SAUDI ARAMCO CONSTRUCTION SAFETY MANUAL

PREFACE
Dhahran, Saudi Arabia
February, 1993

The purpose of the Saudi Aramco Construction Safety Manual (CSM) is to

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

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

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February 1993 - Construction Safety Manual: Table of Contents Page

I. Administration...........................................................1
1.0SAUDI ARAMCO LOSS PREVENTION POLICY AND PROGRAM....2
1.1 Loss Prevention Policy Implementation.....................2
1.1.1 Compliance With Construction Requirements...2
1.1.2 Operating Standards and Instructions................2
1.1.3 Personal Protection.............................................2
1.1.4 Inspection............................................................ 2
1.1.5 Education and Training.......................................3
1.1.6 Motivation and Recognition...............................3
1.1.7 Job Placement.....................................................3
1.1.8 Response to Accidental Occurrences..................3
1.1.9 Contractor Safety................................................3
1.1.10Off-The-Job Safety...............................................3
1.1.11Traffic Safety.......................................................3
1.1.12Accountability.....................................................4
1.1.13Compliance Reviews...........................................4
1.2 Saudi Aramco Loss Prevention Requirements For Contractors
4
1.2.1 Non-Compliance..................................................4
1.2.2 Assistance............................................................4
1.2.3 Standards and Instructions.................................5
1.3 Contractor's Loss Prevention Program.......................5
1.3.1 Written Program.................................................5
1.3.2 Hazard Identification Plan...................................6
1.3.3 Safety Supervisor................................................6
1.3.4 Safety Discussion.................................................6

2.0SAUDI ARAMCO LOSS PREVENTION DEPARTMENT SERVICES...7

2.1 Loss Prevention Program...........................................7
2.2 Program Management Services.................................8
2.3 Program Maintenance Services.................................9

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

3.1 Reports Required by Saudi Aramco............................10
3.2 Accident Investigation...............................................11

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 3.2.1 Responsibilities for Investigation........................11
3.2.1.1 Supervisor/Safety Representative.......11
3.2.1.2 Project Manager..................................11
3.3 Cases to be Investigated............................................12
3.4 Accident Investigation Guidelines..............................12
3.5 Accident Analysis........................................................12
3.5.1 Classification.......................................................12

4.0RESPONSIBILITIES FOR SAFETY.................................................16

4.1 Contractor Senior Management.................................16
4.2 Design Engineer.........................................................16
4.3 Contractor's Safety Officer.........................................16
4.4 Construction Manager/Superintendent.....................17
4.5 Site Safety Supervisor................................................18
4.6 Equipment Manager/Supervisor................................18
4.7 Engineer/Supervisor..................................................18
4.8 Foreman....................................................................18
4.9 Worker......................................................................19

5.0EMERGENCY PROCEDURES.......................................................20
5.1 Action to be Taken.....................................................20
5.2 Contact After Office Hours.........................................20
5.3 Help in an Emergency................................................20

6.0SAFETY TRAINING.....................................................................22
6.1 Safety Training for Supervisors..................................22
6.2 Safety Training for Workmen.....................................22
6.2.1 Integrated Practices............................................22
6.2.2 Specialized Training.............................................22
6.2.3 Use of Persuasion................................................23
6.2.4 Course Requirements..........................................23
6.3 Scope of Training.......................................................24
6.3.1 Safety Training Topics For Supervisors...............25
6.3.2 Induction Safety Topics For Workmen................27

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

7.1 Initial Planning...........................................................28
7.1.1 Hazard Identification Plan...................................28

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 7.1.2 Loss Prevention Program....................................29
7.1.3 Protection of Employees and Equipment...........29
7.1.4 Transportation....................................................29
7.1.5 Lifting Equipment................................................29
7.1.6 Demolition...........................................................29
7.1.7 Excavations..........................................................29
7.1.8 Scaffolding...........................................................29
7.2 Site Layout.................................................................30
7.2.1 Site Accommodation...........................................30
7.2.2 Adequate Access Roads......................................30
7.2.3 Project Sign.........................................................30
7.2.4 Safe Means of Access and Egress........................31
7.2.5 Parking Facilities..................................................31
7.2.6 Drainage..............................................................31
7.2.7 Vehicle / Heavy Equipment Paths On Site Vs Pedestrian
Paths....................................................................31
7.2.8 Sand.....................................................................31
7.2.9 Fire Prevention....................................................31
7.2.10Site Illumination..................................................31
7.3 Storage Areas............................................................31
7.4 Welfare Facilities.......................................................32
7.5 Good Housekeeping...................................................33
7.6 Construction Sites and Materials Storage Yards.........33

8.0FIRST AID..................................................................................36
8.1 Provision of First Aid Facilities...................................36
8.2 First Aid Attendants...................................................37
8.3 First Aid Facilities At Work Site..................................38
8.4 Labor And Workmen Law..........................................40

9.0PERSONAL PROTECTIVE EQUIPMENT........................................42

9.1 Head Protection.........................................................43
9.2 Eye and Face Protection.............................................43
9.2.1 Eye Protection from Impact................................44
9.2.2 Eye Protection from Radiant Energies................44
9.2.3 Face Protection...................................................44
9.3 Hand Protection.........................................................44

