricity (24V - 110V).  Atmospheric Hazards: Lack of oxygen, presence of
 Proper communication between confined space toxic gases (e.g., hydrogen sulfide), flammable
attender vapors.
 person working inside the confined space. Use  Physical Hazards: Restricted movement, extreme
appropriate respirator if necessary temperatures, slippery surfaces, and falling objects.
Toxic Gasses in CS  Engulfment and Entrapment: Risks from loose
 Benzene, materials or liquids.
 Ethylene Oxide, Legal and Industry Standards:
 Sulphur Dioxide, (SO2)  OSHA 29 CFR 1910.146: Guidelines on confined
 Hydrogen Sulfide, (H2S) space entry.
 Ammonia,  API Standards: American Petroleum Institute
 Carbon Monoxide, provides specific guidelines for the oil and gas
 Carbon Dioxide, industry.
 Ethylene Chloride  Local Regulations: Compliance with regional safety
WHO IS CONFINED SPACE ATTENNDANT? laws and standards.
He is one who is aware of the confined space Life-Saving Devices in Confined Spaces
hazards and knows how to react if anything goes wrong,  Gas Tester- Portable multi-gas detectors,
able to maintain confined space entry log sheet etc.  Respiratory Protection: Self-contained breathing
 Trained and Competent apparatus (SCBA) or air-purifying respirators (APRs)
 Authorized for gas test  Protective Clothing: Flame-resistant clothing
 Able to Maintain Log Sheet. (FRC), gloves, and boots to protect against
 Trained for Emergency Evacuation chemical, thermal, and physical hazards.
 Not assign for any other work  Head, Eye, and Hearing Protection: Helmets,
 He is responsible for the safety of entrants, safety goggles, and ear protection for physical
 Maintain update entry log sheet, safety.
 Maintain continuous communication with entrants Communication Method.
 Prevent unauthorized personnel  Verbal, Face to Face, Radio OATH METHOD
TOXIC GASSt  O-OK, A-Advance me rope, T-Take me up, H-Help.
Sulfur Dioxide (SO₂):
 Properties: Colorless gas with a pungent, irritating
Hydrogen Sulfide (H₂S) odor. Heavier than air.
 Sources: Natural gas, crude oil, sulfur deposits, and  Hazards:
drilling operations o Toxicity: Can cause respiratory problems,
 Properties: Colorless gas with a characteristic eye irritation, and aggravate conditions like
"rotten egg" odor at low concentrations. Heavier asthma. High concentrations can be life-
than air and colorless. threatening.
Hazards: o Corrosivity: Can form sulfuric acid when
 Toxicity: Extremely toxic, even at low combined with water, leading to corrosive
concentrations. Can cause irritation of the eyes, damage to equipment.
nose, and throat, respiratory distress, and can be  Sources: Produced during the refining process,
fatal at high levels. especially in facilities processing sour crude oil.
 Flammability: Highly flammable and can form Nitrogen Oxides (NO2):
explosive mixtures with air.  Properties: Group of gases including nitric oxide
H₂S Exposure Limits (NO) and nitrogen dioxide (NO₂). Brownish-red in
TWA Definition: The average concentration of H₂S that a color with a sharp, biting odor.
worker can be exposed to over a standard 8-hour workday  Hazards:
or 40-hour workweek without adverse effects. o Toxicity: Can irritate the respiratory
 PEL 10 PPM system, cause lung damage, and contribute
 TVL (Threshold Limit Value): 1 ppm to the formation of smog and acid rain.
 REL – 10 PPM o Flammability: While not flammable, NOx
STEL Definition: The maximum concentration of H₂S to gases can react with other chemicals to
which workers can be exposed for a short period (typically produce hazardous compounds.
15 minutes), with no more than four exposures per day and  Sources: Combustion processes in engines, flares,
at least 60 minutes between exposures. and heaters.
 STEL: 5 ppm (15 minutes) Ammonia (NH₃):
 LEL: 4.3%  Properties: Colorless gas with a pungent odor.
 UEL: 46% Lighter than air.
Methane (CH₄):  Hazards:
 Sources: Natural gas fields, oil drilling, and coal o Toxicity: Can cause respiratory irritation,
mining. burns, and severe lung damage at high
 Properties: Colorless, odorless gas. Lighter than air. concentrations.
Hazards: o Flammability: Flammable under certain
 Flammability: Highly flammable and can form conditions and can create explosive
explosive mixtures with air. mixtures in air.
