SAFETY

HANDBOOK

Minimum Safety Rules

Safety Department - Petro Rabigh

Emergency Actions

Report All Emergencies Immediately

How to Report Emergencies?

• Petro Rabigh telephone, call 911

• Mobile phone, call 012-425-0911

• Tetra, move to channel 1_PRC

and press “Alert”

• Say, “This is a real emergency!”

• Describe the incident (Problem &

Product(s)).

• Describe the incident location

(Emergency Grid Location).

• Wind Direction.

• Report injuries, if any.

• Give your name and Badge

Number.

• Repeat the above information.

• Stay on the line until further

instructed.

What to Do During

Emergencies?

• Follow local plans or instructions.

• Remain calm.

• Stop work.

• Proceed safely to assembly point.

• Remain at assembly area until All

Clear signal has been given.

Name: ............................................................................................

Badge Number: .............................................................................

SAFETY HANDBOOK

Minimum Safety Rules

This handbook contains the minimum safety rules

applicable to employees, contractors, visitors or anyone

performing Petro Rabigh work activities. Compliance to

these rules is a condition of employment for Petro Rabigh

employees and a contractual obligation for contractor

employees. All the safety topics cannot be included in such

a handbook. There are many applications on safety - many

more than what can be addressed in such a handbook. If

you see an unsafe condition or behavior, do not disregard

it just because it is not listed in this handbook.

Please carry this Handbook with you

while on work for ready reference.

For additional information, consult Safety Department.

ﻎﺑاروﺮﺘﺑ ﻲﻓ ﺔﻣﻼﺴﻟا ئدﺎﺒﻣو تاﺪﻘﺘﻌﻣ

SAFETY BELIEFS AND PRINCIPLES AT PETRO RABIGH

SAFETY BELIEFS

Safety is everyone's responsibility

All incidents and injuries are preventable

SAFETY PRINCIPLES

ﺔﻣﻼﺴﻟا ئدﺎﺒﻣ

.ﻊﻴﻤﺠﻟا ﺔﻴﻟوﺆﺴﻣ ﺔﻣﻼﺴﻟا

.ﺎﻬﻳدﺎﻔﺗ ﻦﻜﻤﻳ تﺎﺑﺎﺻﻹاو ثداﻮﺤﻟا عاﻮﻧأ ﻊﻴﻤﺟ

ﺔﻣﻼﺴﻟا تاﺪﻘﺘﻌﻣ

Safety is equally as important as

Production “Safe & Sustainable

Production”

Management is responsible to

demonstrate leadership and

commitment to safety

Safe behaviors and safe conditions

come from a caring-mind

Employee training and

engagement are essential for Safe

Operations

Incident reporting, investigation

and sharing information is crucial

to learn and prevent recurrences

O-the-Job Safety is an important part

of the safety eort

All unsafe acts and unsafe

conditions must be reported

immediately

Understanding of hazards and

control measures is paramount to

eliminate or reduce risks

‘Partnering’ is the ‘Key’ for Safe

Operations, in the spirit of mutual

respect and empathy

Safety is a condition of

employment

ﻦﻋ ﺔﻴﻤﻫأ ﻞﻘﺗ ﻻ ﺔﻣﻼﺴﻟا

"ماﺪﺘﺴﻤﻟاو ﻦﻣﻵا جﺎﺘﻧﻹا" جﺎﺘﻧﻹا

طوﺮﺷ ﻦﻣ طﺮﺷ ﺔﻣﻼﺴﻟا

ﻒﻴﻇﻮﺘﻟا

ﺔﻣﻼﺴﻟا فوﺮﻇو تﺎﻴﻛﻮﻠﺳ

ﻲﻧﻼﻘﻌﻟا ﺮﻴﻜﻔﺘﻟاو ﻲﻧﺄﺘﻟا ﻦﻣ ﻲﺗﺄﺗ

حور رﺎﻬﻇإ ةرادﻹا ﺔﻴﻟوﺆﺴﻣ

ﺔﻣﻼﺴﻟﺎﺑ ماﺰﺘﻟﻹاو ةدﺎﻴﻘﻟا

"حﺎﺘﻔﻤﻟا" ﻲﻫ "ﺔﻛرﺎﺸﻤﻟا"

ماﺮﺘﺣﻻا حوﺮﺑ ،ﻦﻣﻵا ﻞﻴﻐﺸﺘﻠﻟ

ﻒﻃﺎﻌﺘﻟاو لدﺎﺒﺘﻤﻟا

ًاءﺰﺟ ﻞﻤﻌﻟا جرﺎﺧ ﺔﻣﻼﺴﻟا ﺪﻌﺗ

ﺔﻣﻼﺴﻟا دﻮﻬﺟ ﻦﻣ ًﺎﻤﻬﻣ

ﻢﻬﺘﻛرﺎﺸﻣو ﻦﻴﻔﻇﻮﻤﻟا ﺐﻳرﺪﺗ

ﺔﻨﻣآ ﻞﻤﻋ ﺔﺌﻴﺒﻟ يروﺮﺿ ﺮﻣأ

تﺎﻃﺎﻴﺘﺣﻹا ﺔﻓﺮﻌﻣو ﺮﻃﺎﺨﻤﻟا ﻢﻬﻓ

ﺪﺤﻠﻟ ﺔﻴﻤﻫﻷا ﺎﻐﻟﺎﺑ ناﺮﻣأ ﺎﻤﻫ ﺔﻣزﻼﻟا

ﺮﻃﺎﺨﻤﻟا ﻦﻣ ﻞﻴﻠﻘﺘﻟا وأ

ﻊﻴﻤﺟ ﻦﻋ ًارﻮﻓ غﻼﺑﻹا ﺐﺠﻳ

ﺔﻨﻣآ ﺮﻴﻐﻟا عﺎﺿوﻷاو تﺎﻓﺮﺼﺘﻟا

ﻖﻴﻘﺤﺘﻟاو ثداﻮﺤﻟا ﻦﻋ غﻼﺑﻹا ﺪﻌﻳ

ًارﻮﻣأ تﺎﻣﻮﻠﻌﻤﻟا ﺔﻛرﺎﺸﻣو ﺎﻬﻴﻓ

ﺎﻫاراﺮﻜﺗ ﻊﻨﻣو ﺎﻬﻨﻣ ﻢﻠﻌﺘﻠﻟ ﺔﻳروﺮﺿ

ﻎﺑاروﺮﺘﺑ ﻲﻓ ﺔﻣﻼﺴﻟا ئدﺎﺒﻣو تاﺪﻘﺘﻌﻣ

SAFETY BELIEFS AND PRINCIPLES AT PETRO RABIGH

SAFETY BELIEFS

Safety is everyone's responsibility

All incidents and injuries are preventable

SAFETY PRINCIPLES

ﺔﻣﻼﺴﻟا ئدﺎﺒﻣ

.ﻊﻴﻤﺠﻟا ﺔﻴﻟوﺆﺴﻣ ﺔﻣﻼﺴﻟا

.ﺎﻬﻳدﺎﻔﺗ ﻦﻜﻤﻳ تﺎﺑﺎﺻﻹاو ثداﻮﺤﻟا عاﻮﻧأ ﻊﻴﻤﺟ

ﺔﻣﻼﺴﻟا تاﺪﻘﺘﻌﻣ

Safety is equally as important as

Production “Safe & Sustainable

Production”

Management is responsible to

demonstrate leadership and

commitment to safety

Safe behaviors and safe conditions

come from a caring-mind

Employee training and

engagement are essential for Safe

Operations

Incident reporting, investigation

and sharing information is crucial

to learn and prevent recurrences

O-the-Job Safety is an important part

of the safety eort

All unsafe acts and unsafe

conditions must be reported

immediately

Understanding of hazards and

control measures is paramount to

eliminate or reduce risks

‘Partnering’ is the ‘Key’ for Safe

Operations, in the spirit of mutual

respect and empathy

Safety is a condition of

employment

ﻦﻋ ﺔﻴﻤﻫأ ﻞﻘﺗ ﻻ ﺔﻣﻼﺴﻟا

"ماﺪﺘﺴﻤﻟاو ﻦﻣﻵا جﺎﺘﻧﻹا" جﺎﺘﻧﻹا

طوﺮﺷ ﻦﻣ طﺮﺷ ﺔﻣﻼﺴﻟا

ﻒﻴﻇﻮﺘﻟا

ﺔﻣﻼﺴﻟا فوﺮﻇو تﺎﻴﻛﻮﻠﺳ

ﻲﻧﻼﻘﻌﻟا ﺮﻴﻜﻔﺘﻟاو ﻲﻧﺄﺘﻟا ﻦﻣ ﻲﺗﺄﺗ

حور رﺎﻬﻇإ ةرادﻹا ﺔﻴﻟوﺆﺴﻣ

ﺔﻣﻼﺴﻟﺎﺑ ماﺰﺘﻟﻹاو ةدﺎﻴﻘﻟا

"حﺎﺘﻔﻤﻟا" ﻲﻫ "ﺔﻛرﺎﺸﻤﻟا"

ماﺮﺘﺣﻻا حوﺮﺑ ،ﻦﻣﻵا ﻞﻴﻐﺸﺘﻠﻟ

ﻒﻃﺎﻌﺘﻟاو لدﺎﺒﺘﻤﻟا

ًاءﺰﺟ ﻞﻤﻌﻟا جرﺎﺧ ﺔﻣﻼﺴﻟا ﺪﻌﺗ

ﺔﻣﻼﺴﻟا دﻮﻬﺟ ﻦﻣ ًﺎﻤﻬﻣ

ﻢﻬﺘﻛرﺎﺸﻣو ﻦﻴﻔﻇﻮﻤﻟا ﺐﻳرﺪﺗ

ﺔﻨﻣآ ﻞﻤﻋ ﺔﺌﻴﺒﻟ يروﺮﺿ ﺮﻣأ

تﺎﻃﺎﻴﺘﺣﻹا ﺔﻓﺮﻌﻣو ﺮﻃﺎﺨﻤﻟا ﻢﻬﻓ

ﺪﺤﻠﻟ ﺔﻴﻤﻫﻷا ﺎﻐﻟﺎﺑ ناﺮﻣأ ﺎﻤﻫ ﺔﻣزﻼﻟا

ﺮﻃﺎﺨﻤﻟا ﻦﻣ ﻞﻴﻠﻘﺘﻟا وأ

ﻊﻴﻤﺟ ﻦﻋ ًارﻮﻓ غﻼﺑﻹا ﺐﺠﻳ

ﺔﻨﻣآ ﺮﻴﻐﻟا عﺎﺿوﻷاو تﺎﻓﺮﺼﺘﻟا

ﻖﻴﻘﺤﺘﻟاو ثداﻮﺤﻟا ﻦﻋ غﻼﺑﻹا ﺪﻌﻳ

ًارﻮﻣأ تﺎﻣﻮﻠﻌﻤﻟا ﺔﻛرﺎﺸﻣو ﺎﻬﻴﻓ

ﺎﻫاراﺮﻜﺗ ﻊﻨﻣو ﺎﻬﻨﻣ ﻢﻠﻌﺘﻠﻟ ﺔﻳروﺮﺿ

CONTENT

I. Safety Responsibilities 12

This section contains outlines safety

responsibilities of managers / section heads,

supervisors, employees and contractors.

II. Basic Safety Rules 17

This section contains the safety rules

applicable to all areas that shall be followed at

all times.

III. Operational Safety Processes 22

This section outlines the six (6) key operational

safety processes essential to daily safe

operations.

Work Permit Procedure – General 23

1. Hot Work Permit 26

2. Cold Work Permit 28

3. Conned Space Entry Permit 29

4. Equipment Opening/Line Break Permit 33

5. Excavation Safety 39

6. Isolation, Lockout, and Use of Hold Tags 45

IV. Risk Management Overview 45

IV. Safety Topics 48

This section contains rules and precautions for

specic safety topics and hazards. Topics are

arranged in alphabetical order.

CONTENT

1. Abrasive Blasting and

Coating 49

2. Chemical Safety 50

3. Compressed Gas

Cylinders 51

4. Conveyors 54

5. Crane Operation 56

6. Cutting, Welding,

Grinding and Brazing 59

7. Electrical Safety 61

8. Fall Protection 64

9. Fire Protection 69

10. Forklift Safety 71

11. Heat Stress 73

12. Heavy Equipment 79

13. Hoists 81

14. Housekeeping 82

15. Hydrogen Sulde 83

16. Hydrojetting Safety 85

17. Marine Safety 88

18. Pyrophoric Materials 90

19. Ofce Safety 92

20. Pressure Testing 96

21. Radiation Safety 97

22. Rigging Safety 102

23. Scaffold Safety 103

24. Tools Safety 105

25. Tubular Goods 107

26. Vehicle Safety 108

SAFETY

RESPONSIBILITIES

Personnel, as referred to in this handbook,

include employees of Petro Rabigh,

contractors and visitors. Petro Rabigh

managers, section heads, supervisors,

employees, contractors and visitors have

the following safety responsibilities.

Management Responsibilities

Establish and

communicate safety

rules and standards

to all employees and

contractors.

Provide appropriate

resources, tools, and

training for employees.

Award contracts using

safety, health, and

environmental criteria.

Conduct and document

safety meetings.

Correct unsafe

acts and conditions

promptly.

Conduct safety obser-

vations, routine safety

inspections and tours.

Maintain facility

emergency plans

and conduct regular

emergency drills.

Report and Investigate

injuries, res, leak,

spills, MVAs and other

incidents

Review organization

and employee

safety performance

periodically and

provide feedback.

Employee Responsibilities

Comply with applicable

rules, standards, and

safe work practices.

Communicate safety

rules and standards

to contractors and

coworkers.

Correct or report

unsafe acts or

conditions.

Maintain knowledge of

safety requirements,

including emergency

response action.

Participate in safety

meetings.

Operate, inspect, and

maintain facilities in a

safe condition.

Report injuries,

spills, unsafe acts

and conditions, near

misses, and incidents

immediately.

Assist in incident

investigations as

necessary.

Contractor Responsibilities

Ensure that

contractor

employees and

their subcontractors

are trained in Petro

Rabigh safety rules

and are competent in

their craft or skill.

Comply with all

Petro Rabigh

rules, policies, and

procedures.

Report injuries, res,

leak, spills, MVAs

and other incidents

immediately

including unsafe

acts / conditions and

Near Miss.

Operate Petro

Rabigh equipment

only with proper

authorization and

valid certication.

Hold pre-job

meetings and other

safety meetings

during the job.

Assist in incident

investigations as

necessary.

Visitor Responsibilities

Comply with all

Petro Rabigh

rules, policies and

procedures.

Report injuries,

incidents, near

misses, unsafe act

and conditions

immediately.

In an emergency

follow directions

from your PR

coordinator /

sponsor.