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

10.0 BREATHING APPARATUS........................................................52

10.1 Selection of Equipment..............................................52
10.1.1Requirements For Use.........................................53
10.1.2Misuse.................................................................53
10.1.3Hazardous Substances........................................54
10.1.4Contaminants......................................................54
10.2 Respiratory Protective Devices..................................54
10.2.1Air Purifying Respirators.....................................54
10.2.1.1 Gas Masks............................................54
10.2.1.2 Chemical Cartridge Respirators...........55
10.2.1.3 Particulate Filter Respirators (Dust Respirators)
55
10.2.2Supplied Air Respirators......................................55
10.2.2.1 Air Line Respirators..............................55
10.2.2.2 Abrasive Blasting Respirators..............56
10.2.2.3 Air Supplied Suits.................................56
10.2.3Self Contained Breathing Apparatus (SCBA).......56
10.3 Training.....................................................................57
10.4 Safety Precautions.....................................................57
10.4.1Air Compressors..................................................57

11.0 FIRE PREVENTION..................................................................60

11.1 Before the Job Starts.................................................60
11.2 Layout........................................................................61
11.3 Equipment Protection................................................61
11.4 Control of Ignition Sources........................................62
11.5 Flammable Liquids.....................................................62
11.5.1Storage................................................................62
11.5.2Handling of Flammable Liquids...........................63
11.5.3Ventilation...........................................................63
11.6 Combustible Materials...............................................63

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 11.7 Housekeeping............................................................63
11.8 Emergency Equipment...............................................63
11.8.1Water-Type Fire Extinguisher.............................64
11.8.2Carbon Dioxide Type Extinguisher......................64
11.8.3Dry Chemical Type Extinguisher..........................64
11.8.4Pressurized Water...............................................64
11.9 Reporting a Fire.........................................................65
11.10 End-of-Shift Checks....................................................65

12.0 RADIO COMMUNICATIONS....................................................67

12.1 Equipment.................................................................68
12.1.1Remote Control Unit...........................................68
12.2 Safe Operation...........................................................68
12.3 Radio Phrases............................................................68
12.4 Phonetic Alphabet.....................................................69
12.5 International Communications Union Agreement......70
12.5.1Monitoring of Circuits.........................................71
12.5.2Secrecy Act..........................................................71
12.5.3Penalties..............................................................71
12.6 Message Priorities for Company Operations..............71
12.7 Distress Messages......................................................73
12.7.1MAYDAY..............................................................73
12.7.2Urgency Signal.....................................................74
12.7.3Priority Traffic......................................................75

13.0 TRANSPORTATION................................................................76
13.1 Driver Requirements..................................................76
13.2 Driver's Responsibilities.............................................76
13.3 Motor Vehicle Regulations: Saudi Arab Government and
Saudi Aramco.............................................................78
13.4 Vehicle Condition.......................................................78
13.5 Driver Training...........................................................80
13.6 Enforcement of Safe Driving Practices.......................80
13.7 Action Taken After a Saudi Aramco Motor Vehicle Accident
81
13.7.1Emergencies........................................................81
13.7.2Remain at Scene..................................................81

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 13.8 Passenger Seating and Seat Belts...............................82
13.9 Desert Driving............................................................82
13.9.1Stay With Vehicle................................................82
13.9.2Sand Tires............................................................82
13.10 Vehicle Admittance to Restricted Areas.....................83
13.11 Operation of Motor Vehicles Within Saudi Aramco
Communities.............................................................83
13.11.1...........................................................................Seat
Belts.....................................................................83
13.11.2 Traffic Regulations..................................83

14.0 AIRCRAFT OPERATION..........................................................84

14.1 General Operating Responsibilities............................84
14.1.1Captain/Pilot.......................................................84
14.1.2Camp Supervisors................................................84
14.2 Passenger Briefing/Instructions, General (All Aircraft Types)
85
14.3 Transportation of Dangerous Goods..........................86
14.4 Hours of Operation for Single-Engine Helicopters......86
14.5 General Precautions for Helicopters..........................86
14.5.1Life Vests.............................................................86

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II. General And Civil......................................................87
1.0 WORK PERMIT SYSTEM..........................................................88
1.1 Definitions.................................................................88
1.1.1 Restricted Areas..................................................88
1.1.2 Issuer (Operation Supervisors)............................89
1.1.3 Receiver (Authorized Craftsmen)........................89
1.1.4 Work Permit........................................................89
1.2 Issuance and Approval...............................................89
1.2.1 Power Distribution Department Clearances.......90
1.3 Precautions................................................................90
1.3.1 Checklist..............................................................90
1.3.2 Clear Area............................................................90
1.3.3 Work Stoppage....................................................90
1.4 Handling of Issued Work Permit................................90
1.5 Closing Out and Filing the Permit...............................91
1.6 Certification...............................................................91
1.7 12 Rules on Work Permit Procedure..........................91
1.8 Hold Tags and Multiple Lockouts...............................91

2.0 EXCAVATIONS, TRENCHING AND SHORING............................96

2.1 Before Work Starts....................................................99
2.2 Work Permit..............................................................99
2.2.1 Excavation near Saudi Telephone Cables...........99
2.3 Underground Obstructions........................................100
2.4 General Precautions..................................................100
2.4.1 Shoring Protective Systems.................................100
2.4.2 Personnel Protection..........................................100
2.4.3 Inspection............................................................101
2.4.4 Clearance.............................................................101
2.4.5 Mechanical Excavator.........................................101
2.4.6 Walkways............................................................101
2.5 Access and Egress......................................................101
2.6 Hazardous Atmospheres and Materials.....................101
2.6.1 Ventilation...........................................................101
2.6.1.1 Hazardous Atmospheres.....................102