 Asphyxiation: In high concentrations, it can  Sources: Used as a refrigerant, in gas treatment
displace oxygen and cause suffocation. processes, and as a chemical feedstock.
Carbon Monoxide (CO): Carbon Dioxide (CO₂):
 Properties: Colorless, odorless gas. Slightly lighter  Properties: Colorless, odorless gas. Heavier than
than air. air.
 Hazards:  Hazards:
o Toxicity: Highly toxic. Binds to hemoglobin o Asphyxiation: In high concentrations, it can
in the blood, preventing oxygen transport, displace oxygen, leading to suffocation.
leading to headaches, dizziness, o Corrosivity: Can lead to corrosion in
unconsciousness, and death. pipelines and equipment when dissolved in
o Flammability: Flammable and can water, forming carbonic acid.
contribute to fires and explosions.  Sources: Result of combustion processes, natural
 Sources: Incomplete combustion of carbon- gas processing, and as a byproduct in oil recovery
containing fuels, gas flares, and engine exhausts. operations.
Gas Tester.
HYDRO-TESTING
Hydro-testing involves filling a vessel, pipeline, or other
components with water to a specific pressure to test its
integrity, strength, and leak resistance. It is crucial in the oil
L=0.15D α 0.4 (P/ ∛ρ)
and gas industry to ensure the safety and reliability of L= Minimum Safe Distance in Meter.
equipment, preventing potential leaks, ruptures, and D=Internal Dia
failures that could lead to hazardous incidents.
Main hazards associated with hydro-testing?. P=Pressure in Bar
 High Pressure: The most significant hazard is the
high pressure used during the test, which can
α = Safety Factor= I/D
cause catastrophic failures, leading to explosions I= Length of System
or flying debris. ρ = Density of fluid (1000 for water)
 Leaks and Bursts: A leak or burst in the pipeline or What documentation is required before, during, and after
vessel being tested can result in a sudden release a hydro-test?
of pressure, causing injuries or fatalities. Before the Test:
 Slips and Falls: Water used in the test can create  Test Plan: A detailed test plan including
wet and slippery surfaces, increasing the risk of procedures, safety measures, and emergency
slips and falls. response plans.
 Mechanical Failures: Failure of hoses, valves, or  Risk Assessment: Documented risk assessment and
other equipment can lead to unintended pressure safety analysis specific to the hydro-test.
releases or uncontrolled movements.  Permits: Necessary permits to work, including
 Noise: The process can generate high noise levels, approval from relevant authorities.
which can lead to hearing damage if not properly  Equipment Inspection Records: Documentation of
managed. pre-test inspections and equipment calibrations.
Key precautions include: During the Test:
 Exclusion Zones: Establish and clearly mark  Test Log: A real-time log of test conditions,
exclusion zones around the test area to keep non- including pressure readings, temperature, and any
essential personnel at a safe distance. anomalies observed.
 Pressure Relief: Ensure pressure relief valves are  Incident Reports: Immediate documentation of
installed and functioning to prevent over- any incidents or near-misses that occur.
pressurization. After the Test:
 PPE Requirements: Mandate the use of  Test Results: A comprehensive report of the test
appropriate personal protective equipment (PPE) results, including data, observations, and any
such as hard hats, safety goggles, ear protection, deviations from the plan.
and steel-toed boots.  Post-Test Inspection: Documentation of the post-
 Equipment Inspection: Thoroughly inspect all test inspection to ensure the integrity of the
equipment, including hoses, gauges, and valves, to equipment.
ensure they are rated for the test pressure and free  Incident Investigation Report: If any incidents
of defects. occurred, a detailed investigation report outlining
 Monitoring: Continuous monitoring of pressure the cause, impact, and corrective actions.
levels and equipment during the test is essential.
Assign a dedicated team member to monitor
gauges and systems.
 Emergency Procedures: Have clear and rehearsed
emergency procedures in place, including
immediate shutdown protocols and evacuation
plans.
SAFE DISTANCE
The safe distance during a hydro-test is calculated based on
factors such as the test pressure, the volume of the vessel
or pipeline being tested, and the potential energy release
in case of failure.