BASIC SAFETY RULES

Are divided into Four main groups

1. Immediately report all work related injuries / illnesses or vehicle

collisions, no matter how slight, to your supervisor.

2. Immediately report all res, spills, and releases, no matter how

small, to your supervisor.

3. Immediately report any unsafe condition, practice, near miss,

or incident to your supervisor.

4. Apply Lock Out and Tag Out (LOTO) before performing any

maintenance work on equipment handling hazardous energies

such as electrical, mechanical, hydraulic, pneumatic, chemical,

thermal, etc.

5. Operators of vehicles shall comply with all trafc requirements,

particularly speed limits.

6. All persons in vehicles shall wear seat belts at all times.

7. When ascending or descending stairways, use the handrail,

and take only one step at a time.

8. Erect barricades / agging or hazard warning lights if required

around hazardous works, areas such as holes in decking

and oor surfaces, trenches, road crossings, and overhead

hazardous works.

9. Use only proper tools and equipment maintained in a safe

working condition. Home-made tools are prohibited. Tools

and safety equipment used by contractor must be inspected

and have valid certication by 3rd Party Inspectors/Inspection

Agencies authorized by Petro Rabigh.

10. Maintain good housekeeping in your work area at all times.

Report Incidents

Follow Safe Practices

11. Smoking is prohibited except in designated areas only. Matches

and lighters are prohibited in restricted areas.

12. Eating or resting is permitted in designated areas only.

13. Use proper manual lifting techniques, or obtain assistance or

mechanical lifting aids when lifting loads.

14. All operating machinery and electrical switchgear shall have all

safety guards, switches, and alarms in place and functional.

15. Whenever a safety device is removed from service and/or

defeated, the appropriate supervisor and affected parties shall be

notied, the device tagged, and the action properly documented.

16. All block valves on pressure relief systems in service shall be

chain-locked or car-sealed open.

17. All re extinguishers and other emergency equipment shall be

in good condition, inspected regularly, and kept clear of any

obstruction; re extinguishers shall be provided with approved

covers for outdoor areas.

18. All chemical or hazardous material containers shall be properly

labeled and stored. Drums shall be stored in areas with

secondary containment.

19. Climbing or standing on equipment, piping, cable trays, valves,

or unstable surfaces (e.g., chairs or barrels) to perform work is

prohibited.

20. Approved fall protection measures (e.g., Full Body Harness or

Scaffolding) shall be used if the working height is greater than

1.8 m (6 ft.).

21. Running in work areas is prohibited, except during

emergencies.

22. Finger rings, wristwatches, jewelry, loose clothing, unsecured

long hair, and other loose accessories shall not be worn within

an arm’s reach of rotating equipment or electrical switchgear.

23. Do not remove the machine guards from any rotating

equipment in operation.

24. Do not apply compressed air or other gases to yourself or others.

25. Operating equipment having a “DANGER, DO NOT OPERATE”

(hold) tag is prohibited.

26. No work shall be started in any area or on any equipment

without consent of the Petro Rabigh person-in-charge.

27. Non - approved electrical / electronic devices (e.g., cellular

phones, tablets, and instruments) shall not be carried or used

in classied areas unless properly permitted.

28. Horseplay or ghting on Petro Rabigh premises is prohibited.

29. Cooking of food and use of hot plates / cooking range is strictly

prohibited inside PR industrial complex.

30. Approved hard hats without defects shall be worn in designated

areas. Metallic hard hats are prohibited.

31. Approved safety footwear shall be worn in eld operations,

process areas, and other designated areas.

32. Approved safety eyewear with side protection shall be worn

where designated.

Avoid Unsafe Practices

Protect Yourself

33. Approved additional hazard-specic eye / face protection (e.g.,

goggles and / or a face shield) shall be worn where foreign

objects may injure the eye or face (e.g., while grinding, welding,

drilling, or scraping).

34. Proper personal protective equipment (PPE) prescribed by the

Material Hazard Bulletin (MHB) or Safety Data Sheet (SDS)

shall be worn when handling chemicals or hazardous materials.

35. Approved hearing protection shall be worn in high noise areas

(i.e., 85 decibels [dBA] or higher).

36. Proper hand protection (e.g., gloves) shall be worn when

performing tasks that may present a hand injury risk.

37. Proper Self Contained Breathing Apparatus (SCBA) for Non-

Respirable environment or Conned Space Entries shall be

used. The SCBA shall be certied and the user properly trained

on using the equipment.

OPERATIONAL SAFETY

PROCESSES

This section outlines general permitting

and isolation requirements for the following

safety processes in Petro Rabigh facilities

1. A work permit is not required for routine activity and

housekeeping.

2. Work permit receiver requests appropriate permit(s) from the

permit Issuer (i.e., Supervisor).

3. A joint site inspection shall be conducted by the Issuer or his

designated representative and the Receiver before the permit

is approved / signed and after job completion prior closing the

permit.

4. The Issuer reviews the permit, assesses any potential hazards,

species requirements for type of work, veries required gas

tests, lists applicable isolation and other precautions per Safety

Process 6, “Isolation, Lockout, and Use of Hold Tags,” then

signs and issues the permit.

5. The Issuer obtains approval and signature of other operations

supervisors (Issuers) whose operations may be affected.

6. The Issuer and Receiver are jointly responsible for the safety of

people and equipment in the area. Periodic reviews of the job

site, including gas testing, shall be conducted.

7. The Receiver shall not leave the job site unless replaced by

another certied delegate who has been approved by the Issuer.

8. The Receiver shall display the active permit at the job site.

Often, these safety processes are related and used in conjunction

with each other in safe operations. However, each work permit

has a specic purpose, and to ensure proper individual review and

approval of these important activities, each permit type shall only

be used for its intended purpose.

Permit Procedure – General

9. Suspend the job whenever unsafe practices or unsafe

conditions are noticed until the deviations are corrected.

10. Permits are closed by obtaining the signatures of both the

Issuer and Receiver.

11. The Issuer copy and the Receiver copy of the work permits

should be maintained by the Issuer and the Receiver

respectively for a minimum of 3 months.

• One (1) shift or end of job, whichever occurs rst.

• Permit can be extended only for one shift by agreement and

signatures of the Issuer and Receiver.

• Any unscheduled work stoppage, emergency and / or condition

change shall cancel the permit.

Permit Duration

Gas Test Information

Items Gas Tester’s

Results Action/ Requirements

Combustible

Gases /

Vapors

Above 0% LEL No Hot Work is permitted

Up to 5% LEL Cold Work and Conned Space

Entry Permitted

5% to 20% LEL

Breathing apparatus must be

used and Issuing Section Head

must countersign on Work

Permit

Above 20% LEL No work is permitted

H2S

Below 10 ppm Ok to work

At or above 10

ppm, but less than

or equal to 100

ppm

Breathing apparatus must be

used and Issuing Section Head

must countersign on Work

Permit

Above 100 ppm No work is permitted

Below 20%

Breathing apparatus must be

used end Issuing Section Head

must countersign on Work

Permit

Above 23.5% No work is permitted

25 ppm to 400

ppm

Breathing apparatus must be

used and Issuing Section Head

must countersign on Work

Permit

Above 400 ppm No work is permitted.

The purpose of the Hot Work Permit process is to ensure proper

initiation, review, approval, and execution of hot work activity.

A Hot Work Permit (Form No. PR/IS/SFD/F-051) is required for the

following operations:

• Open ames, welding, or torch cutting within facility restricted areas.

• Open ames, welding or torch cutting within 23 m (75 ft.) of a pipeline

or facility containing hydrocarbons in non-restricted areas.

• Work on live electrical equipment or use of unapproved electrical

devices (e.g., computers, mobile phones, etc.) in a classied area.

• Other operations that could present a re hazard (e.g., internal

combustion engines within facilities or welding/cutting/Grinding

inside ofce or warehouse facilities).

• Any other work activities that produce heat and can potentially cause

a spark to be produced, such as grinding, abrasive-blasting, etc.

Note: See “Cutting, Welding, Grinding and Brazing” section for

additional precautions. For welding on lines in-service and hot tapping,

see additional precautions are provided in “In- Service Welding and Hot

Tapping.”

In-Service Welding and Hot Tapping

The following additional precautions shall apply to Hot Work Permits for

in-service welding (welding of any kind on a hydrocarbon line in service,

e.g., bracing or hot tap connection) or hot tapping (actual penetration of

the ow line for purposes of connection)

• Preparation of a hot tap procedure including a complete design review

and drawing review of the line to be welded (see Figure 1). The

calculation sheet shall be attached to the Hot Work Permit.

• A eld verication of minimum wall thickness and pipe conditions

shall be conducted. Welding on wall shall be approved by concerned

parties before the job is conducted.

Safety Process 1

Hot Work Permit

• No welding on pressurized lines with zero ow rates. A minimum

ow rate shall be calculated and included in the hot tap procedure.

• The rating of the hot tap machine shall be greater than the

maximum operating pressure of the line.

• A eld travel distance check shall be made prior to beginning the hot tap.

• No welding on compressed air lines from a lubricated compressor.

• No welding on lines containing greater than 23.5% Oxygen (O2).

Measuring Rod

Hot Tap Machine

Hot Tap Housing Bleeder Valve

Cutter /Pilot Assembly

Hot Tap Fitting

Hot Tap Valve

Figure 1. Example of a Typical Tapping Setup

The purpose of the Cold Work Permit process is to control work

activities that may not produce sufcient energy to ignite ammable

atmospheres or combustible materials, but could contribute to injury.

A Cold Work Permit (Form No. PR/IS/SFD/F-052) shall be used for

such activities.

Examples include:

• Structural demolition or collapse of non-operational buildings.

• Work activities involving cryogenic materials.

• Movement of oversized loads on roadways.

• Maintenance work not involving open ame.

• Repacking a gland.

• Maintenance work not involving arc welding or open ame in air

conditioning (AC) plants and cooling towers.

Note: Ask your Supervisor if you have questions on applications of

the Cold Work Permit.

Safety Process 2

Cold Work Permit

Safety Process 3

Confined Space Entry Permit

The purpose of the Conned Space Entry (CSE) Permit process is

to ensure:

• Proper preparation of conned spaces/vessels to be entered.

• Safe entry by personnel, including plans for rescue.

• Restoration of conned spaces.

A CSE Permit (Form No. PR/IS/SFD/F-053) shall be used to protect

personnel from CSE hazards. CSE is the entry of personnel into any

space or structure (e.g., tank, vessel, duct, or vault) not normally

intended for human occupancy, in which entry, movement within or

exit is restricted. Any part of the body passing through the opening is

considered entry. Examples include but not limited to:

• Vessel cleaning.

• Tank internal inspection.

• Work in sewers, sump pits, or valve boxes.

• Excavations or trenches deeper than 1.2 m (4 ft.) that meet the

denition of a conned space.

Note: A Hot Work or Cold Work Permit may also be required depending

on the type of work to be performed within the conned space.

A. Preparation

1. Conduct JSA for every conned space entry.

2. The conned space or vessel shall be properly isolated in

accordance with Safety Process 6, “Isolation, Lockout, and Use

of Hold Tags” (i.e., blinding). A sketch is recommended to assist in

isolation of all sources.

3. The space shall be purged, steam washed, and cleaned

as necessary to sufciently free the space of all possible

contaminants (e.g., hazardous materials; iron sulde deposits).

4. Mechanical ventilation (e.g., air movers) shall be used to

ensure positive ventilation and remove all hazardous airborne

contaminants.

5. Mechanical ventilation shall be stopped during atmospheric

testing.

6. Atmosphere tests for O2 and explosive and toxic gases and

vapors shall be performed and recorded immediately prior to

entry, after breaks, or interruptions in the work procedure and at

periodic intervals by a certied gas tester. If other atmospheric

hazards, such as carbon monoxide (CO) and naturally occurring

radioactive material (NORM), are suspected to exist, appropriate

air monitoring shall be conducted by a qualied person.

7. O2 concentration shall be 20% minimum; ammable shall be

zero; and the concentration of hydrogen sulde (H2S) shall not

exceed 10 parts per million (ppm).

8. All sources of ignition shall be eliminated or controlled. If ignition

sources are present (e.g., sparks or open ames), a Hot Work

Permit shall be completed in accordance with Safety Process 1,

“Hot Work Permit”.

9. All equipment, including air movers, shall be properly grounded

or bonded. Lighting equipment shall be explosion proof.

10. Physical hazards, including falling objects and contact with hot

surfaces, shall be controlled.

11. All required PPE, including respiratory protection, shall be worn

during conned space entries.

12. A means of egress and communication shall be identied and

emergency/rescue contact numbers shall be recorded on the

permit.

13. The permit and signs and/or barricades shall be posted outside

conned spaces to notify personnel that entry is in progress and

to prohibit unauthorized entry.

14. Trained and designated standby man for conned space

entry rescue shall be properly equipped (e.g., PPE, radio, or

retrieval line) and stationed outside the space to remain in direct

communication with the workers inside.

15. Proper rescue equipment including lifelines, harnesses, and

hoists shall be used when entering conned spaces 1.8 m (6 ft.)

or deeper (e.g., vessels or towers).

16. Critical safety equipment such as Air movers, harnesses,

Breathing Apparatus and lifelines must be inspected and

having valid Certication by Petro Rabigh Inspector or 3rd Party

Inspection Agencies approved by Petro Rabigh.

17. If Inert Entry (under Nitrogen Purge Atmosphere) is required,

the strictest precautionary safety measures are to be taken and

proper SCBA and rescue equipment are to be used. Initial Inert

Entry shall be authorized by Issuing Department Manager and

Field Maintenance Section Head.

18. Rescue plan shall be prepared in conjunction with Fire Protection

Department as per Annexure-3 of General Instruction on

Conned Space Entry (PR/IS/SFD/GI-033) for every conned

space entry.

B. Entry

1. Only authorized personnel shall enter the conned space.

2. All authorized personnel entering the conned space shall sign

a log sheet upon entering and exiting the conned space to

account for all personnel.

3. Continuous Gas Test is MANDATORY for conned space entry.

Continuous monitoring results shall be recorded at a minimum of

every 15 minutes while the space is occupied

4. If the conned space entry is suspended, the entrance shall be

blocked and a “NO ENTRY” sign posted.

C. Restoration

When work is complete and the conned space is ready to be

returned to service, the permit shall be used as a checklist for proper

restoration of the space. In addition to items listed on the permit,

ensure that:

1. All personnel are out of the space.

2. All equipment and tools are removed.

3. All man ways and anges are closed and sealed. All vessels and

relief valves are restored to operating condition.

4. All blinds are removed using the Blind List as required by Safety

Process 6, - “Isolation, Lockout, and Use of Hold Tags.”

5. All startup procedures are followed.

The purpose of Equipment Opening/Line Break Permit process is to

ensure proper planning and precautions during work activities where

the potential release of hazardous liquids or gases may occur.