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 2.6.1.2 Emergency Rescue Equipment............102
2.6.2 Exhaust Gases.....................................................103
2.6.3 Organic Lead.......................................................103
2.7 Edge Protection, Markers and Fixed Lighting.............103
2.8 Roads, Streets, and Sidewalks....................................103
2.9 Backfilling..................................................................103
2.10 Borrow Pits................................................................103

3.0 DEMOLITION..........................................................................124
3.1 Before Work Starts....................................................125
3.1.1 Responsible Supervisor.......................................125
3.1.2 Original Drawings................................................125
3.1.3 Disconnections....................................................125
3.1.4 Adjacent Structures and Public Areas.................125
3.1.5 Barricades/Signs..................................................125
3.2 Method of Demolition...............................................125
3.2.1 Demolition of Equipment Containing PCB:
Polychlorinated Biphenyl (ASKAREL)..................126
3.2.2 Demolition Of Buildings With Asbestos / Insulation
Materials.............................................................126
3.3 Stability During Demolition........................................126
3.4 Working Place Clearance...........................................126
3.4.1 Access..................................................................126
3.4.2 Glass Removal.....................................................126
3.5 Structural Steel Removal...........................................127
3.6 Tanks, Vessels and Pipe Work (Explosion Prevention)127
3.6.1 Welding and Hot Cutting.....................................127
3.6.2 Cold Cutting.........................................................127
3.6.3 Steaming and Ventilation....................................127
3.6.4 Residue Cleaning.................................................127
3.7 Protective Clothing and Equipment...........................127
3.8 Mechanical Equipment Guards..................................128

4.0 ASBESTOS AND OTHER FIBERS................................................129

4.1 Types of Asbestos......................................................129
4.2 Health Risks...............................................................129
4.3 Before Work Starts....................................................130

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 4.3.1 Air Sampling........................................................130
4.3.2 Job Details...........................................................130
4.3.3 Chest X-rays.........................................................130
4.4 Storage and Transportation.......................................130
4.5 Work Area.................................................................131
4.6 Handling and Use.......................................................131
4.6.1 Wetting/Ventilation............................................131
4.6.2 Cutting.................................................................131
4.6.3 Protective Equipment.........................................131
4.7 Protective Clothing....................................................132
4.7.1 Types...................................................................132
4.7.2 Contamination....................................................132
4.7.3 Review.................................................................132
4.8 Respiratory Equipment..............................................132
4.8.1 Type.....................................................................132
4.8.2 Use.......................................................................132
4.8.3 Care.....................................................................133
4.9 Washing and Changing Facilities................................133
4.10 Disposal of Waste Asbestos Materials/Clothing.........133
4.11 Cleanliness of Work Areas and Equipment................133

5.0 WELDING, CUTTING, AND BRAZING........................................134

5.1 Gas Welding: Oxy-Acetylene Equipment and Use.....134
5.1.1 Gases...................................................................134
5.1.2 Color Coding of Cylinders....................................135
5.1.3 Storage Of Cylinders...........................................135
5.1.4 Handling of Cylinders..........................................136
5.1.5 Inspecting Equipment.........................................137
5.1.6 Faults...................................................................139
5.1.7 Fuel Gas and Oxygen Manifolds..........................140
5.2 Electric Arc Welding...................................................140
5.2.1 Voltage................................................................140
5.2.2 Welding Connections..........................................141
5.3 Protective Measures..................................................142
5.4 Welding and Cutting: Tanks, Vessels and Drums.......144
5.5 Confined Spaces.........................................................144
5.6 Personnel Protection.................................................145

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

6.0 EXPLOSIVE MATERIALS...........................................................148

7.0 PILING OPERATIONS...............................................................149

7.1 Before Work Starts....................................................149
7.1.1 Cranes..................................................................150
7.1.2 Pile Gates.............................................................150
7.1.3 Inspection............................................................150
7.1.4 Wedges................................................................150
7.1.5 Timber Block.......................................................150
7.1.6 Ground Support..................................................151
7.2 Driving Piles...............................................................151
7.2.1 Pitching................................................................151
7.2.2 Driving.................................................................151
7.3 Pile Extraction............................................................151
7.4 General Precautions..................................................152

8.0 ROADWORKS..........................................................................153
8.1 General......................................................................153
8.2 Street and Road Construction, Excavations, and Maintenance
Traffic Controls..........................................................154

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

9.1 Working Places, General............................................156
9.1.1 Falls.....................................................................156
9.1.2 Access and Egress................................................156
9.1.3 Lighting................................................................156
9.1.4 Prevention of Falls...............................................156
9.1.5 Ramps..................................................................156
9.1.6 Falling Material...................................................157
9.1.7 Hot Surfaces........................................................157
9.1.8 Slipping and Tripping...........................................157
9.1.9 Roof Work...........................................................157
9.1.10Insecure Structures.............................................157
9.1.11Work Over Water................................................158