PRE-COMMISSIONING
Pre-commissioning is the process of preparing and
testing systems, equipment, and pipelines before they are  Communication and Coordination: Ensure clear
put into operation. This includes activities such as cleaning, communication and coordination among all teams
flushing, pressure testing, and verifying the functionality of involved in pre-commissioning to prevent
systems. It is crucial to ensure that everything is installed misunderstandings and accidents.
correctly, free from defects, and ready for safe and  Emergency Preparedness: Have an emergency
efficient operation. This step helps to identify and rectify response plan in place, including the availability of
issues before the actual commissioning, reducing the risk of fire-fighting equipment, first aid, and evacuation
failures during operation. routes.
2. What are the main hazards associated with pre- 4. What methods are commonly used during pre-
commissioning activities? commissioning?
Answer: Key hazards during pre-commissioning include: Answer: Common pre-commissioning methods include:
 Hydrostatic Testing: Testing pipelines and vessels
 High Pressure and Hydrocarbon Leaks: Testing
systems under pressure can lead to leaks, bursts, with water under pressure to check for leaks and
or uncontrolled releases of hydrocarbons, posing integrity.
 Pneumatic Testing: Using compressed air or inert
explosion or fire hazards.
 Chemical Exposure: The use of chemicals for
gases to test systems for leaks, typically at lower
cleaning, flushing, or preservation can expose pressures than hydrostatic tests.
 Flushing and Cleaning: Removing debris,
workers to toxic or corrosive substances.
 Confined Space Entry: Many pre-commissioning
contaminants, and preservation chemicals from
activities occur in confined spaces, increasing the pipelines and equipment using water, air, or
risk of asphyxiation, toxic exposure, or entrapment. chemical solutions.
 Chemical Cleaning: Applying chemical solutions to
 Electrical Hazards: Energizing systems for testing
can lead to electrical shocks or arc flash incidents if remove scale, rust, or other deposits from
not handled correctly. equipment and pipelines.
 Blowdown: Using compressed air or nitrogen to
 Mechanical and Structural Failures: Improperly
installed equipment or structural components can blow out any remaining debris or moisture from
fail under load, leading to collapses, equipment systems.
 Electrical Continuity and Insulation Resistance
damage, or injuries.
Testing: Ensuring that electrical systems are
3. What precautions would you implement to ensure
properly connected and insulated before
safety during pre-commissioning?
energization.
Answer: Key precautions include:
 Valve and Instrument Calibration: Checking and
 Risk Assessment and Planning: Conduct a detailed
calibrating control valves, pressure relief devices,
risk assessment to identify potential hazards and
and instrumentation to ensure proper functioning.
plan mitigation measures.
5. How do you manage confined space hazards
 Permit to Work (PTW) System: Implement a
permit-to-work system to ensure that all pre- during pre-commissioning?
commissioning activities are authorized and Answer: Managing confined space hazards involves:
 Confined Space Entry Permit: Implementing a
supervised.
 PPE Requirements: Ensure that all personnel wear
confined space entry permit system to control
appropriate personal protective equipment (PPE), access and ensure that all safety protocols are
such as hard hats, safety goggles, gloves, and followed.
 Atmospheric Testing: Continuously monitoring the
flame-resistant clothing.
 Gas Monitoring: Use gas detectors and monitoring
atmosphere within the confined space for oxygen
systems to detect the presence of hazardous gases, levels, toxic gases, and explosive atmospheres.
 Ventilation: Providing adequate ventilation to
especially in confined spaces.
 Isolation of Energy Sources: Isolate and lock
remove hazardous gases and supply fresh air.
 Rescue Plan: Preparing a confined space rescue
out/tag out (LOTO) all energy sources before
beginning any work on equipment to prevent plan, including having trained rescue personnel and
accidental start-up. equipment readily available.
 Buddy System: Ensuring that workers never enter a
6. What steps would you take to ensure compliance confined space alone and that a standby person is
with industry standards and regulations during pre- always present to monitor and assist.
commissioning?
Answer: Ensuring compliance involves:
 Adherence to Standards: Following industry
standards such as those set by API (American
Petroleum Institute), ASME (American Society of
Mechanical Engineers), and local regulatory bodies.
 Documentation: Keeping detailed records of all
pre-commissioning activities, including risk
assessments, test results, and inspections.
 Training: Providing training to all personnel on
relevant standards, procedures, and safety
requirements.
 Third-Party Inspections: Engaging third-party
inspectors to verify that all systems and equipment
meet the required standards before
commissioning.
 Regular Audits: Conducting regular audits to
ensure that all pre-commissioning activities comply
with regulatory requirements and company
policies.