An Equipment Opening/Line Break Permit (Form No. PR/IS/SF-

D/F-050) is required for any work that has the potential for actual or

possible release of ammable, combustible, toxic and other injurious

materials in levels that can pose a hazard to personnel, property or

the environment. This permit is not intended to authorize a release

but to ensure proper precautions are in place for a potential release.

Examples of work activities requiring an Equipment Opening/

Line Break Permit include:

• Opening oil or gas lines or systems.

• Opening of all steam and condensate lines or systems.

• Opening of all lines or systems containing H2S. Opening of all lines

or systems containing nitrogen (N2).

• Opening of all lines or systems containing hazardous material

(e.g., caustic or sulfuric acid).

• Opening of pressurize utility services.

In addition to the above steps, Equipment Opening/Line Break

Permit requirements include:

• Proper PPE for all personnel.

• Proper isolation prior to opening the line in accordance with Safety

Process 6, “Isolation, Lockout, and Use of Hold Tags.”

• Proper containment of anticipated liquids or gases.

• Proper communication with manufacturing personnel.

• Immediate notication of unanticipated leaks or releases.

Note: Respirator protection is mandatory where IDLH conditions

are expected.

Safety Process 4

Equipment Opening/Line Break Permit

The purpose of the Excavation process is to ensure proper planning

and design of excavation operations, including entry of personnel.

An Excavation Safety Checklist is required for:

• All excavations 1.2 m (4 ft.) and deeper.

Note: Excavations 1.2 m (4 ft.) and deeper also require a CSE Permit

as outlined in Safety Process 3, “Conned Space Entry Permit.”

Requirements for Excavation Design

A qualied person shall design the excavation. A qualied person is

one who is capable of identifying existing and predictable hazards,

soil types, or working conditions that are unsanitary, hazardous, or

dangerous to personnel. The qualied person shall:

• Determine the appropriate method of excavation benching,

shoring or sloping, or combination of methods depending on

space available, nature of operations, and soil type.

• Determine soil type prior to entry (i.e., stable rock, or Type A, B, or

C soil) as described in Table 1.

• Decide whether to guard the walls by benching, shoring, sloping,

or a combination. If sloping is used, it shall be per Table 1.

Safety Process 5

Excavation Safety

Soil Type Cross Section

Stable Rock - Natural solid

mineral matter.

Table 1. Maximum Allowable Slopes for Height (h) < 6 m (20 ft.)

Type A Soil - A cohesive (tight)

Soil, such as clay or rock. Previously

disturbed Type A soil becomes Type B

or Type C soil.

Type B Soil - A less cohesive soil,

such as a mix of sand, rocks, and

clay. Previously disturbed Type B soil

becomes Type C soil.

Type C Soil - The least cohesive soil,

such as gravel, sand, muddy or freely

seeping soils, and submerged rock

that is not stable.

Sloping or benching for excavations greater than 6 m (20 ft.) deep

shall be designed by a qualied engineer.

Requirements for Excavation Construction

• All utilities and lines shall be properly identied and appropriate

parties notied before beginning any digging or cleanup work.

• Spoil piles shall be at least 0.6 m (2 ft.) from the edge of the

excavation.

• Scaffold bases shall be at least 1.5 times the depth of an

excavation away from the edges of the excavation (including

trenches).

• Mechanical excavators shall not be used within 3 m (10 ft.) of any

pipes, cables, or other obstructions.

• Heavy equipment shall not be operated within 1.8 m (6 ft.) of any

excavation.

• Cranes shall not be operated closer than the depth of the

excavation.

• A qualied person shall make daily inspections of excavations

prior to the start of the work shift.

• Guardrails or barricades as necessary, shall be established a safe

distance from the excavation to protect individuals and mobile

operating equipment above the excavation, or if the excavation is

left unattended overnight.

• No personnel are permitted in the excavation or trench when

power/excavation equipment is being used to perform the

excavation.

• Blinking warning lights shall be used at excavations at night where

there are personnel or vehicle movement.

Requirements for Personnel in Excavation

• Only authorized personnel shall enter the excavation.

• Ensure there is no water seepage into the excavation.

• Certied gas tester shall test and monitor the atmosphere while

personnel are present (e.g., combustibles, toxic gases, or low O2).

• Ladders or other means of access shall be provided every 7.5 m

(25 ft.) in all occupied excavations, extending a minimum of 1m

(3 ft.) above the top of excavation wall.

• Emergency rescue equipment shall be immediately available for

excavations considered as conned spaces.

The purpose of the Isolation, Lockout, and Use of Hold Tag process

is to ensure that before any employee performs any servicing or

maintenance on machinery or equipment, where the unexpected

energizing, start up or release of any type of energy (electrical,

kinetic, potential, thermal, chemical) could occur and could cause

injury. This process applies to electrical sources of energy as well as

other sources of potentially stored energy described below.

Electrical isolation, lockout, and use of hold tag procedures shall be

used before and during any activity requiring personnel to work on or

near de-energized circuit parts or where there is danger of injury due

to unexpected startup of equipment (i.e., a motor driven pump).

Other energy sources such as pressurized gas, process uids, and

hydraulic, pneumatic, thermal, chemical, and mechanical systems

shall be isolated by lockout and tag procedures, such as chaining,

blinding, or disconnecting. Additionally:

• Locked equipment shall be tagged using Petro Rabigh Lock/Hold

Tag (See Figure 2).

Safety Process 6

Isolation, Lockout, and Use of Hold Tags

Lock/Hold Tag (Front) Lock/Hold Tag (Back)

Figure 2. Petro Rabigh Lock/Hold Tag.

Note: This tag shall not be used for other purposes such as valve

isolation for operational activities.

Electrical Lockout and Tag Procedure

The following procedures for electrical lockout and tag (Lock, Tag,

Clear, Try) shall be followed when exposed to electrical hazards:

1. Facility proponent work permit issuer shall identify isolating

locations and types of isolating devices required in determining

potential exposure.

2. Authorized personnel doing the work shall notify affected

personnel and properly shut down / de- energize the equipment.

Isolation is complete only when no associated control device is

capable of energizing equipment.

3. Facility proponent (facility owner or controlling organization) shall

always be the rst to install an approved Lock.

4. The person doing the work shall lock out a device using his

approved Lock. Remember to lock open the circuit breaker(s). If

the device cannot be physically locked out, it shall, at a minimum,

be de-energized and tagged.

5. Tag the lock with a “DANGER, DO NOT OPERATE” tag. The

tag shall contain date, time, organization, name, badge number,

equipment name, phone contact and signature of the installer,

and reason for installation.

6. Isolation of equipment more than 480 V and racking out of the

breakers shall be done by ESO (Electric System Operator) after

getting approved isolation request through the online request

system from Proponent.

7. Other organizations (maintenance, contractors) or individuals

working on equipment shall also install their locks and tags at

locations identied by facility proponent. Multiple lockout clips

(hasps) shall be used if necessary.

8. Each lock shall be identiable. Each organization shall have a

system of uniquely identifying locks (e.g., color coding).

9. Each lock shall be keyed separately with no duplicate key

available to ensure removal only by the installer.

10. Clear the area of personnel and tools prior to trying to start the

equipment.

11. Before starting work, try to start or energize the equipment

locally. Verify the equipment cannot be energized.

12. Only the person originally attaching the lock and tag is authorized

to remove his lock and tag within the same shift. Incoming shifts

may attach their own locks and tags and / or transfer keys after

approval by supervision. If person(s) are unavailable, the Section

Head (or PRSM, during off hours) can assume responsibility for

removing the lock and tag and notify all parties.

13. Petro Rabigh facility proponent employees or controlling

organization shall remove locks and tags when equipment is safe

to energize.

14. LOTO logbook (Form No. PR/IS/SFD/F-17) shall be maintained

and updated accordingly.

15. When work is complete, affected personnel shall be notied and

equipment placed back in service.

Mechanical Energy Lockout and Tag Procedures

Chains, blocking, locking pins, or other hardware shall be used

for isolating, securing, or blocking of machines or equipment from

mechanical energy sources.

Process, Hydraulic, and Pneumatic Energy Sources Lockout

and Tag Procedures

At least one of the following lockout and tag methods shall be

used to safely isolate other types of stored energy sources such as

process piping with gas pressure. Generally, these four methods of

isolation reect an increasing order of preference, depending on the

nature of work activity, materials involved, and piping arrangement.

Single block valves

Single block valves closed, locked, and tagged shall be used as

a minimum isolation procedure for certain routine maintenance

operations where no open ame work is required (e.g., changing

a gauge or sock lters).

Double block and bleed

Double block and bleed process piping where block valves are

closed, locked (chained), and tagged with a bleed or vent valve

locked and tagged open in between (see Figure 3). While superior to

a single locked and tagged valve situation (described previously) for

open ame work or long-term construction or maintenance activity,

a double block and bleed setup may not always guarantee total

isolation and safety. For example, the bleed valve may be plugged

and/or typically cannot handle the ow or pressure that may be

“passing” through the upstream valve. Also, for nearby work that

requires permitting, ammable or toxic gases or liquids potentially

vented through the bleed valve shall be securely piped or hosed

away to a safe point.

Bleed Valve Opened, Chain Locked, and Tagged

Figure 3. Example of Double Block and Bleed Isolation

Disconnection of piping

Disconnection of piping is typically done by dropping a spool

piece. This isolation method is also superior to a single locked and

tagged valve for open ame work or long-term construction work,

or maintenance activity. However, steps shall be taken to ensure no

hazardous materials can leak or be discharged from the open ends

of piping, for example, blind anging (described below) and tagging.

Blinding

Blinding of process piping, vessels, and equipment is the fourth

method of isolation for stored process energy with requirements

described as follows.

As another method of isolation of process piping, blinds shall be

installed to prevent the release of combustible and toxic liquids,

vapors, and gases into the work area during maintenance or

construction. Blinds shall be installed at vessels scheduled for entry

as outlined in Safety Process 3, “Conned Space Entry Permit.”

Additional requirements for blinding are as follows.

Procedure:

• A full-rated blind shall be installed with three considerations:

a) Rating – Properly manufactured, preferably purchased, blinds

shall be in accordance with Table 2.

b) Location – Will the blind effectively isolate? Is it accessible?

c) Size – Does the blind match line size?

1. A Blind List shall be prepared where blinds are used to ensure

proper installation and removal. The Blind List shall include

the blind number, location, date installed, date removed, and

appropriate signatures.

2. Isolation valves shall be properly locked and tagged prior to

opening of anges for installation of blinds.

3. Proper line entry procedures shall be followed in opening anges

for installation of blinds.

4. Proper rigging practices shall be used during installation of blinds.

5. Blinds shall be installed as close as possible to the vessel or

equipment to be isolated and using the required number of bolts.

6. Blinds shall be tagged for identication as an isolation device.

7. All blinds shall be removed when work is completed.

8. Types of blinds are shown below in Figure 4.

Figure 4. Types of Blinds

Spectacle Blind Slip Blind Flange Blind

Pipe Size Pipe Rating (#) and Corresponding Blind

Thicknesses (Inches)

Inches 150# 300# 600# 900#

1 1/4 1/4 1/4 1/4

1 ½ 1/4 1/4 1/4 5/16

2 1/4 1/4 5/16 3/8

3 1/4 3/8 7/16 9/16

4 1/4 1/2 9/16 11/16

6 1/2 5/8 13/16 1

8 1/2 3/4 1 - 1/16 1 - 5/16

10 5/8 1 1 - 3/16 1 - 5/8

12 3/4 1 - 1/8 1 - 9/16 1 - 5/16

14 3/4 1 - 1/4 1 - 3/4 2 - 1/8

16 7/8 1 - 3/8 2 2 - 3/8

18 1 1 - 9/16 2 - 1/8 2 - 5/8

20 1 - 1/16 1 - 3/4 1 - 1/2 2 - 7/8

24 1 - 1/4 2 2 - 7/8 3

26 1 - 1/4 2 - 1/8 2 - 7/8 3 - 1/2

28 1 - 3/8 2 - 1/4 3 - 1/8 3 - 3/4

30 1 - 1/2 2 - 3/8 3 - 3/8 4 - 1/8

32 1 - 5/8 2 - 1/2 3 - 1/2 4 - 3/8

34 1 - 3/4 2 - 5/8 3 - 3/4 4 - 5/8

36 1 - 3/4 2 - 7/8 4 4 - 7/8

Table 2. Blind Rating Selection Chart per ANS I31.3 (Material ASTM A36)

RISK MANAGEMENT OVERVIEW

HSE Risk Management in Petro Rabigh follows

the Company Risk Management Policy. The HSE

Risk Management framework involves; hazard

identication, risk analysis & evaluation, risk

treatment, monitoring & review, and communication.

Key terms & denitions with relevance to HSE Risk

Management are listed below;

Hazard: An agent with the potential to cause harm

to people, damage to assets, or an impact on the

environment or reputation.

Hazard Identication: A structured and systematic

team-based brainstorming technique, based on

review of a Hazard Checklist to identify potential

HSE hazards and effects.

Hazard Register: A list of the Hazards that are

associated with an Asset, facility or activity, together

with their potential effect and assessed risks.

Risk Assessment Matrix (RAM): A tool used to

assess the Consequence and Risks of Hazards.

The results are referred to as a RAM Severity rating

and a RAM Risk rating (See Figure 5).

Risk: The combination of the Consequence of a

specic Hazard being released and the Likelihood

of it happening.

Risk Assessment: The process of identifying the

Consequence of the Worst-Case Credible Scenario

arising from the release of a Hazard, and estimating

the Likelihood of that scenario.

Risk Management Overview

Rare Unlikely Possible Likely

Almost Certain

A similar outcome

has never

occurred in the

industry

A similar

outcome has

occurred in the

industry, but not

in Petro Rabigh.

A similar outcome

has occurred in

Petro Ra bigh or

more tha n once

per yea r in the

industry.

A similar outcome

has occurred

more tha n once

per yea r but at

different pl ants /

si tes of Petro

Rabi gh.

A similar outcome

has oc curred more

than once per year

at specific plant /

site within Petro

Rabi gh.

Has n't happened

in the indus try i n

the la st 50 years

Could have

happened in the

last 20-30 years

Could have

happened in the

last 5-10 years

Could have

happened within

the la st 5 years

Could have

happened once or

more duri ng la st

year

Severity

Health & Safety Environment Legal & Regulatory Compliance

Project Delivery

(Project Value > US$4M)

Reputation Financial Impact

#A B C D E

Catastrophic

Multiple worker fatalities or

single public fatality resulting

from an accident or

occupational illness (poisoning,

cancer).

Severe and permanent

impac t on ma ny

attributes of the

environment in large

public areas

Inability to comply with laws, regulations

and/or contracts resulting in substantially

material losses. Regulatory sanction,

prosec ution or prolonged multiple

litigations.