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 9.2 Ladders and Stepladders............................................158
9.2.1 Selection..............................................................158
9.2.2 Condition.............................................................159
9.2.3 Position................................................................159
9.2.4 Use.......................................................................160
9.2.5 Stepladders.........................................................162
9.2.6 General................................................................162
9.3 Scaffolding Components............................................163
9.4 Requirements Common to All Scaffolding..................168
9.4.1 Foundations........................................................168
9.4.2 Posts....................................................................168
9.4.3 Runners...............................................................169
9.4.4 Bearers................................................................169
9.4.5 Board Bearers......................................................169
9.4.6 Bracing.................................................................170
9.4.7 Ties......................................................................170
9.4.8 Platform Units.....................................................171
9.4.9 Guardrail Systems and Toeboards......................172
9.4.10Access..................................................................172
9.4.11Scaffold Ladders..................................................172
9.4.11.1 Portable Straight and Extension Ladders173
9.4.11.2 Vertical Ladder.....................................173
9.4.12Workmanship......................................................174
9.4.13Inspections..........................................................174
9.5 Fabricated Tubular Frame and System Scaffolding.....174
9.6 Tube and Coupler Scaffolds........................................176
9.6.1 Independent Tied Scaffold..................................176
9.6.2 Light Duty Tube and Coupler Scaffolds...............176
9.6.2.1 Design, Loading and Dimensions.........176
9.6.2.2 Platform...............................................177
9.6.2.3 Limitations...........................................177
9.6.3. Medium Duty Tube and Coupler Scaffold...........177
9.6.3.1 Design, Loading, and Dimensions........177
9.6.3.2 Platform...............................................177
9.6.3.3 Limitations...........................................178
9.6.3.4 Bearers.................................................178

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 9.6.4 Heavy Duty Tube and Coupler Scaffolds.............178
9.6.4.1 Design, Loading and Dimensions.........178
9.6.4.2 Platform...............................................178
9.6.4.3 Limitations...........................................178
9.6.4.4 Bearers.................................................179
9.7 Free-Standing Tower Scaffolds...................................179
9.7.1 General Requirements........................................179
9.7.2 Design, Loading and Dimensions........................179
9.7.3 Runners and Bearers...........................................179
9.7.4 Bracing.................................................................179
9.7.5 Ties......................................................................179
9.7.6 Platform...............................................................180
9.7.7 Access..................................................................180
9.7.8 Limitations...........................................................180
9.8 Mobile Tower Scaffolds.............................................180
9.8.1 Foundations........................................................180
9.8.2 Operation............................................................181
9.8.3 Limitations...........................................................181
9.9 Scaffolds for Tanks and Vessels..................................181
9.9.1 Bracket Scaffolds.................................................181
9.10 Special Scaffolds........................................................182
9.11 Scaffold Terminology.................................................182

10.0 HAND TOOLS AND POWER TOOLS........................................193

10.1 Hand Tools, General..................................................194
10.1.1Quality.................................................................194
10.1.2Cleanliness...........................................................194
10.1.3Repair and Storage..............................................194
10.1.4Selection..............................................................194
10.1.5Electrical Risks.....................................................194
10.2 Individual Hand Tools, Precautions............................194
10.2.1Screwdrivers........................................................194
10.2.2Hammer..............................................................195
10.2.3Chisels.................................................................195
10.2.4Picks and Shovels................................................195
10.2.5Spanners and Wrenches.....................................195
10.2.6Pipe Wrenches....................................................195

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 10.2.7Pliers....................................................................196
10.2.8Jacks....................................................................196
10.2.9Hacksaws.............................................................196
10.2.10...........................................................................Hand
saws.....................................................................196
10.3 Power Tools, General.................................................196
10.3.1Quality.................................................................196
10.3.2Repair and Storage..............................................197
10.4 Pneumatic Tools........................................................197
10.4.1General................................................................197
10.4.2Individual Tools, Precautions..............................198
10.4.2.1 Jack Hammer and Concrete Breakers..198
10.4.2.2 Rock Drill..............................................198
10.4.2.3 Grinding Machine................................198
10.5 Cartridge Operated Tools...........................................203
10.5.1General................................................................203
10.5.2Storage................................................................203
10.5.3Selection and Training of Personnel...................203
10.5.4Personal Protective Equipment..........................204
10.5.5Issue and Returns................................................204
10.5.6Work Permits......................................................204
10.5.7Use.......................................................................204
10.5.8Maintenance and Repair.....................................206
10.6 Electrically Operated Tools........................................207
10.6.1General................................................................207
10.6.2Maintenance and Storage...................................208
10.6.3Personal Protective Equipment..........................208
10.6.4Individual Tools, Precautions..............................209
10.6.4.1 Grinders...............................................209
10.6.4.2 Drills.....................................................209
10.6.4.3 Saws.....................................................209
10.6.4.4 Radial Saws..........................................210

11.0 PAINTS AND COATINGS........................................................220

11.1 Flammability Hazards of Coating Materials................220
11.1.1Flammable Materials..........................................220
11.1.2Flash Point (Definition)........................................220

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

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

12.1 General......................................................................232
12.2 Reinforcing Steel........................................................232
12.3 Bulk Concrete Handling.............................................232
12.4 Concrete Placement...................................................232
12.4.1Concrete Mixers..................................................232
12.4.2Guardrails............................................................232
12.4.3Bull Floats............................................................232
12.4.4Powered Concrete Trowels.................................233
12.4.5Concrete Buggies................................................233
12.4.6Pumpcrete Systems.............................................233
12.4.7Concrete Buckets................................................233
12.4.8Discharging on Slope...........................................233
12.4.9Back-Up Man, Truck Spotter...............................233
12.4.10 Pneumatic Hose.....................................233
12.5 Vertical Shoring.........................................................233

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 12.5.1General Requirements........................................233
12.5.2Tubular Welded Frame Shoring..........................234
12.6 Forms and Shoring.....................................................234
12.6.1General Provisions..............................................234
12.6.2Vertical Slip Forms...............................................235
12.6.3Tube and Coupler Shoring...................................235
12.6.4Single Post Shores...............................................236