7. Can you describe a challenging situation during
pre-commissioning and how you handled it?
Answer: (Example Scenario) During a pre-commissioning
phase, we encountered a situation where a critical valve
failed during a hydrostatic test, leading to a potential leak
of high-pressure water. I immediately halted the test,
isolated the affected section, and initiated an investigation.
We replaced the faulty valve, rechecked the integrity of the
system, and conducted a thorough risk assessment before
resuming the test. This proactive approach prevented any
serious incident and ensured that the system was safe for
commissioning.
LIFTING
WHAT ARE THE REQUIRMENTS OF A CRANE LIFTING? 4. Road Roller:
Crane positions on firm and level ground with wood pads - Inspection of roller drums and compaction mechanisms.
and steel plates. Outriggers are fully extended tires are off - Functional brakes and steering.
the ground. Certified operator and rigger are available safe - Adequate warning signals and lights.
load indicator is working the check list filled by competent - Operator visibility and seating condition.
persons.
WHAT IS WORK RADIUS? 5. Excavator:
Is the maximum distance where a certain activities - Check for hydraulic leaks and fluid levels.
for lifting or rigging jobs in progress. - Functionality of the digging bucket and arm.
- Inspection of tracks or wheels.
WHAT IS SWL? - Proper operation of safety features.
Safe Working Load is the maximum load
that can apply to the lifting tool, safely 6. Dump Truck:
- Inspection of brakes and steering.
WHAT IS LIFTING PLAN? - Functional dump bed operation.
IT Is the documents prepare for planning a critical lift by - Adequate tire condition.
calculating and considering all factors which is going to - Check for load securement and proper signage.
effect the lift and there by selecting the correct tools and
cranes and ensure the safe lifting procedure to be followed 7. Forklift:
for the particular lift, which is used for lifting and what the - Inspection of lifting mechanisms and forks.
safe factor is, where the load is lifted, where it is fitted, size - Condition of tires.
and SWL of each lifting tool used JSA and load-chart are - Functionality of brakes and steering.
attached with it. - Adequate training and certification for operators.

WHAT IS TANDUM LIFT? What are the requirements for a crane lifting?
A lift in wich two crane are used for Lifting is called Crane positioned on firm and level ground with wood pads
Tandum Lifting. and steel plates. Outriggers are fully extended, Tires are off
ground, Certified operator and rigger are available, Safe
As a safety officer, when inspecting various equipment, load indicator is working, The check list is filled by
you should focus on: competent person, Crane has valid inspection sticker,
1. Mobile Crane: Insurance and third party certificate, The load’s weight is
- Structural integrity of the crane. confirmed and is within the safe working limit of the crane,
- Functionality of lifting and hoisting mechanisms. Safety devices are not bypassed, The swing arm radius is
- Inspection of cables, hooks, and other lifting accessories. barricaded to prevent unauthorized persons entry, The
- Operation of safety devices and alarms. lifting tools are free from defects, Pads are used to protect
the slings from load and vice versa, Wind speed is less
2. Manlift: than32km/, Approved lifting plan is available for critical
- Stability and levelness of the platform. lifts, Permit for the activity is obtained, Crane operators
- Functional controls and emergency stop mechanisms. and rigger’s vision is not obstructed, The load is well
- Inspection of safety rails and harness attachment points. balanced and tag lines are used to control the weight etc.
- Adequate training and certification for operators.
What are the hazards of lifting?
3. Bobcat: Equipment damage, ground collapse, fall hazards, over
- Condition of tires and tracks. load, Material slipping, suspended load etc.
- Functionality of the bucket or attachment.
- Check for hydraulic leaks.
- Proper operation of controls.

Who can prepare by a critical lifting plan?

Class 1st level rigging supervisor.
What are the hazards of lifting?
Equipment damage, ground collapse, fall hazards, over
load, Material slipping, suspended load etc.
What is gas cutting? What are safety precautions during
gas cutting?

The cylinders oxygen and acetylene using gas cutting work.

The color of acetylene cylinder is yellow and use the tube
color is red. The color of oxygen cylinder is green and use
the tube color is also same. Make sure that both end of the
tube must be fitted with flash back arrester. Carrying
cylinder one place to another place must be in standing
position. When not use cylinders remove the pressure gage
and put in the cylinder cap properly and should be
protected with wall. During storage of oxygen and
acetylene cylinders they must be separated by fire resistant
wall or a distance of 20feet