- Litigation or prosecution with damages

greater than US$15MM

- One or more Pla nts c ompletely stopped

by the regul ator(s) for noncomplianc e or

legal issues.

Project having financial

impact of more than $150MM

/ yea r due to:

- Missing major milestones

- Cost overruns

- Failure to achieve the

designed performance levels

International Impact

Serious international impact and public

attention, i.e. extensive adverse

coverage in the international media with

potentially s evere impact on licenses.

Effect will spread internationally and

affect other indus try players . C ould

affect founding s harehol ders' reputation

and financials.

Financial loss or

inc rea sed c os t (or

saving s opportunity)

greater than

US$150MM / year

55A 5B 5C 5D 5E

Major

Single worker fatality or

permanent total disability or

serious injury to public

resulting from an accident or

occupational illness (poisoning,

cancer).

Negative impact on the

surrounding

environment with l ong

term recovery and

repeated non

compliances

Major breach of l aw, contract or

regulation. External investigation(s),

significant regulatory sanction(s) or major

litigation

- Litigation or prosecution with damages

from US$1.5 MM to US$15 MM

- One Pl ant tempora ril y s hut down a nd/or

sl owed down for noncompl iance or l egal

issues.

Project having financial

impact ranging from

US$50MM to US$150MM /

year due to:

- Missing major milestones

- Cost overruns

- Failure to achieve the

designed performance levels

National Impact

Significant national impact and public

concern, i.e. extensive adverse attention

in the national media. Effect could last a

few months a nd li kely to sprea d to c lose

indus try partners . It may a ffect founding

shareholders. Could res ult i n dec reas e of

public s harehol ders support.

Financial loss or

inc rea sed c os t (or

saving s opportunity)

rang ing from

US$50MM to

US$150MM / year

44A 4B 4C 4D 4E

Moderate

Serious injuries or heal th

effects or permanent partial

disability affecting work

performanc e on the long term,

as well as Lost Time Injury (LTI:

absences, irreversible health

damag e, c hronic c ondition

etc.).

Reversible impact on

the environment but

frequent non

compliances

Serious breach of la w, c ontract or

regulation. Moderate fines / litigation,

requi ring reporting to reg ulator(s)

- Litigation or prosecution with damages

from US$150K to US$1.5 MM

- Plant downg raded or havi ng reduced

throughput for noncompli ance or leg al

issues

Project having financial

impact ranging from

US$10MM to US$50MM / year

due to:

- Missing major milestones

- Cost overruns

- Failure to achieve the

designed performance levels

Considerable impact

Adverse attention in local media or from

local government and various action

groups. Could result in decrea se of public

shareholders s upport.

Financial loss or

inc rea sed c os t (or

saving s opportunity)

rang ing from

US$10MM to

US$50MM / year

33A 3B 3C 3D 3E

Minor

Minor inj uries or health effects

or Reversible effects (Medical

Treatment) res ulting weeks to

months recovery time wi thout

loss time injury.

Impact limited to the

organizational

surrounding but short

term a nd revers ible

Minor breach of law, contract or regulation

where mild regulatory sanction or minor

litigation

- Litigation or prosecution with damages

from US$$15K to US$150K

Project having financial

impact ranging from US$2MM

to US$10MM / year due to:

- Missing major milestones

- Cost overruns

- Failure to achieve the

designed performance levels

Limited Impact

Some local media / political attention.

Effect will last a few days only.

Conce rns on performance rais ed by

shareholders.

Financial loss or

inc rea sed c os t (or

saving s opportunity)

rang ing fro m US$2 MM

to US$10MM / year

22A 2B 2C 2D 2E

Insignificant

Slight i njury or health eff ects /

short- term eff ects (First Aid

Case) resulting days to weeks

recove ry time without l oss time

injury.

Impact limited to fenc e

area (manufa cturing

area)

Low-level legal or business ethics is sue.

Litigation or regulatory sanction unlikely.

- Litigation or prosecution with damages

less than US$15K

Project having financial

impact less than US$2MM /

year due to:

- Missing major milestones

- Cost overruns

- Failure to achieve the

designed performance levels

Slight Impact:

Sli ght impa ct - no publi c c oncern

Financial loss or

inc rea sed c os t (or

saving s opportunity)

less than US$2MM /

year

11A 1B 1C 1D 1E

Moderate

Low

* "Sign off Authori ty" means that the Func tion & Department level ris ks s hall be reviewed and a pproved by the res pective manag ement authori ties as per C urrent Res idual ris k le vels; whereas the Corporate risk regis ter or corporate ri sks shal l be revie wed and approved by Pres ident & CEO

Potentia l to impact busine ss plan and pe rformanc e obje ctives , but does not mandate an immediate attention of ma nagement. Ris k reducti on meas ures shal l be planned and documented

May not directly impact the objectives and KPIs of the organization, but risk(s) need(s) to be re-appraised to take into account changing objectives and circumstances; Periodic management review is required to ass ess impact;

Correction(s) may be applied as resources allow.

Sig noff by Department Mana ger

Enterprise Risk Management (ERM)

Critical

High

Fundamentally undermines the ability to achieve core business / program objectives, leading to severe financial impact and erosion of value; Immediate action shall be taken to lower the risk.

Potential to adversely impact the strategic objectives of the company for achieving sustainable profitable growth; Needs immediate attention of management and Immediate action shall be taken to lower the risk.

Signoff by President & CEO

Signoff by SVP/ VP/ CFO

Risk Level

Petro Rabigh Risk Assessment Matrix (RAM)

Likelihood

Minimum Required Action

Management Signoff Authority

Rare Unlikely Possible Likely

Almost Certain

A similar outcome

has never

occurred in the

industry

A similar

outcome has

occurred in the

industry, but not

in Petro Rabigh.

A similar outcome

has occurred in

Petro Rabi gh or

more tha n once

per yea r in the

industry.

A similar outcome

has occurred

more tha n once

per yea r but at

different plants /

si tes of Petro

Rabigh.

A similar outcome

has oc curred more

than once per yea r

at specific plant /

site within Petro

Rabigh.

Has n' t happened

in the industry in

the las t 50 years

Could have

happened in the

last 20-30 years

Could have

happened in the

last 5-10 years

Could have

happened within

the las t 5 years

Could have

happened once or

more during las t

year

Severity

Health & Safety Environment Legal & Regulatory Compliance

Project Delivery

(Project Value > US$4M)

Reputation Financial Impact

#A B C D E

Catastrophic

Multiple worker fatalities or

single public fatality resulting

from an accident or

occupational illness (poisoning,

cancer).

Severe and permanent

impac t on many

attributes of the

environment in large

public a reas

Inability to comply with laws, regulations

and/or contracts resulting in substantially

material losses. Regulatory sanction,

prosecution or prolonged multipl e

litigations.

- Litigation or prosecution with damages

greater than US$15MM

- One or more Plants completely stopped

by the regulator(s ) for noncompliance or

legal issues.

Project having financial

impact of more than $150MM

/ yea r due to:

- Missing major milestones

- Cost overruns

- Failure to achieve the

designed performance levels

International Impact

Serious international impact and public

attention, i.e. extensive adverse

coverage in the international media with

potentially severe impact on licenses.

Effect will spread internationally and

affect other industry players. Could

affect founding shareholders ' reputation

and financials.

Financial loss or

inc reas ed cost ( or

savings opportunity)

greater than

US$150MM / year

5A 5B 5C 5D 5E

Major

Single worker fatality or

permanent total disability or

serious injury to publi c

resulting from an accident or

occupational illness (poisoning,

cancer).

Negative impact on the

surrounding

environment with long

term recovery and

repeated non

compliances

Major breach of law, contract or

regulation. External investigation(s),

significant regulatory sanction(s) or major

litigation

- Litigation or prosecution with damages

from US$1.5 MM to US$15 MM

- One Pla nt temporaril y shut down a nd/or

sl owed down for noncompliance or lega l

issues.

Project having financial

impact ranging from

US$50MM to US$150MM /

year due to:

- Missing major milestones

- Cost overruns

- Failure to achieve the

designed performance levels

National Impact

Significant national impact and public

concern, i.e. extensive adverse attention

in the national media. Effect could last a

few months and likel y to spread to cl ose

indus try partners . It may a ffect founding

shareholders. C ould result in decreas e of

public s hareholders support.

Financial loss or

inc reas ed cost ( or

savings opportunity)

rang ing from

US$50MM to

US$150MM / year

4A 4B 4C 4D 4E

Moderate

Serious injuries or heal th

effects or permanent partial

disability affecting work

performance on the long term,

as well as Lost Time Injury (LTI:

absences, irreversible health

damag e, c hronic condition

etc.).

Reversible impact on

the environment but

frequent non

compliances

Serious breach of law, contract or

regulation. Moderate fines / litigation,

requi ring reporting to regulator(s )

- Litigation or prosecution with damages

from US$150K to US$1.5 MM

- Plant downgraded or having reduced

throughput for noncompliance or legal

issues

Project having financial

impact ranging from

US$10MM to US$50MM / year

due to:

- Missing major milestones

- Cost overruns

- Failure to achieve the

designed performance levels

Considerable impact

Adverse attention in local media or from

local government and various action

groups. Could res ult in decreas e of public

shareholders support.

Financial loss or

inc reas ed cost ( or

savings opportunity)

rang ing from

US$10MM to

US$50MM / year

3A 3B 3C 3D 3E

Minor

Minor injuries or health effects

or Reversible effects (Medical

Treatment) res ulting weeks to

months recovery time without

loss time injury.

Impact limited to the

organizational

surrounding but short

term a nd revers ible

Minor breach of law, contract or regulation

where mild regulatory sanction or minor

litigation

- Litigation or prosecution with damages

from US$$15K to US$150K

Project having financial

impact ranging from US$2MM

to US$10MM / year due to:

- Missing major milestones

- Cost overruns

- Failure to achieve the

designed performance levels

Limited Impact

Some local media / political attention.

Effect will last a few days only.

Concerns on performance rais ed by

shareholders.

Financial loss or

inc reas ed cost ( or

savings opportunity)

ranging from US$ 2MM

to US$10MM / year

2A 2B 2C 2D 2E

Insignificant

Slight injury or health effects/

short- term effects (First Aid

Case) resulting days to weeks

recovery time without los s time

injury.

Impact limited to fence

area (manufacturing

area)

Low-level legal or business ethics issue.

Litigation or regulatory sanction unlikely.

- Litigation or prosecution with damages

less than US$15K

Project having financial

impact less than US$2MM /

year due to:

- Missing major milestones

- Cost overruns

- Failure to achieve the

designed performance levels

Slight Impact:

Slight impact - no public concern

Financial loss or

inc reas ed cost ( or

savings opportunity)

less than US$2MM /

year

1A 1B 1C 1D 1E

Moderate

Low

* "Sig n off Authority" means that the Function & Department level ris ks shall be revi ewed a nd approved by the respective manag ement authorities as per Current R esidual ris k levels; whereas the C orporate ris k regis ter or corporate ris ks shall be revi ewed a nd approved by Pres ident & CEO

Potential to impact business plan and performance objec tives, but does not mandate an immediate attention of mana gement. Risk reducti on meas ures shall be planned and documented

Correction(s) may be applied as resources allow.

Signoff by Department Mana ger

Enterprise Risk Management (ERM)

Critical

High

Fundamentally undermines the ability to achieve core business / program objectives, leading to severe financial impact and erosion of value; Immediate action shall be taken to lower the risk.

Signoff by President & CEO

Signoff by SVP/ VP/ CFO

Risk Level

Petro Rabigh Risk Assessment Matrix (RAM)

Likelihood

Minimum Required Action

Management Signoff Authority

Figure 5. Risk Assessment Matrix

SAFETY TOPICS

This section contains rules and precautions

for specic safety topics and associated

hazards. Some of the topics herein may

not relate to your specic job and the

associated safety hazards you may face.

These twenty six (26) safety topics are

arranged in alphabetical order for your use.

The following precautions shall

be followed during abrasive

blasting and coating operations:

1. Only qualied and certied

individuals by approved

Petro Rabigh 3rd Party

agencies shall operate

abrasive blasting and

coating equipment.

2. All personnel in the area

affected by abrasive blasting

and coating shall wear

proper Personal Protective

Equipment (PPE) and

respiratory protection (e.g.,

ventilated hoods).

3. Supplied air for hoods

or respirators shall be of

the proper type (grade D)

and the delivery system

per the manufacturer’s

specications.

4. Operators shall inspect

compressors and the air

delivery system on a regular

basis.

5. Operators shall perform

mechanical integrity

testing (i.e., wall thickness

measurement) on

equipment that will undergo

abrasive blasting.

6. Only approved abrasive

blasting materials shall

be used. Silica sand is

prohibited as an abrasive

blasting material.

7. Abrasive blasting and

coating equipment shall be

properly grounded / bonded.

8. A deadman’s switch

(automatic shut-off) is

required on the abrasive

blasting nozzle.

9. Proper safety pins and

connecting lines shall be

in place at all potential

disconnect points.

10. Fall protection is required

for heights above 1.8 m (6

ft.) (e.g., proper scaffolding,

work platforms, and

harnesses).

11. Abrasive blasting and

coating areas shall be

properly contained.

12. Proper barricades and

warning signs shall be in

place.

13. Never point an abrasive

blasting nozzle at any

person or part of your body.

14. Air compressors used

to supply breathing air

shall be 3rd party certied,

quarterly by a Petro Rabigh

recognized testing agency.

SAFETY TOPIC 1

Abrasive Blasting

and Coating

Labeling of Chemicals

1. Chemicals shall be properly

labeled.

2. Material Hazard Bulletins

(MHBs) or Safety Data

Sheets (SDSs) shall be

readily available for each

chemical on-site.

Use of Chemicals

1. Use appropriate Personal

Protective Equipment (PPE)/

respiratory equipment as

set out in the relevant SDS/

MHB.

2. Do not smell or taste

chemicals or eat, drink,

smoke,

3. or chew gum in areas where

chemicals are present.

4. Wash hands thoroughly after

handling chemicals.

5. Do not mix incompatible

chemicals.

6. When mixing chemicals, use

proper lab equipment.

7. In case of eye or skin

contact, promptly ush

affected areas with clean

water for a prolonged period

(15 minutes minimum),

remove contaminated

clothing, and seek medical

attention.

8. Promptly clean spills while

wearing appropriate Personal

Protective Equipment (PPE),

and properly dispose of all

contaminated materials.

SAFETY TOPIC 2

Chemical Safety

SAFETY TOPIC 2

Chemical Safety

Storing Chemicals

1. Indoor storage of ammable

and combustible materials

shall be in approved metal

cabinets.

2. Chemicals stored must be

properly labeled. The Risks

and Hazards are easily

identiable.

3. Users shall periodically

examine chemical

containers for integrity.

4. Chemical storage shall

be minimized. Storage on

bench tops or at high levels

is not recommended.