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III. Mechanical Equipment And Materials.....................237
1.0 CRANES AND LIFTING EQUIPMENT.........................................238
1.1 Competent Person.....................................................239
1.2 Saudi Aramco Crane Operations (General Requirements)
239
1.3 Saudi Aramco Crane Operator Qualifications.............240
1.4 Special Crane Operating Procedures..........................240
1.5 Effect of Wind Speeds on Crane Operations...............240
1.6 Overhead Power Lines...............................................240

2.0 SLINGS AND LIFTING GEAR (RIGGING)....................................245

2.1. Safe Working Load (SWL)...........................................245
2.2. Chain Slings................................................................246
2.2.1 Grades.................................................................246
2.2.2 Repairs.................................................................246
2.3 Wire Rope Slings........................................................246
2.4 Synthetic Webbing Slings...........................................247
2.4.1 Removal from Service.........................................247
2.4.2 Repaired Slings....................................................247
2.5 Synthetic and Natural Fiber Rope Slings....................248
2.6 Care of Slings.............................................................249
2.7 Hooks........................................................................249
2.8 Spreader Bars............................................................250
2.9 Eyebolts And Safety Hoist Rings.................................250
2.10 Shackles.....................................................................251
2.11 Rigger........................................................................251

3.0 MECHANICAL EQUIPMENT......................................................257

3.1 Operators..................................................................258
3.1.1 Qualifications......................................................258
3.1.2 Licensing Requirements......................................258
3.2 Machinery Guards.....................................................259
3.2.1 Multi-Piece Tire Rims and Locking Rings.............259
3.3 General Requirements...............................................259
3.4 Compressors..............................................................260

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 3.5 Concrete Mixers and Batching Plants.........................261
3.6 Dumpers and Dump Trucks........................................262
3.7 Excavators.................................................................263
3.8 Fork Lift Trucks..........................................................264
3.9 Generators.................................................................265
3.10 Graders, Dozers, Scrapers, Loaders And Miniloaders. 266
3.11 Woodworking Machinery..........................................266

4.0 MATERIALS HANDLING...........................................................268

4.1 Planning.....................................................................268
4.2 Machine Transport....................................................269
4.2.1 Dumpers..............................................................269
4.2.2 Tractors and Trailers...........................................270
4.2.3 Conveyor Belts and Monorails............................270
4.2.4 Concrete Pumps..................................................270
4.3 Site Stores..................................................................270
4.4 Manual Handling.......................................................271

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IV. Electrical And Radiation...........................................275
1.0 ELECTRICITY............................................................................276
1.1 Voltage......................................................................277
1.2 Temporary Installations.............................................277
1.3 Hand Tools and Lighting.............................................278
1.4 Work on Live Equipment............................................279
1.5 Overhead and Underground Cables...........................280
1.6 Overhead Power Transmission and Distribution........281
1.6.1 Initial Inspections, Tests, or Determinations......281
1.6.2 De-energizing Lines and Equipment...................282
1.6.3 Emergency Procedures and First Aid..................282
1.6.4 Night Work..........................................................282
1.6.5 Work Near/Over Water......................................282
1.6.6 Hydraulic Fluids...................................................283
1.6.7 Live-Line Tools (Hot Sticks).................................283
1.6.8 Material Handling...............................................283
1.6.8.1 Unloading.............................................283
1.6.8.2 Pole Hauling.........................................283
1.6.8.3 Storage.................................................283
1.6.8.4 Framing................................................283
1.6.8.5 Attaching the Load...............................284
1.6.9 Grounding for Protection of Workers.................284
1.6.9.1 Isolation and Voltage Testing..............284
1.6.9.2 Applying and Removing Grounds........284
1.6.9.3 Grounding Distance.............................284
1.6.9.4 Removal of Grounds for Testing Purposes
284
1.6.9.5 Grounding Electrode............................284
1.6.9.6 Grounding Cables And Clamps............285
1.6.10Overhead Lines....................................................285
1.6.10.1 Metal Tower Construction...................285
1.6.10.2 Stringing/Removing De-energized Conductors
287
1.6.10.3 Stringing Adjacent to Energized Lines. 288
1.6.11Underground Lines..............................................289

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 1.6.11.1 Work in Manholes...............................290
1.6.11.2 Trenching and Excavating....................290
1.6.12Construction in Energized Substations...............291
1.6.12.1 Barricades and Barriers.......................291
1.6.12.2 Control Panels......................................291
1.6.12.3 Mechanized Equipment.......................291
1.6.12.4 Substation Fences................................291
1.7 Electric Shock.............................................................292

2.0 IONIZING RADIATION.............................................................295

2.1 Methods of Protection Against Radiation..................295
2.1.1 Distance...............................................................295
2.1.2 Time.....................................................................295
2.1.3 Shielding..............................................................296
2.2 Classification of Personnel and Exposure Limits.........296
2.2.1 Radiation Workers..............................................296
2.2.2 Non-Radiation Workers......................................296
2.2.3 Exposure Limits...................................................296
2.3 Responsibilities for Safe Handling..............................297
2.3.1 Contractor...........................................................297
2.3.2 Competent Person..............................................297
2.3.3. Radiographer.......................................................297
2.4 Shipping and Transportation......................................298
2.5 Storage Areas............................................................298

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V. Chemicals And Operations........................................300
1.0 LIQUEFIED PETROLEUM GASES...............................................301
1.1 General......................................................................301
1.2 Storage......................................................................302
1.3 Handling of Cylinders.................................................302
1.4 Leakage.....................................................................303
1.5 Transportation...........................................................304
1.6 Operation..................................................................304
1.7 Action in Case of Fire.................................................305
1.8 Bulk Installations.......................................................306
1.9 First Aid.....................................................................306

2.0 PLANT OPERATIONS...............................................................307

2.1 Additional Information On Saudi Aramco Instructions and
Standards..................................................................307
2.1.1 General Instruction Manual................................308
2.1.2 Producing Instruction Manual............................308
2.1.3 Refinery Instruction Manual...............................308
2.1.4 Saudi Aramco Engineering Standards.................308
2.2 Work Permit System..................................................308
2.3 Operation of Plant Equipment...................................308
2.4 Shutdown and Maintenance in Plant Operations.......309
2.5 Commissioning..........................................................309
2.6 Emergency Procedures: Saudi Aramco Disaster Plan.309
2.6.1 Gas Release Emergency Procedures...................310

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

3.1 Preparation................................................................312
3.1.1 SAES-A-004 (Pressure Testing)............................312
3.1.2 Supports..............................................................312
3.1.3 Vents and Drains.................................................313
3.1.4 Valves..................................................................313
3.1.5 Pipings And Joints...............................................313
3.1.6 Vacuums..............................................................313
3.2 General Requirements...............................................313

February 1993 - Table Of Contents Page

 3.3 Test Liquid.................................................................314

4.0 CHEMICALS.............................................................................316
4.1 Hazard Identification System.....................................317
4.2 Health Hazards..........................................................318
4.2.1 Inhalation Pathway Hazard.................................318
4.2.2 Skin Hazards........................................................319
4.2.3 Hazards of Swallowing Chemicals.......................319
4.3 Emergency Treatment...............................................319
4.3.1 Artificial Respiration............................................319
4.3.2 First Aid...............................................................319
4.3.3 Showers and Eyewash Fountains........................319
4.4 Fire Hazards...............................................................321
4.5 Reactivity Hazards.....................................................321
4.6 Transportation, Storage and Disposal........................321
4.6.1 Transportation....................................................321
4.6.2 Storage................................................................322
4.6.3 Containers...........................................................322
4.6.4 Disposal...............................................................322
4.7 Work on Equipment Which Has Contained Tetraethyl Lead
(Organic Lead Compounds)........................................324
4.7.1 Introduction........................................................324
4.7.2 Precautions.........................................................325

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VI. Marine.....................................................................329
1.0 COFFERDAMS.........................................................................330
1.1 Design........................................................................330
1.2 Before Work Starts....................................................330
1.3 Construction..............................................................330
1.4 Potential Hazards.......................................................331
1.4.1 Structural Collapse..............................................331
1.4.2 Overhead Loads..................................................331
1.4.3 Dislodgment of Struts and Wales.......................331
1.5 Inspection..................................................................331
1.6 Leaks..........................................................................332

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

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

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

3.1 Employment of Qualified Divers................................337
3.2 Diving Equipment......................................................338
3.2.1 Compressors........................................................338
3.2.2 Reserve Air Supply..............................................339
3.2.3 Bail-Out Equipment.............................................339
3.2.4 Maintenance.......................................................339
3.3 Safeguards.................................................................340
3.4 Physical Fitness..........................................................344
3.5 Medical Diving Emergencies: Procedures and Responsibilities
345
3.5.1 Sports Divers.......................................................345
3.5.2 Commercial Divers..............................................345
3.5.3 Coordinator, Diving Emergencies.......................345

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 3.5.4 Diving Medical Team...........................................345
3.5.5 Marine Department............................................346
3.6 Personnel Transfer at Sea..........................................346

February 1993 - Table Of Contents Page

Appendix A....................................................................349
INDEX TO APPENDIX A..................................................................350

A.1................................................................................................PROJECT
MANAGEMENT AND CONTRACTOR'S SAFETY COMPETITION SITE
REGISTRATION FORM....................................................................351

A.2
CONTRACTOR SAFETY COMPETITION, RULES OF COMPETITION352

A.3................................................................................................Saudi
Aramco Safety, Health and Environmental Requirements.............357
1. Compliance With Safety Rules - Schedule 'D'............357
2. Deviations From Safety Rules....................................357
3. Failure To Comply......................................................357
4. Saudi Aramco Assistance...........................................357
5. Loss Prevention Program...........................................358
6. Work Permits.............................................................358
7. Welding And Cutting Equipment................................358
8. Personal Protective Equipment..................................358
9. Tools And Portable Power Tools................................358
10. Cartridge Operated Tools...........................................359
11. Ladders......................................................................359
12. Scaffolding.................................................................359
13. Electrical Installations And Equipment.......................359
14. Cranes And Rigging Equipment..................................359
15. Mechanical Equipment..............................................359
16. Saudi Aramco Plant Operations.................................360
17. Transportation...........................................................360
18. Injury And Damage Reporting....................................360
19. Excavations................................................................361
20. Work Over Or Adjacent To Water..............................361
21. Fire Prevention..........................................................361
22. Formwork..................................................................361
23. Ionizing Radiation......................................................361
24. First-Aid Facilities.......................................................361

February 1993 - Table Of Contents Page

 25. Handling, Transportation And Disposal Of Hazardous
Materials And Waste.................................................362
26. Explosives..................................................................363
27. Sandblasting..............................................................363

A.4................................................................................................HAZARD
IDENTIFICATION PLAN (HIP)..........................................................364
HAZARD IDENTIFICATION PLAN:..........................................365
I. Conduct Hazards Identification Review..............365
II. List Potential Hazards..........................................365
III. Hazard Classification...........................................365
IV. Corrective Action.................................................366

February 1993 - Table Of Contents Page

Appendix B: Emergency/Disaster Planning And Response368
B.1.................................................................................................SEARCH
AND RESCUE PROCEDURES............................................................369