5. Incompatible chemicals

shall not be stored near

each other.

6. Toxic substances shall

be segregated in a well-

identied area with local

exhaust ventilation.

7. Highly toxic chemicals,

whose containers have

been opened, shall be in

secondary containment.

Loading/Unloading of

Chemicals

Before attempting unloading of

Chemical make sure that you

understand the plant relevant

Standard Operating Procedure

(SOP) and the potential

hazards associated with the

handling subject Chemical.

1. Ensure compliance with work

permits

2. Conduct pre unloading,

during unloading and post

unloading checks as per

plant relevant SOP/Checklist

3. Position the trailer as level as

possible, apply hand brake,

shut off the engine and block

the wheels by applying chocks

4. Ensure grounding connection

from the tank body to existing

grounding system in the plant

5. Do not allow any hot work

in the vicinity of the loading/

unloading activity if the

chemical is ammable

6. Ensure availability and

operability of Safety Shower

and Eye Wash in the vicinity

of activity.

7. Carefully check the storage

tank into which the contents

of the truck are to be

unloaded to be certain that it

contains the same chemical

and not some other

chemical or compound.

Also, check the gauge

on the storage tank to be

sure that there is sufcient

room to receive the entire

contents of the tank truck.

8. Check all “product

identication” or “bulk” tags

to be certain about the

product being unloaded.

9. Do not breathe vapors.

Wear proper protective

equipment, including

an approved respiratory

protective device.

10. Attach the loading/

unloading standard hose

which is tested and in good

operating condition. Do not

use Hoses with damaged

couplings.

11. Loading/Unloading must be

closely monitored.

SAFETY TOPIC 2

Chemical Safety

Handling Cylinders

1. Secure protective caps on all

cylinders not in use.

2. Properly secure cylinders in

an upright position during

movement and storage.

3. Do not use slings or ropes

for moving cylinders.

4. All cylinders shall be

properly labeled.

5. Only rely on the supplier’s

tag to determine the

contents of a compressed

gas cylinder.

6. Do not strike cylinders

together.

7. Keep valves on empty

cylinders closed at all times.

8. Use cylinder trolleys,

material baskets, cylinder

racks, and other proper

types of equipment to

transport cylinders.

Using Cylinders

1. Use approved pressure-

reducing regulators with

a check valve connected

to the cylinder valve on all

cylinders.

2. Always close the cylinder

valve before attempting to

stop leaks.

3. Do not use oil or grease

as a lubricant on valves or

attachments.

4. Threads on ttings shall

correspond to cylinder valve

outlets.

5. Inspect cylinders for safe

condition before use.

6. Protect cylinders from direct

ame, sunlight, and other

heat sources.

7. Inspect all gauges,

regulators, hoses, and

cylinders for damage and

current hydro-test date.

8. Place ashback arrestors

at O2 / acetylene cylinder

regulators (See “Cutting,

Welding, Grinding and

Brazing” topic).

SAFETY TOPIC 3

Compressed Gas

Cylinders

Storing Cylinders

1. Store cylinders in an upright,

secured position; use bottle

/ cylinder racks wherever

possible.

2. Keep stored O2 cylinders

separated from fuel gas

cylinders by a 6.1 m (20 ft.)

or by a 1.5 m (5 ft.) high,

non-combustible barrier.

3. Keep cylinders away from

direct ame, sunlight, and

other heat sources.

4. Do not store cylinders at

temperatures exceeding

54 °C (130 °F).

5. Properly identify empty and

full cylinders.

SAFETY TOPIC 3

Compressed Gas

Cylinders

The most common reported

cause of accidents around

conveyors is getting caught

by the moving conveyor belt

or pulley. Following safety

precautions should be observed

1. All conveyors must have

an emergency shutoff

mechanism, such as a pull

cord. Before operating the

conveyor, make a mental

note of where the emergency

shutoff is located to operate

in case of an emergency.

2. Do not wear loose clothing,

jewelry or other items that

can get caught in conveyors.

Long hair should be tied up

to prevent being caught in

moving conveyor parts.

3. Never ride or climb a

conveyor.

4. Do not operate a conveyor

unless you have been trained

in its operation.

5. Never load a conveyor

beyond its capacity.

6. Before operating, ensure

that the rollers and belt are

guarded.

7. Do not attempt to remove

or install guards on the

operating conveyors.

8. Do not use hand or tools to

remove material from

moving rolls.

SAFETY TOPIC 4

Conveyors

This section applies to all types

of cranes including mobile and

overhead cranes. See “Rigging

Safety” topic for rigging

precautions.

Inspection

1. All Petro Rabigh, contractor,

or 3rd party mobile or

overhead cranes shall be

inspected by the operator

prior to use with the Petro

Rabigh Crane Operator Daily

Inspection Checklist.

2. All cranes shall have a

valid inspection sticker

from Petro Rabigh or

Petro Rabigh approved 3rd

party. Supplemental lifting

equipment used below the

hook (e.g., spreader bars,

crane suspended personnel

platforms, man-baskets,

slings, web belts and chain

blocks) shall have a valid

inspection sticker from a

Petro Rabigh approved 3rd

Party certied inspector.

Operations

1. Only the following personnel

shall operate cranes:

• Petro Rabigh or approved 3rd

Party certied crane operators

for the type of mobile crane,

overhead crane, or extensions

/ attachments indicated on his

certicate.

• Trainees under the direct

supervision of a qualied

trainer.

• Crane maintenance personnel

and inspectors in the

performance of their duties.

2. Details of crane lifts shall

be communicated to the

affected personnel in the

area.

3. A designated signal man

and crane operator shall use

universal hand and/or radio

signals.

4. The crane operator’s line

of sight to the designated

signal man shall not be

obstructed.

5. All cab glass shall be safety

glass and kept clean without

obstructions or damage.

SAFETY TOPIC 5

Crane Operations

6. Tag-lines shall be used on

all lifts, except when their

use may create a greater

hazard.

7. Do not side load.

8. Avoid load swings over

personnel or trafc areas.

9. Know the accurate weight

of all loads and lifting gear

prior to the lift.

10. Personnel shall only be

transferred by approved

personnel transfer

equipment.

11. In positioned lifts, outriggers

shall be used with

appropriate pads and mats.

Booms shall not be swung

without outriggers being

extended in accordance

with the manufacturer’s

specication.

12. Crane operator shall not

leave the crane cab while the

crane is attached to a load.

13. Position (lower) hydraulic

crane booms and secure

hook while traveling.

14. Certied riggers by an

approved Petro Rabigh 3rd

Party shall inspect slings,

ttings, and shackles prior

to use.

15. All crane loads shall be

rigged by an approved Petro

Rabigh 3rd Party certied

rigger.

16. Crane lifts shall not be

allowed at wind speeds

above 32 km/h (20 mph-

17.4 knots- 9 meters/

second).

17. Crane suspended man

basket operations shall not

be allowed at wind speeds

greater than 25 km/h (15

mph).

18. Cranes shall not be

operated any closer than the

depth of an excavation.

19. Cranes shall be operated

around power lines in

accordance with the

distances provided in the

“Electrical Safety” topic.

20. Mats shall not be

permanently afxed to the

crane outrigger pads.

SAFETY TOPIC 5

Crane Operations

21. Critical Lift Plans are

required together with

proper risk assessment of

the job for certain conditions

and activities including:

• Cranes operating around

power lines.

• Operating around

hydrocarbons and above-

ground pressurized piping

areas, and populated/trafc

areas.

• All loads of 40 tons or greater.

• All loads exceeding 85% of

the rated load capacity of the

crane for that specic lift.

• Tandem, multiple, or tailing

lifts (any lift requiring two or

more cranes to lift one load).

• Crane suspended personnel

platforms (man-baskets).

• High level and/or long reach

crane lifts.

• Nighttime crane lifts (except

as approved during a

turnaround and inspection

[T&I] or shutdown).

• Other lifts as determined by

Petro Rabigh Mangt.

SAFETY TOPIC 5

Crane Operations

General Safety Precautions

1. All welders and braziers

shall be Petro Rabigh

approved 3rd Party certied.

2. All welders and braziers

including helpers shall use

proper Personal Protective

Equipment (PPE).

3. Equipment shall be visually

inspected by the user daily.

4. Defective equipment shall

be removed and replaced.

5. All welding and brazing

operations shall have proper

ventilation.

6. All unsecured work pieces

shall be properly clamped.

7. All equipment shall be

turned off when not in use.

8. A portable Fire extinguisher

shall be available within 3 m

(10 ft.).

9. Combustibles around the

work area shall be removed

/ protected.

10. All sewers within 23 m (75 ft.)

shall be covered prior to work.

11. A qualied re watch shall

be maintained during

operations and for 30

minutes afterwards.

12. Cutting, Welding, Grinding

and brazing are not allowed

in O2 enriched environments

(i.e., O2 Concentration

greater than 23.5%).

Electric Arc Welding

Operations

Also see “Electrical Safety” topic.

1. Electric welding machines

shall be properly bonded

and grounded and shall

comply with Petro Rabigh

electrical requirements.

2. Electric welding machine

electrical outlets shall

not exceed 220 volt (V),

3-pronged type with ground

fault protection device.

3. Welding cables shall be

continuous within 3 m (10

ft.) of the electrode holder.

4. All damaged welding

cables shall be removed

from service; temporary

repairs and taped joints are

prohibited.

SAFETY TOPIC 6

Cutting, Welding,

Grinding and Brazing

5. Proper welding screens

shall be used near other

personnel.

Gas Welding, Cutting,

Grinding and Brazing

Operations

Also see “Compressed Gas

Cylinders” section.

1. Lighted torches shall not be

left unattended.

2. Compressed type ttings

shall be utilized on hose

connections.

3. All connections / equipment

shall be checked for leaks

before use (e.g., soap

solution).

4. Gas regulators shall be

turned off and hoses bled off

at the end of shift or task.

5. Hoses shall be protected

from potential damage

during operations.

6. Flashback arrestors shall

be placed at O2 / acetylene

cylinder regulators and

torches as shown in Figure 6.

7. Only strikers shall be used

to light a torch; never light

a torch with matches or a

lighter.

8. When opening an O2 or fuel

cylinder valve, always crack

it open rst.

9. Stand to the side of a

regulator, not in front of

it when opening cylinder

valves.

10. Acetylene cylinders in use

shall have a handle or valve

wrench in place at all times.

SAFETY TOPIC 6

Cutting, Welding,

Grinding and Brazing

Figure 6. Flashback Arrestor Position on O2

/Acetylene Cylinders

Qualications

1. Only individuals qualied for

the type of electrical work to

be undertaken shall repair or

install electrical equipment,

or work around live circuits

(e.g., switchman).

2. Individuals who need to

identify and possibly de-

energize an electrical circuit

shall attend specialized

electrical safety training.

3. Qualied personnel

authorized to work on

electrical circuits shall be

trained in First Aid and Basic

Life Support (BLS).

Work Practices

1. All electrical conductors shall

be considered energized

unless properly Locked,

Tagged, Cleared, and Tried.

2. De-energize all circuits

before beginning work.

Use Safety Process 6,

“Isolation, Lockout, and Use

of Hold Tags” to prevent the

electrical circuits from being

inadvertently energized.

3. Use proper PPE including

insulated rubber gloves

for high voltage work.

Additionally, mats and

blankets may be required to

provide insulation from other

elements that are energized

or grounded.

4. Personnel shall not wear

rings, wristwatches, other

jewelry, glasses with metal

frames, or other similar

metallic objects while

working within arm’s length

of energized electrical

equipment.

5. Do not cause electrical

interlocks to be inoperative

by removing, modifying, or

destroying them.

6. Blown fuses shall be

removed with approved fuse

pullers and replaced only

with the proper type and

rated fuses.

7. Metal ladders shall not be

used when working on or

near electrical equipment

or conductors; use only

nonconductive ladders.

SAFETY TOPIC 7

Electrical Safety

8. Never use defective electrical

equipment, defective

extension cords, or shop-

made extension cords.

9. When opening or closing a

disconnect switch, personnel

shall stand to the side, turn

head away from switch, and

throw switch with a quick

upward or downward single

motion.

10. Extension cords shall not be

used in place of permanent

wiring.

11. Ground fault circuit

interrupters (GFCIs) or

ground isolation systems

shall be used for all portable

electrical tools (including

hand-held / portable lights),

temporary wiring, and in

potentially damp areas.

12. Maximum voltage for

portable electrical hand tools

shall not exceed 220 Volt.

13. Frequently update the

electrical panel board breaker

list for proper isolation in case

of emergency.

14. Do not use electrical rooms

as storage or resting areas.

15. Battery rooms shall be

properly ventilated.

Safety Requirements for

Electrical Substations

Below are some of the

substation safety requirements

which must be used to prevent

work related incidents at

substations:

1. Exercise strict access

control to the substation

to prohibit unauthorized

personnel entry.

2. Display clear warning

signs indicating hazards

and precautions at the

entrance and on other

prominent locations inside

the substation.

3. Door, panel and covers

enclosing live equipment

must be kept closed/ locked

all times.

4. Ensure the necessary

rst aid kits, re blankets,

electrical grounding tools

with insulated handles are

available in the substation.

SAFETY TOPIC 7

Electrical Safety

5. Always wear ame-resistant

clothing (FRC) when entering

a substation.

6. Never wear rings,

wristwatches and metallic

objects while working within

arm’s length of energized

electrical equipment.

7. All work including inspection

inside the substation must be

carried out under work permit

system.

8. Only trained and authorized

personnel should be allowed

to work on electrical equipment

in a substation.

9. Ensure that the electrical

system is de-energized,

locked out and tagged before

conducting any job on it.

10. Always maintain safe

distances between yourself

and live contacts and

terminals. Do not touch

exposed terminals even if you

think they are not energized.

11. Use tools which are of the

correct voltage rating, tested,

certied by approved Petro

Rabigh 3rd Party.

12. Do not work alone; work with

another worker or employee.

13. Never store tools and

materials inside the

substation.

14. Wear Arc rated Category 4

suits while working on high

voltages (more than 480 V).

Energized Overhead Power

Lines

All power lines shall be

considered energized unless

proper measures have been

taken for de-energizing. When

cranes or heavy equipment are

used near energized overhead

power lines, no part of the

crane, boom, mast, gin poles,

or machinery shall be permitted

within the distances shown in

Table 3.

Line Voltage Minimum Approach Limit

Up to 50,000 v 3 m (10 ft.)

50,000 to 250,000 v 6 m (20 ft.)

Over 250,000 v 7.6 m (25 ft.)

SAFETY TOPIC 7

Electrical Safety

Table 3. Minimum Safe Distance from Overhead Power Lines

Approved fall protection

measures (e.g., personal fall

arrest systems and scaffolding)

shall be used if the working at

height is greater than 1.8 m (6 ft.)

from oor or platform level.

Personal Fall Arrest Systems

1. Fall arrest system components

shall be properly rated,

mutually compatible, and

consist of the following:

I. Connectors including a double

line shock- absorbing lanyard

as shown in Figure 7.

II. Full-body harness as shown in

Figures 8 and 9.

2. Users shall inspect fall arrest

systems prior to each use.

3. Remove defective components

from service.

4. Fall arrest system components

shall be protected against cuts

or abrasions.

5. Fall arrest systems and

components shall not be used

to hoist materials.

6. Personal fall arrest systems

to be rigged such that an

employee can neither free fall

more than 6 ft. (1.8 m), nor

contact any lower level.

7. When using full-body

harnesses with shock-

absorbing lanyards, they shall

be properly secured at least

5.6 m (18 ft.) above impact

surface and shall not be

reused after stopping a fall.

8. Waist belts and manual locking

or non-self-locking snap hooks

are prohibited for use as part

of a fall arrest system.

9. Knots must not be tied in a

lanyard. Secure lanyard while

not in use to prevent trip and

fall hazard.

10. Do not anchor lanyards to

small diameter pipes, cable

trays, electrical conduits, etc.

11. Anchor points for lanyards /

harnesses should be placed

above shoulder height and

should be free of sharp edges

to avoid cutting the lanyard.

SAFETY TOPIC 8

Fall Protection

Figure 7. Shock-absorbing Lanyard

SAFETY TOPIC 8

Fall Protection

Chest strap with pass through

adjuster buckle

Back D-ring for fall arrest

Back pad

Slotted hip pad

Sub pelvic strap for

added support

Identication and wearer

Instruction label

Side D-rings for restraint or

positioning (if present)

Leg strap adjuster buckle

Leg strap

Figure 8. Fall Arrest System (Front)

Figure 9. Fall Arrest System (Back)

Ladder Safety

1. Users shall inspect all

ladders before use and

remove defective ladders.

2. Ensure ladders extend a

minimum of 1 m (3 ft.) above

the top landing point. In

general, set ladders at a 4:1

slope. See Figure 10.

Figure 10. Ladder Safety 4:1 Rule

3. Properly secure ladders at

the top and provide stable

footing.

4. Only one person shall be on

a ladder at a time.

5. Never work off the top step of

a stepladder or stand on its

non-step side.

6. Do not use temporary work

platforms, such as scaffolds,

to support a ladder.

7. Metal ladders shall not be

used when working on or

near electrical equipment

or conductors; use only

nonconductive ladders.

8. Personal fall arrest system

shall be used on any xed

ladder that is over 6 m (20

ft.) and not equipped with a

cage.

9. If the work is over 1.8 m

(6 ft.) above the ground or

working surface, long - term

in nature, or requires heavy

physical exertion, other

methods such as scaffolds or

personnel lifts shall be used

instead of ladders.

10. When climbing up or down

any ladder, face the ladder

and maintain three points of

contact with hands free of

materials. See Figure 11.

11. Open stepladder fully and

lock it before use.

SAFETY TOPIC 8

Fall Protection

12. Close drop bar / gates of

monkey ladder after its use.

Figure 11. Maintaining Three

Points of Contact on Ladder

Fixed Elevated Work

Surfaces

1. Personnel shall inspect all

xed elevated work surfaces

prior to use (i.e., gratings

clips).

2. Personnel shall provide

warning signs and guard

/ barricade oor openings

including open vaults,

excavations, and grating

that have been removed.

3. Standing on a guardrail or

ladder in close proximity

to the edge of an elevated

platform is prohibited.

Elevating Work Platforms

1. Only qualied personnel

shall operate elevating

work platforms (man

lifts hydraulic/scissor/

telescoping).

2. Personnel lifts shall have

a valid Petro Rabigh or

PRC approved 3rd party

Inspection Sticker.

3. A second person shall be

used to guide the operator

while moving the lift from

one location to the other.

4. Appropriate clearance from

overhead obstructions

while raising or lowering

the platform shall be

maintained.

SAFETY TOPIC 8

Fall Protection

5. Modication of personnel

lifts is prohibited without

written consent from th

lifting manufacturer.

6. Never use personnel lifts

designed for indoor use

outdoors.

7. Outriggers shall be used

on lifts equipped with

outriggers.

8. Personnel shall wear a full-

body harness with lanyard

attached to an anchor point

on the lift.

9. All entrance gates or

chains shall be in their

fully closed position and

secured shut before

moving or raising the lift.

10. Never sit or climb on the

edge or handrail of the lift.

11. Equipment and tools shall

not be carried on personnel

lifts designed only for

personnel transfer.

SAFETY TOPIC 8

Fall Protection

Response Procedures in

Case of Fire

1. Summon Help/Sound

Alarm.

2. Only trained personnel

shall operate re

extinguishers and

equipment.

3. Ensure that all personnel

are evacuated per the local

emergency response plan.

4. Isolate all fuel sources and

/ or threatened facilities

and close doors; do not

attempt to extinguish gas

res.

5. Do not ght res beyond

the incipient (initial) stage

or beyond your level

of training. Locate the

reghting equipment and

approach the re from the

upwind side.

6. Never operate an

extinguisher in such a

manner that any part

of your body is located

directly above the ll cap.

7. Test the extinguisher before

attempting to extinguish re.

8. After the re is extinguished,

stand by to ensure that there

is no re-ignition.

Fire Prevention Guidelines

1. Class A re materials (e.g.,

paper and wood) storage

shall be minimized in process

and electrical areas.

2. Trained personnel shall

visually inspect all re

equipment monthly.

3. Report and repair all

hydrocarbon liquid or gas

leaks immediately.

4. In the event of a hydrocarbon

liquid or gas leak, remove

sources of ignition

immediately (e.g., shut down

engines).

5. Do not use gasoline as a

cleaning agent.

6. Always ll portable gasoline

containers on the ground

and never place gasoline

containers inside vehicle

passenger compartments.

SAFETY TOPIC 9

Fire Protection

7. When transferring

hydrocarbons (ammable

liquids) from a line

or vessel to another

container, the source

container and the

receiving container shall

be electrically bonded to

prevent ignition due to

static electricity.

8. Plastic cups/buckets shall

not be used for collection

of hydrocarbon samples.

9. Do not smoke, use cellular

phones, other electrical

devices while refueling

or within electrically

classied areas.

SAFETY TOPIC 9

Fire Protection

1. Only Petro Rabigh

approved 3rd Party certied

forklift operators shall

operate forklifts.

2. Rollover protective

structures (ROPS) shall not

be removed.

3. Seat belts shall be worn

when operating forklifts.

4. Personnel other than the

operator shall be prohibited

from riding.

5. Forks shall not be used to lift

personnel or used as a work

platform unless used with an

approved Petro Rabigh 3rd

Party certied platform.

6. Operators shall inspect

forklifts before and after use,

including the back / reverse

warning and safety devices.

Report any deciency to

their Supervisor.

7. Brakes shall be set and

the wheels blocked on the

trailer or truck being loaded

or unloaded.

8. Do not allow any person

to stand or walk under

elevated forks, whether

loaded or empty.

9. Move all drums in the

upright position, using a

drum containment pallet,

drum rack, basket, or with

a drum handling extension.

No drums shall be moved

by sandwiching them

between forks.

10. Forks shall not be used to

tow or push equipment or

objects.

11. Forklifts shall not be used

beyond their rated capacity.

12. Forks shall not be left in

the up position while forklift

is unattended.

13. Forklifts shall not be left

running while unattended.

14. Forklifts shall not be

operated on uneven or

unstable surfaces.

15. Load forklifts only when

moving on a level surface or

uphill on an incline.

16. Keep all parts of the body

inside the forklift cabin.

SAFETY TOPIC 10

Forklift Safety

Tilt Back

As low as possible

SAFETY TOPIC 10

Forklift Safety

Figure 12. Proper Forklift Load Movement

17. Forklift operators shall

have valid Heavy Vehicle

driving license from

Saudi Government and

Certicate from Petro

Rabigh approved 3rd

Party Agency.

18. Carry loads low, with forks

just off the ground and

tilted back (see gure 12).

Heat-Related Illnesses

1. Heat Cramps (an early

warning sign for heat

exhaustion).

Treatment includes: Stop all

activity; rest in a cool, shaded

area; loosen clothing; drink

water; and if symptoms persist,

seek medical aid.

2. Heat Exhaustion (weakness;

dizziness; sweating; rapid

pulse; pale or ushed skin).

Treatment includes: Move the

victim to a cool place; call for

medical help; loosen clothes;

apply cool compresses;

shower with cool water; and

drink water or sport drinks that

have electrolytes.

3. Heat Stroke (lack of

sweating; high body

temperature; chills; strong

and rapid pulse; confusion;

weakness; nausea; and loss

of consciousness).

Treatment includes: Treat as a

medical emergency and call for

a doctor immediately; move to

a cool, shaded area; cool the

body with water; and have the

victim lie at with feet elevated.

Any employee experiencing

symptoms of a heat-related

illness shall be allowed to

fully recover in an appropriate

recovery area before returning

to work. Victims of heat

exhaustion or heat stroke shall

be immediately evacuated to

the nearest medical facility for

treatment.

Site Management/Supervisors

1. When the potential for heat-

related illness exists, monitor

environmental conditions (i.e.,

air temperature, humidity)

and communicate the

current heat stress danger

category (see Table 4) and

necessary control measures

to personnel.

2. Develop a work plan to

avoid heat-related illness

during periods of high heat

stress potential. This plan

may include:

• Scheduling work during the

cooler times of the day and

work/rest rotations.

SAFETY TOPIC 11

Heat Stress

• Providing measures (e.g.,

shading and ventilation)

when work in direct sunlight

is required.

• Monitoring employees for

symptoms of heat- related

illness.

• Communicating to workers

the locations of designated

break/recovery areas and

emergency procedures.

• Adjusting work/execution

plans (e.g., use mechanical/

powered equipment to

replace manual labor) as

practical.

3. Do not let schedule or

productivity demands

supersede heat stress

awareness or controls.

4. Conduct periodic (e.g.,

weekly) safety meetings/talks

and distribute educational

information on heat stress

hazards and precautions.

5. Provide drinking water

stations and designated

shaded and cool areas for

periodic “cool down” breaks

for workers.

6. Periodically determine

(e.g., every hour) the actual

heat index at the work site

using calibrated weather

monitoring equipment when

the potential for heat- related

illness exists.

7. Communicate the current

heat stress danger category

and corresponding control

measures to employees as

conditions change.

Employees

1. Follow instructions for

controlling heat stress,

including taking periodic

“cool down” breaks and

drinking enough water.

2. Wear appropriate clothing

(e.g., light colored,

lightweight, breathable,

loose clothing is best).

3. Know and be alert for signs/

symptoms of heat-related

illnesses.

4. Take appropriate action upon

developing symptoms of heat

cramps, heat exhaustion, or

heat stroke.

SAFETY TOPIC 11

Heat Stress

Control and Prevention of

Heat Stress

During periods of high heat

stress potential at the work

site, implement measures

as applicable to control

heat stress. As with any

hazard, feasible engineering

controls are the primary

control measure, followed

by administrative (work

practice) controls and personal

protective equipment controls.

Engineering controls include

1. Shaded break/rest areas – at

a distance not greater than

100 m (330 ft) from personnel

working in direct sunlight.

2. Local ventilation – fans or

portable air movers may be

used when temperature is

less than 37 °C (99 °F).

3. Portable air cooling systems

– for cooling conned

spaces and similar enclosed

work areas.

Administrative controls

include:

1. Scheduling – work during

cooler times of the day.

2. Acclimatization – expose

new employees to

hot environment for

progressively longer periods.

3. Water replacement

(hydration) – supplies of

drinking water located within

100 m (330 ft) walking

distance of each worker.

4. Work/rest rotations – rest

periods based on actual heat

index (see Table 4).

5. Personal monitoring –

personnel observe each

other for signs of heat

related illness.

Personal protective

equipment controls include

1. Ice cooling garments – ice

vests, neck wraps, etc.

2. Clothing – light colored,

lightweight, breathable

clothing; work plans adjusted

when personnel are required

to wear ame resistant

clothing (FRC).

SAFETY TOPIC 11

Heat Stress

3. Wetted clothing/towels – water supplies separate from drinking water

to cool the body.

Table 4. Heat Index Guidelines and Calculation Heat Index Danger

Safety Topic 11: Heat Stress

3. Wetted clothing/towels – water supplies separate from

drinking water to cool the body.

Table 4. Heat Index Guidelines and Calculation Heat Index

Danger

SAFETY TOPIC 11

Heat Stress

Safety Topic 11: Heat Stress

SAFETY TOPIC 11

Heat Stress

Safety Topic 11: Heat Stress

SAFETY TOPIC 11

Heat Stress

The following safety

precautions apply to mobile

heavy equipment such as, but

not limited to, front end loaders,

backhoes, excavators, boom

trucks, scrapers, and roller

compactors.

Safe Operation

1. Only Petro Rabigh

approved 3rd Party Agencies

certied and Saudi Arabian

Government certied

operators shall operate

heavy equipment.

2. Identify all utilities and lines

and notify appropriate parties

before beginning any digging

or cleanup work.

3. Heavy equipment shall be

operated around power

lines in accordance with the

distances provided in the

“Electrical Safety” topic.

4. Ground personnel shall

maintain a safe distance from

operating equipment and

establish eye contact with the

operator before approaching.

5. The operator shall not jump

from the equipment to the

ground. Maintain three points

of contact during entry/ exit.

6. Personnel shall not be

allowed to ride in or work off

any part of the equipment

unless specically designed

for personnel.

7. The operator shall designate

a spotter (or a signal person)

when visibility is obstructed.

8. Heavy equipment shall not

be left running unattended.

9. Sleeping or resting under

or near heavy equipment is

prohibited.

10. All boom trucks shall be

loaded/unloaded by an

approved Petro Rabigh 3rd

Party certied rigger.

Equipment Condition

1. Heavy equipment shall be

inspected tagged / certied

by Petro Rabigh approved 3rd

Party for use in plant areas.

2. All heavy equipment shall

have an audible back /

reverse alarm.

SAFETY TOPIC 12

Heavy Equipment

3. Heavy equipment shall be

maintained in operable

condition, including seat

belts.

4. All cab glass shall be safety

glass and kept clean without

obstructions or damage.

Rollover Protective Structure

(ROPS)

All material handling equipment

designed to include ROPS

(e.g., bulldozers, loaders, and

scrapers) shall be equipped

with them.

SAFETY TOPIC 12

Heavy Equipment

1. Inspect the hoist daily. Look

for frayed cables, broken

welds, bent struts and faulty

mechanical parts. Make

sure guards are intact and in

place.

2. Never leave a suspended

load unattended.

3. Never move underneath

suspended load.