B.2
EMERGENCY/DISASTER PLANNING AND RESPONSE.................370
B.2.1 General Provisions.....................................................371
B.2.2 Definitions.................................................................371
B.2.3 Plan Development Action Items.................................377

February 1993 - Table Of Contents Page

Appendix C: Fire Safety Checklist For Evaluating Construction
Materials Store Yard......................................................397
C.1.................................................................................................Fire
Safety Checklist For Evaluating Construction Materials Store Yard398

February 1993 - Table Of Contents Page

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

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

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

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

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

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

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

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Appendix K: Forms........................................................421
Preliminary Accident Report.........................................................423

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

Injury Summary.............................................................................425
..............................................................................................
..............................................................................................
(Page ___of___).......................................................................425

Lift Plan For Cranes........................................................................426

Wire Rope Sling Inspection Log.....................................................427

Cartridge/Tool Issuance Control....................................................428

Emergency Reporting Instructions.................................................429

Project Management And Contractor's Safety Competition Site

Registration Form..........................................................................430

February 1993 - Table Of Contents Page

I. Administration

February 1993 - Construction Safety Manual: I. Administration Page 1

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

In fulfilling this commitment, which is as essential and equally important

as production objectives, Saudi Aramco will provide and maintain a safe
and healthful work environment and protect the public against
foreseeable hazards resulting from operations.

Loss in production and property resulting from accidental occurrences can

be minimized through good management. Loss prevention is one aspect
of this loss control philosophy and is the direct responsibility of line
management.

All management functions, including business line and associated

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

1.1 Loss Prevention Policy Implementation

1.1.1 Compliance With Construction Requirements

The application of the best petroleum industry loss

control practices minimizes risk to personnel and
property. The design, construction, modification,
operation and maintenance of facilities and equipment
and construction as practiced by Saudi Aramco and/or
contractors, will meet Saudi Arab Government and Saudi
Aramco safety requirements as covered in this manual
and in relevant General Instructions, including the

February 1993 - Construction Safety Manual: Saudi Aramco Loss Prevention Policy And Program Page 2
 Company's Engineering Standards. When conformity with
any of these requirements is impractical or not cost
effective, a waiver will be sought from the Chief Engineer.

1.1.2 Operating Standards and Instructions

Risks that cannot be eliminated through design are

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

1.1.3 Personal Protection

Personal protective equipment, periodic environmental

monitoring and bio-surveillance will be used to help to
protect all employees against exposure to safety and
health hazards (e.g., radiation, H2S, etc.) which cannot be
eliminated.

1.1.4 Inspection

Inspections to detect and correct unsafe practices and

conditions will be conducted periodically by Saudi Aramco
and/or contractor.

1.1.5 Education and Training

All employees shall be provided with ongoing safety

education and training as well as helping to develop those
skills that are required to perform, supervise and manage
assigned tasks without mishap.

1.1.6 Motivation and Recognition

Good communications, a viable suggestion system and

the recognition of good safety performance, encourages
employee participation in loss prevention programs.

February 1993 - 1.0 Saudi Aramco Loss Prevention Policy And Program Page 3
 1.1.7 Job Placement

Employees must only be assigned tasks that are

consistent with their physical capacities and job skills; this
enable employees to work without endangering
themselves or others.

1.1.8 Response to Accidental Occurrences

Site specific effective emergency response plans must be

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

1.1.9 Contractor Safety

Saudi Aramco proponent departments will monitor all

construction activity to ensure that services are
performed in conformity with Saudi Aramco loss
prevention policies, principles and practices and do not
imperil any person or property. Proponents will register
each contractor employing 50 or more persons in the
Saudi Aramco Contractor Safety Competition. (See
Appendix A - Figures A.1, A.2 and A.3.)

1.1.10 Off-The-Job Safety

Off-the-job safety training (e.g. seat belt use) shall be

vigorously practiced to provide the means for all
employees to protect themselves and their families from
harm during off-duty hours.

February 1993 - 1.0 Saudi Aramco Loss Prevention Policy And Program Page 4
 1.1.11 Traffic Safety

Operators of Company vehicles must receive defensive

driving training and driver evaluations and be in
possession of a current Saudi Arab government driver's
license. A vehicle operator will be held accountable for
the vehicle assigned to him and he must ensure that it is
always operated in a safe and lawful manner.

1.1.12 Accountability

All employees shall be held accountable for personal and

functional safety performance. An important factor in an
employee's overall job performance evaluation will be
how well the employee meets his safety responsibilities.

1.1.13 Compliance Reviews

On a selective basis, compliance reviews will be

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

1.2 Saudi Aramco Loss Prevention Requirements For

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

The requirements in Schedule 'D' are the minimum acceptable to

Saudi Aramco. Any deviation from the requirements of Schedule
'D' must be signed in writing by the Company representative.
The contractor shall also take any additional measures which the
Company representative may determine to be reasonable and

February 1993 - 1.0 Saudi Aramco Loss Prevention Policy And Program Page 5
 necessary to protect against the injury (or death) of any person,
or damage (or loss) of any property during the contractor's
performance of the work under the contract.

1.2.1 Non-Compliance

The Company representative will notify the contractor, in

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

1.2.2 Assistance

The contractor may request advice on establishing

feasible and effective safety practices for the job. The
company representative will assist the contractor's
representative by providing guidance on good safety
practices, pointing out unsafe conditions, and applying his
experience and judgment in helping to improve the
contractor's overall job safety.