4. Slings, hooks and rigging

items should be inspected

prior to each use.

5. Make sure that the hoisting

area is free of debris.

6. Use barricades to limit

pedestrian travel near the

hoisting area.

7. Do not exceed the rated

capacity of the hoist.

8. Do not assume that your

equipment is in the same

condition as when you last

used it.

9. Rig loads with properly

rated slings and safety

hooks. Safety hooks must

be equipped with a spring-

loaded latch. Lift the load

momentarily to check the

securement of the load and

its balance.

10. Always use enough

counterweight. As a rule of

thumb, use 2 pounds (0.9

kg) of counterweight for

every 1 pound (0.45 kg) of

load. Do not use construction

materials as counter weight,

nor materials that ow, such

as water or sand. Always

follow the manufacturer’s

specications.

11. All ground personnel must

wear hard hats. Stay out from

under suspended loads.

SAFETY TOPIC 13

Hoists

Good housekeeping efforts

are part of enhancing re

prevention and accident

prevention standards. One of

the easiest ways to prevent

accident is to maintain a neat

and orderly job site.

1. Materials must be stacked

and placed away from foot

trafc.

2. Materials and equipment

should not be stored within

1.8 m (6 ft.) from the edge of

the roof.

3. Tools and equipment must

be put properly in their

respective place.

4. Where necessary, wheels

on rolling equipment shall

be wedge locked.

5. Trash and scraps are

re hazards and must be

collected and disposed them

off immediately.

6. Keep exits and entrances

always clear.

7. Store all liquids (including

ammable liquids) in

approved, clearly labeled

containers in designated

storage areas only.

8. Keep lighting sources clean

and clear.

9. Keep sprinklers, re alarms

and re extinguishers clear

of obstruction.

10. Keep temporary cables,

and hoses away from the

walkways.

11. Remove grass and brush

frequently to prevent growth

in plant facilities, including

inside tank farm dikes.

SAFETY TOPIC 14

Housekeeping

Hydrogen sulde (H2S) may

be encountered in many Petro

Rabigh operations areas. The

physical effects of H2S in high

concentrations may result in

death (see Table 5 for physical

effects of H2S). Contact your

supervisor for additional

information concerning H2S

procedures and / or emergency

response plans.

Precautions

1. All Personnel who work in

areas that contain H2S shall

have current H2S safety

training and First Aid / BLS

training.

2. Upon hearing an H2S alarm,

personnel shall leave

the area in an upwind or

crosswind direction.

3. Do not open any line, vessel,

tank, or equipment that

may contain H2S without

proper notication of all

concerned parties, obtaining

work permit, properly worn

respiratory protection, and

H2S detection equipment.

4. H2S is a highly ammable,

colorless, and transparent gas.

5. It is heavier than air and

may accumulate in low

places.

6. Do not rely on your sense of

smell to detect H2S.

7. Personal monitors shall be

worn as required by local

operations’ procedures

in areas /plant that have

known concentrations of

H2S (greater than zero).

8. All Personnel performing

work in areas where H2S

concentrations have been

detected at 10 ppm shall

wear approved respiratory

equipment.

9. During the execution of

works, work permit issuers

or delegates must frequently

inspect the work site. This

is applicable to all work

activities but becomes of

extra importance in activities

nearby potential H2S

sources.

10. Where concentrations have

been detected at 10 ppm or

greater, H2S warning signs

and wind direction indicators

shall be displayed warning

SAFETY TOPIC 15

Hydrogen Sulfide

of the potential presence of

H2S in the areas.

11. During emergency, follow local

Emergency Response Plan

or instructions from incident

commander.

12. No entry shall be allowed

in atmospheres of 100 ppm

(immediately dangerous to life

or health [IDLH] or above).

13. Never attempt to rescue an

H2S victim without proper

respiratory protection in the

form of a self-contained

breathing apparatus (SCBA).

14. Iron sulde deposits may be

found in tanks, vessels, and

piping where H2S has been

present. Iron sulde scale

(pyrophoric material) open to

air can ignite and shall always

be kept wet to prevent ignition.

SAFETY TOPIC 15

Hydrogen Sulfide

PPM Effects

0.10 Odor threshold (similar to rotten eggs)

10 Eye irritation and threshold limit value (TLV) – time weighted

average (TWA).

25 Severe conjunctivitis with prolonged exposure.

50 Severe conjunctivitis with prolonged exposure.

100 Severe eye irritation and coughing. Loss of sense of smell in 1 to

5 minutes. Immediately dangerous to life or health (IDLH).

250 Pulmonary edema and gastrointestinal disturbance.

500 Dizziness and loss of consciousness possible within 30 minutes.

1000 Immediate unconsciousness and death within minutes.

Table 5. Physical Effects of Hydrogen Sulfide

High pressure water jetting

(hydrojetting) uses high speed

streams of high-pressure water

to cut through almost all solid

materials and to clean various

surfaces. Hydrojetting is one

of the most critical activity

performed during shutdowns

and turnarounds. Following

safety precautions should be

observed:

1. Hydrojetting machine shall

have a valid inspection sticker

from Petro Rabigh approved

3rd party agencies.

2. Only experienced personnel

who have been certied by

Petro Rabigh approved 3rd

party agencies and trained

by specialized training

organization in accordance

with the ‘Equipment

Manufacturers’ instructional

material shall operate

hydrojetting machine.

3. Maintain the hydrojetting

machine in accordance

with the manufacturer’s

instructions and specications.

4. Hydrojetting machine, hoses,

jetting gun, and ttings, etc.

shall be inspected prior to

use.

5. Hoses and ttings shall be

suitable for the hydrojetting

machine’s maximum

pressure rating.

6. When performing hydrojetting

job, operators must

wear personal protective

equipment such as; suitable

jet-resistant waterproof

clothing, eye protection,

hearing protection, helmet

with face shield, cut-resistant

waterproof leg protection

i.e. metatarsal guard, leg

guard, waterproof hand

gloves, and full body harness

while working at height.

While cleaning equipment

that might be contaminated

with hazardous chemicals,

the operator shall wear

appropriate additional

protection specied by MHB/

SDS.

7. If standby person(s) is

exposed to the same

hazards as the operator,

similar PPEs shall be worn

by the standby person also.

SAFETY TOPIC 16

Hydrojetting Safety

8. Standby man shall be

deputed near hydrojetting

machine for emergency

shutting down the machine

in case of any emergency.

9. Position hydrojetting

machine as near as

practical to the equipment

under cleaning for effective

contact between the

operator ,standby man and

team members.

10. Before starting a

hydrojetting job, the team

members, shall agree on a

code of signals to be used

during the job.

11. Hydrojetting areas shall

be barricaded outside the

effective range of the water

jet with suitable barriers

and provide warning

signs to prevent entry of

unauthorized personnel and

to protect against injury due

to high pressure water jet.

12. If the job is above ground

level, barricades and signs

are required at below level.

13. Hydrojetting operator shall

have proper access to the

worksite, and place for

secure footing. The work

area shall be kept clear

of loose items, debris and

cover equipment openings

to prevent tripping and

slipping hazards.

14. Small objects/equipment’s

being hydro jetted shall be

securely fastened to prevent

its inadvertent movement

due to water jet.

15. If any entry is required

made at worksite i.e.

for inspection, stop the

hydrojetting activity

completely before entry.

16. Hydrojetting systems shall be

depressurized and secured

when not in use or while

its components are being

replaced or repairs are being

made.

17. For hydrojetting at elevated

platform (e.g. n fan cooler),

arrangement such as water

collection trays must be

made to collect the sludge/

water.

SAFETY TOPIC 16

Hydrojetting Safety

18. Protect instrument cables,

lines, electrical cables,

nearby equipment’s, etc.

passing through work area

from high pressure water jet.

19. Never direct high-pressure

lance, gun towards a

person whether under

pressure or not.

20. High pressure equipment

shall be tted with actuating

devices operated by hand

or foot.

21. Anti-withdrawal device

shall be used on all ex

lancing jobs.

22. Hose shall be arranged so

that a tripping hazard does

not occur. Support hoses,

and ttings to prevent bends

and damage.

23. Whip-check device shall

be provided on the hose

coupling to prevent hose

from whipping in case of

disconnection.

24. Assigned execution

supervisor shall rotate

operators to minimize fatigue.

25. Avoid awkward body

position while hydrojetting.

26. High pressure equipment

shall be grounded to

prevent the development of

electrostatic charges.

27. Adequate illumination

shall be maintained at

hydrojetting worksite.

28. Ensure appropriate platform

/ scaffold is provided for

hydro- jetting job at higher

elevation.

SAFETY TOPIC 16

Hydrojetting Safety

1. The Captain/Master of a

marine vessel or barge is

responsible for all safety

onboard at all times.

2. All visitors to marine

vessels/barges shall rst

report directly to the person-

in-charge of the vessel with

all the required information

at the time of boarding, such

as swimming ability.

3. The person-in-charge shall

provide all passengers with

orientation of the vessel,

including life raft and safety

equipment. A personnel

otation device (PFD) shall

be worn when boarding,

traveling, or disembarking a

boat/ vessel/barge.

4. When boarding a vessel/

barge from a shore/pier

facility ensure that you have

safe access to the vessel/

barge.

5. When disembarking from a

vessel/barge to a platform/

landing, do not disembark

until the person-in-charge

has given permission to

do so.

6. Never go outside the ship’s

rail unless authorized by the

person-in-charge. The ship’s

rail goes around the outside

deck of the vessel/barge.

7. In the event of a person

falling in the water,

immediately shout “man

overboard”. Assist in the

rescue as directed by the

person-in-charge.

8. Be aware of slippery

surfaces, newly painted

decks, and wet decks,

especially in rough weather,

and decks with oily patches.

9. Be aware of mooring ropes

and wires. Many ropes and

wires are under tension and

can cause serious injury.

10. During crane operations,

be aware that the vessel is

affected by wave action and

passing vessels; this will

affect the control of crane

loads to be lifted.

SAFETY TOPIC 17

Marine Safety

Work Over Water

1. PFDs (personnel otation

devices) shall be properly

worn.

2. Personnel shall be tted with

a safety harness and safety

line.

3. Safety lines shall be tended

by standby personnel.

4. Life buoys shall be available

for rescue.

5. Never work alone; use the

buddy system.

SAFETY TOPIC 17

Marine Safety

A pyrophoric material may

be encountered in many

Petro Rabigh operating

facility / equipment and can

spontaneously ignite in air.

Many pyrophoric materials are

also water reactive, reacting

vigorously with water or high

humidity, often igniting upon

contact. In Petro Rabigh,

typical pyrophoric materials

encountered are, Iron Sulde

(FeS) and Triethylaluminum

(TEAL). They can be handled

safely in inert atmospheres.

Iron Sulde (FeS)

Location: Renery and

Monomer processing plants

and equipment.

Source of Iron Sulde

• Iron react with Sulfur under

exothermic reaction to

produce iron sulde.

Precautions:

1. Rinse the equipment with

potassium permanganate

solution (KMnO4).

2. Keep the Iron Sulde wet

until cleanup is complete.

3. Properly handle in inert

atmosphere within conned

spaces.

4. Keep sludge/scale from

drying-out.

5. Use proper labeling

and tagging system

implementation.

6. Barricade staging area for

FeS.

7. Communicate Hazards

properly.

8. Properly water wash and

blind overhead exchangers.

9. Provide full-face blinds for

removed spool pieces from

the piping / equipment.

10. Properly communicate FeS

material disposal.

11. Use only Class D re

extinguisher to put out

pyrophoric material re.

SAFETY TOPIC 18

Pyrophoric Materials

Triethylaluminum (TEAL)

Location: EPR, HDPE and

Butene-1, PE-1 and 2, PP-1

and 2 plants and equipment.

Precautions

1. Keep away from heat/sparks/

open ames/hot surfaces. -

No smoking.

2. Do not allow contact with air.

3. Handle and store under inert

gas. Protect from moisture.

4. IF IN THE EYES: Rinse

cautiously with water for

several minutes.

5. Use specialized PPE (TEAL

suit) when handling.

SAFETY TOPIC 18

Pyrophoric Materials

The following checklist is recommended to be used in Petro Rabigh

ofce areas to maintain a high level of safety. Quarterly inspections of

ofces shall be conducted as a minimum.

Ofce Safety Checklist

Ofce Space Y/N

Sufficient Ventilation

Open floor space

Workstation Ergonomics Y/N

1- Maintain neutral posture

2- Open floor space

3- Keep arms level

4- Take regular breaks

5- Avoid extended reaches

Walking Surfaces Y/N

Aisles correctly established with 76 cm(30 in.) clear width

Tripping hazards cleared (carpets/mats secure)

Mats available to prevent slipping hazards

Floors dry- not slippery

Caution signs present during cleaning

SAFETY TOPIC 19

Office Safety

Halls, Ramps, Lighting Y/N

Emergency lighting in working condition

Adequate lighting, suitable for work

Ramps have nonslip surface

Handrails installed and in good condition

Halls kept clear of equipment and supplies

Storage Areas Y/N

Shelves and file drawers safely locked

Heavy items stored at waist level

Heavy storage shelves/files secured

No storage within 0.6 m (2 ft.) of ceiling

Noisy equipment isolated (e.g., paper shredder)

Sufficient Ventilation

SAFETY TOPIC 19

Office Safety

Ofce Equipment and tools Y/N

Chairs (springs, casters, hydraulics) in good condition

Fans guarded and secured from falling or tipping

Paper cutter blade down and functional

Safety stepladders available

Chemicals properly labeled /stored

Paper supplies and materials safely stacked

Scissors, sharp tools stored safely

Mechanical equipment properly guarded

Electrical Hazards Y/N

Machines and equipment grounded or double insulated

Proper multi-outlet devices used

Circuits properly loaded

Extension cord-maximum length 3 m (10 ft.)

Power cords, plugs and wall outlet free from defects

Electrical switch panel clear 1 m (3 ft.)

Portable heaters prohibited

SAFETY TOPIC 19

Office Safety

Fire Prevention Y/N

Fire extinguishers properly identified / installed

Fire extinguishers tagged with current inspection

Fire extinguishers hydrostatically tested

Fire extinguishers and fire hoses unobstructed

Fire escapes and routes clear

Stairwell fire doors closed

Exits properly marked

Sprinklers heads unobstructed

Excess paper and trash removed

Smoke Detector devices

Common Areas Y/N

External corridors in good repair

Stairways clear-uncluttered

Restrooms in safe/sanitary condition

Caution barricade and mate available

First aid supplies available

Escape notices and plans posted

Floor dry - not slippery

SAFETY TOPIC 19

Office Safety

Apply the following minimum

safety requirements when

conducting pressure testing of

equipment or piping.

Test Preparation and

Equipment

1. Pressure/ Leak test must

include:

• A blind list with marked

drawing showing vents,

drains and test battery limits.

• Locations of lowest-rated

components that determine

the test pressure.

• Relief valve and vacuum

valve (if any) sizes and set

pressures.

• Pressure Gauge calibration

and set pressures.

• Test medium (water, air or

nitrogen) and location of

lling points.

• Special support

requirements of equipment/

piping being tested, safe

clearance distances, and

locations of barricades and

warning signs.

• Pressure test sequence,

intervals, and duration of

pressure increase and

points of inspection.

• In case of Pneumatic

testing, Foundation or

structural assessment,

stored energy calculations

and exclusion zones

identication shall be

carried out as per ASME

PCC-2.

• Work permit, JSA and risk

assessment, as required.

2. Complete Pressure/ leak

Test Certicate (PR/ES/

AIM/F-003/005) before,

during, and after the test.

3. Locate relief valves on the

test manifold and near the

test pump. Tag relief valves

with relief valve serial

number, set pressure, and

calibration date.

4. Remove or car seal open

all block valves installed on

the inlet and outlet of relief

valves.

5. Install vents at high points

in the system to vent air/

gas while the system is

being lled with the test

SAFETY TOPIC 20

Pressure Testing

liquid. Install drains to allow

removal of test liquid when

the test is nished.

6. Use two or more calibrated

pressure gauges on the

system under test; one must

be located within eyesight

of the pump operator. Verify

that pressure gauges valves

are calibrated (01 month)

prior to the test and their

range shall be such that the

maximum test pressure is

within 30 to 80 percent of

the full range.

7. Disconnect and/or blind

equipment or piping that is

not being pressure tested.

8. Install restraints to restrict

movement of the piping

and joints during the test,

as required.

9. Provide safety chains

(or equivalent) on hoses

connecting the test pumps

to manifolds in order to

prevent whipping in case

a coupling becomes

disconnected.

10. Do not overload supports,

vessels/piping, and any

foundations due to the

weight of the test liquid.

Consult with TSD and

provide temporary supports,

if necessary, to ensure

the system under test can

withstand the weight of the

test liquid.

Conducting Pressure Tests

1. Allow only personnel

involved with the pressure

test near the system at any

time during the test.

2. Do not leave test pumps

unattended while in

operation, unless they are

isolated from the system.

3. Provide vent relief capacity

to ensure vessels are not

subject to vacuum during

the draining of test uid.

4. Keep test relief valves

installed until the test

liquid has been completely

drained to prevent possible

overpressure due to thermal

expansion.

5. In addition to the pressure-

relieving device, a bleed

valve shall be provided

SAFETY TOPIC 20

Pressure Testing

to protect the piping

and equipment from

overpressure. The bleed

valve shall be readily

accessible.

6. Before employing the

pressure-testing manifold in

the actual system pressure

test, it shall be separately

pressure tested to at least

1.2 times the system test

pressure but not less than

the discharge pressure

of the pump used for the

pressure testing.

7. Raise pressure in a gradual

and controlled manner. Use

10-minute holds at each

pressure increase step to

allow time for material to

strain and for personnel to

check for weaknesses and

leaks. In case of pneumatic

testing, strictly follow the test

sequence as mentioned in

the Work instruction# PR/ES/

AIM/WI-013.

8. Depressurize the system

being tested before any

work is performed to stop

leaks or repair weaknesses,

including the tightening of

bolts.

9. Do not depressurize the

system by loosening bolts or

ttings.

10. The test uid shall be

safely disposed and ensure

it drained completely.

Management of waste water

shall follow environmental

section general instruction

document number PR/EOH/

ENS/GI-003.

SAFETY TOPIC 20

Pressure Testing

Working with Ionizing

Radiation Sources

1. Only perform work

involving ionizing radiation

if in possession of a valid

Nuclear and Radiological

Regulatory Commission

(NRRC) issued Radiation

Practice License.

2. Perform work under the

control of a licensed

Radiation Safety Officer

(RSO) approved by the

Nuclear and Radiological

Regulatory Commission

(NRRC).

3. Perform activities involving

radioactive sources with

approved work permits

and within controlled

areas where barricades

and warning signs are

installed.

4. Complete radiation safety

awareness session in the

safe use and handling

of ionizing radiation

sources available at PRC

e-learning system.

5. Use PPE and personal

monitoring equipment

while using/handling

ionizing radiation

equipment.

6. Periodically calibrate

radiation monitoring and

survey equipment per

Nuclear and Radiological

Regulatory Commission

(NRRC) requirements.

7. Ensure all depleted

radioactive sealed

source are shipped

back to manufacture per

Nuclear and Radiological

Regulatory Commission

(NRRC) regulations.

8. Survey radiation sources

before and after their use

or movement. Conduct

annual surveys on ionizing

radiation equipment and

sources.

9. Provide security measures

to prevent the loss or theft

of radiation sources from

shielded storage rooms/

facilities.

10. Comply with Nuclear and

Radiological Regulatory

Commission (NRRC)

SAFETY TOPIC 21

Radiation Safety

100

requirements pertaining

to shielding, penetrations,

monitoring, safety

interlocks, warning signs,

etc., for all rooms/facilities

hosting radiation emitting

equipment.

11. Limit access to authorized

personnel only when

operating radiation

equipment or during

source exposure in rooms/

facilities.

12. Immediately stop all

radiographic work if

unauthorized personnel

enter a controlled area.

Industrial Radiography

(Nondestructive Testing

[NDT])

1. Obtain Asset Integrity

Management Department

(AIMD) approval prior

to using any industrial

radiography techniques

not covered by existing

Nuclear and Radiological

Regulatory Commission

(NRRC) requirements.

2. Use engineering controls

and PPE to ensure that

no individual is exposed

to radiation in excess of

the prescribed dose limits

established by Nuclear and

Radiological Regulatory

Commission (NRRC)

requirements.

3. Provide appropriate

lighting to the work area

when radiographic work

is performed at night.

Flashlights or other hand-

held operated lights are

not considered sufficient.

4. Ensure all personnel

performing radiography

nondestructive testing

(NDT) activities and

radiographic film

interpretation (RTFI) are

certified per Nuclear and

Radiological Regulatory

Commission (NRRC)

requirements and

approved by AIMD.

5. Use approved and

calibrated radiation

dosimeters and monitoring

devices when performing

NDT activities.

SAFETY TOPIC 21

Radiation Safety

101

Radiation Source Transport/

Storage

1. Do not transport radiation

sources in vehicles at

speeds exceeding speed

limits prescribed inside

PRC premises.

2. Ensure vehicles

transporting radiation

sources have the proper

equipment per Nuclear and

Radiological Regulatory

Commission (NRRC)

requirements.

SAFETY TOPIC 21

Radiation Safety

102

Rigging Practices

1. Personnel shall use accepted

rigging techniques.

2. All crane loads shall be

rigged by an approved

Petro Rabigh 3rd Party

certied rigger. See “Crane

Operations” section for

additional information.

3. All rigging equipment shall be

rated for the load being lifted.

4. Avoid sharp bends in slings;

protect slings from sharp

edges and abrasions.

5. Do not stand or walk under

suspended loads.

6. Do not leave suspended

loads unattended, unless

the load is properly secured

to a load bearing structural

member.

7. Rigging from process piping is

prohibited. Rig loads off load-

bearing structural members

only after prior approval.

8. Shackles and other

connecting devices shall be

completely closed / bolted.

Inspection

1. Users shall visually inspect

all rigging hardware before

each use.

2. Users shall properly maintain

all rigging hardware. All

defective components shall

be removed from service.

3. Slings shall have their rated

capacity indicated on a tag or

stamp.

4. All “A-Frames” shall be

inspected and certied by

an approved Petro Rabigh

3rd Party certied inspector

prior to attaching rigging

equipment.

SAFETY TOPIC 22

Rigging Safety

103

When scaffolds are required, they shall be properly designed,

erected, and inspected by an approved Petro Rabigh 3rd party certied

supervisor/ inspector using the appropriate inspection check list. Refer

to table 6 for requirements.

Design and

Review

Special scaffolds or scaffolds taller than 12.2 m (40 ft.)

require scaffold plans and review by the appropriate

organizations.

Qualified Structural Engineer from Petro Rabigh Organiza-

tion or approved 3rd party shall approve Scaffold Plan for

all Special Scaffolds or scaffolds taller than 38 m (125 ft.).

Erection

Scaffolds shorter than 12.2 m (40 ft.) shall be erected

by a qualified scaffold erector.

Special scaffolds or scaffolds taller than 12.2 m (40 ft.)

shall be erected by an approved specialized scaffolding

contractor.

Field

Inspection

and Tagging

Checklist for scaffolds shorter than 6 m (20 ft.) shall be

filled and tags signed by Scaffold Inspector.

Checklist for special scaffolds and scaffolds taller than 6

m (20 ft.) shall be filled and tags signed by both Scaffold

Supervisor and Scaffold Inspector.

Table 6. Scaffold Review, Erection, and Inspection Requirements

SAFETY TOPIC 23

Scaffold Safety

104

Scaffold inspection tags shall

be visible (Red, Green, and

Yellow) to indicate the status of

the scaffold (see gure 13).

Figure 13. Scaffold Inspection Tags

(Red, Green and Yellow)

Petro Rabigh approved 3rd

Party Certied supervisor /

inspectors shall re-inspect

scaffold every two weeks and

after any alteration. When

constructing, altering or

dismantling any scaffolding,

materials and equipment shall

not be thrown to persons above

or below.

SAFETY TOPIC 23

Scaffold Safety

105

Use of tools makes many

tasks easier. However, the

same tools that assist us, if

improperly used or maintained,

can create signicant hazards

in our work areas. Employees

who use tools must be properly

trained to use, adjust, store and

maintain tools properly.

Accidents involving the use

of tools can be prevented by

following ve basic safety rules

1. Keep all tools in good

condition with regular

maintenance.

2. Use the right tool for the job.

3. Examine each tool for

damage before use. Tag

damaged tools for repair or

replacement.

4. Operate according to the

manufacturer’s instructions.

5. Provide and use the proper

protective equipment.

Hand Tools

Hand tools are those that are

manually powered, including

everything from screwdrivers to

hand saws.

1. Do not use any tool with a

cracked, loose or splintered

handle.

2. Wear appropriate personal

protective equipment, such

as safety glasses and gloves.

3. Never use a tool as a pry

bar (unless it is intended for

that purpose).

4. Maintain tools in good

condition; e.g., properly

sharpened, cleaned and

lubricated.

5. Be aware that sparks

caused by metal hand

tools can become an

ignition source for nearby

ammables.

6. Do not use chisels with

mushroomed heads.

Power Tools

Power tools are those powered

pneumatically or by electricity,

gasoline, hydraulics or gun

powder.

1. Consult the manufacturer

manual for proper use,

maintenance and repair

instructions.

2. Never carry a tool by its

cord or hose.

SAFETY TOPIC 24

Tools Safety

106

3. Wear appropriate

eye, face, hand, foot,

hearing, and respiratory

protection.

4. Never operate power

tools while wearing

loose clothing, jewelry or

anything else that could

catch in moving parts.

5. Never remove safety

guards, except during

maintenance and

cleaning. When you

do remove a guard,

immediately replace it

upon completion.

6. Disconnected tools

from their energy

source when changing

attachments or

conducting repairs /

maintenance on the tool.

7. Never turn the tool

on while the guard is

removed.

8. Never modify safety

guards.

SAFETY TOPIC 24

Tools Safety 9. Keep your ngers away

from moving parts. Always

turn off the equipment

before removing any debris.

10. Do not use or store tools in

wet or damp locations.

11. Operate gasoline tools only

in well ventilated area or

outdoors.

12. Always use safety cans for

ammable and combustible

liquids.

13. Turn off gasoline powered

equipment before refueling.

14. Be aware of and warn

others while operating a

tool or piece of equipment

that can shoot objects at

very high speeds, such

as pneumatic or powder

actuated tools.

107

The following precautions shall

be applied when transporting and

handling tubular goods (e.g., drill

pipe, casing, and line pipe):

1. All personnel not assisting in

the operation shall stand clear

of the loading/unloading area.

2. Conduct land-based loading

/ unloading on level ground

wherever possible.

3. Drivers shall check in with

the person-in-charge upon

entering the facility, work

area, or well location.

4. Properly secure all loads

during any truck trailer

movement at the loading/

unloading location.

5. The carrier is responsible

for providing sufcient load

securing equipment (e.g.,

chains, straps, and stakes).

6. The driver is responsible for

positioning the load on the

trailer and breaking the load.

7. Follow proper guidelines

for loading, checking,

and unloading pyramid or

stripped loads.

8. For pipe removed in bundles,

the pipe shall be bundled /

slung in approximately equal

loads.

9. For pipe removed with S

hooks, caution shall be taken

to ensure the S hooks remain

engaged. No more than four

joints shall be picked up at

any one time.

The following safety rules

SAFETY TOPIC 25

Tubular Goods

108

apply to drivers of vehicles

supplied by Petro Rabigh and

also vehicles operated by

contractors or others at Petro

Rabigh premises. Drivers of

vehicles are responsible for the

safe operation of their vehicles,

particularly in relation to speed.

Before You Can Drive

1. All drivers shall hold a

valid (Saudi Arab) driver’s

license.

2. All drivers shall immediately

report any changes in

license status or ability to

drive to their supervisor.

3. Drivers who operate Petro

Rabigh vehicles shall have

valid Driver Improvement

Program certication.

Preparing to Drive

1. Drivers shall perform a 360

degree walk-around before

getting into the vehicle.

2. Drivers shall inspect the

vehicle’s safety equipment

(e.g., spare tires) before

using the vehicle.

3. Driver shall ensure vehicles

have a valid inspection

sticker and are maintained

in a safe operating

condition.

4. Drivers shall report

any unsafe conditions

immediately.

5. Drivers shall regularly

inspect and maintain

tire pressure per

the manufacturer’s

specications.

6. Drivers shall ensure

adequate supplies and

communication equipment

are available for remote

area driving.

While Driving

1. Drivers shall comply with all

applicable laws.

2. Drivers shall observe

speeds in accordance with

posted speed limits and

driving conditions.

3. The use or being under

inuence of intoxicants or

medications which cause

impairment while operating

a vehicle is prohibited.

SAFETY TOPIC 26

Vehicle Safety

109

4. Using a cell phone, eating,

or drinking is prohibited.

5. Only authorized personnel

shall drive or ride in Petro

Rabigh vehicles.

6. All occupants shall wear

seat belts.

7. Drivers shall not leave

vehicles unattended while

the engine is running.

8. Vehicles shall only be

operated or parked in

designated operations

areas, unless authorized by

a Hot Work Permit.

9. Vehicles shall not be fueled

with the engine running or

during use of any electrical

device.

10. Drivers shall report

all vehicle collisions

and moving violations

immediately, no matter how

minor.

SAFETY TOPIC 26

Vehicle Safety

110