1.2.3 Standards and Instructions

All work and equipment must conform to Saudi Aramco

Standards and General Instructions. Where no standard

February 1993 - 1.0 Saudi Aramco Loss Prevention Policy And Program Page 6
 or instruction is available to cover a particular item, the
contractor shall request that Saudi Aramco specify the
standard of work or equipment required. The term,
"Approved Standards" in Schedule 'D' refers to standards
which are approved by Saudi Aramco.

1.3 Contractor's Loss Prevention Program

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

1.3.1 Written Program

Prior to the commencement of contractual activity, the

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

1. Title page (B.I./J.O.)

2. Project title and brief scope of work
3. Organization chart
4. Vicinity map and key plan
5. Hazard identification plan
6. Traffic plan
7. Safety polity and assignment of responsibilities
· Prime and sub contractors
8. Desert driving
· Search and rescue procedures
9. Safety inspections
10.Safety reports and records
11.Contractor camp sanitation and safety
12.Work permit
13.Welding and cutting equipment
14.Personal protective equipment

February 1993 - 1.0 Saudi Aramco Loss Prevention Policy And Program Page 7
 15.Tools and portable power tools
16.Ladders
17.Cartridge operated tools
18.Electrical installation and equipment
19.Scaffolding
20.Cranes and rigging equipment
21.Mechanical equipment
22.Transportation
23.Saudi Aramco plant operations
24.Injury and damage reporting
25.Excavation
26.Fire prevention
27.Form work
28.First-aid facilities
· Medical evacuation procedures
29.Dust control
30.Job site inspections
31.General safety rules
32.Emergency evacuation procedures
33.Hazardous material and waste management
34.Security procedures
35.Ionizing radiation
36.Demobilization plan
37.Work over or adjacent to water
38.Explosives
39.Abrasive blasting & painting/coating
40.Lock out and tag system

1.3.2 Hazard Identification Plan

As part of the Contractor Loss Prevention Program, the

contractor shall develop a detailed Hazard Identification
Plan based on the initial hazard identification data
supplied by Saudi Aramco Project Management Team.

Prior to the start of construction, the contractor shall

conduct a hazard identification tour with the Company

February 1993 - 1.0 Saudi Aramco Loss Prevention Policy And Program Page 8
 representative and the Saudi Aramco Loss Prevention
representative. Once this has been completed, the
contractor will prepare and submit a Hazard Identification
Plan. (See Appendix A - Figures A.3 and A.4.)

1.3.3 Safety Supervisor

The contractor shall designate one or more full-time

safety supervisor(s) to coordinate and monitor the loss
prevention program. The names and addresses of the
Saudi Aramco approved safety supervisors shall be
included with the written program.

1.3.4 Safety Discussion

The contractor shall ensure that every craft and crew

supervisor holds a weekly ten-minute safety meeting with
his men to discuss hazards on the job, and review and
update procedures to prevent accidents. These weekly
meetings shall be documented and such documentation
shall be maintained and made available for review at the
Contractor's on-site office.

February 1993 - 1.0 Saudi Aramco Loss Prevention Policy And Program Page 9
2.0 SAUDI ARAMCO LOSS PREVENTION DEPARTMENT
SERVICES
A full complement of loss prevention services is provided by the area Loss
Prevention divisions.

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

2.1 Loss Prevention Program

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

2.1.1

Directing the review of new plant design in the assigned

area of operation to ensure conformity of facilities to loss
prevention engineering standards.

2.1.2

Providing input to the Board of Engineers in the

development of Saudi Aramco Engineering Standards.

2.1.3

Managing major safety reviews and incident

investigations with Saudi Arab Government officials, US.
Companies, and local area management.

2.1.4

Administering safety-related training programs for local

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

February 1993 - Construction Safety Manual: Saudi Aramco Loss Prevention Department Services Page 10
 2.1.5

Serving on special committees and task forces such as the

Radiation Protection Committee, and providing personnel
to develop or assist in the development of General
Instructions, position papers and standards.

2.1.6

Directing in-depth program reviews of area operations

involving procedures and facilities with follow-up on
implementation of recommendations resulting from these
reviews.

2.1.7

Interfacing with Government Affairs to provide input on

safety related issues to non-Saudi Aramco projects and
providing monitoring of these projects to assure
conformity.

2.2 Program Management Services

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

2.2.1

Assisting with the development of formal loss prevention

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

2.2.2

Monitoring and evaluating loss prevention systems

through the Compliance Review Program.

February 1993 - 2.0 Saudi Aramco Loss Prevention Department Services Page 11
 2.2.3

Providing project review, waiver and other technical

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

2.2.4

Analyzing, interpreting and reporting accident statistical

data.

2.2.5

Initiating and administering safety management training.

2.2.6

Coordinating response to government concerns about fire

and safety issues.

2.2.7

Serving on special accident investigation committees.

2.3 Program Maintenance Services

Superintendents and their subordinates provide program
maintenance services such as:

2.3.1

Providing technical interpretation of standards,

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

2.3.2

Conducting loss prevention policy, program and

procedural surveys and inspections.

February 1993 - 2.0 Saudi Aramco Loss Prevention Department Services Page 12
 2.3.3

Identifying and assessing processes, operations and other

risks (or hazards) and recommending solutions.

2.3.4

Initiating and administering supervisory and highly

specialized safety training beyond the capability of
operating management or training specialists.

2.3.5

Administering work permit and certain other safe work

procedures.

2.3.6

Acting as Saudi Aramco's representative to the Saudi Arab

Government on local safety issues.

2.3.7

Advising on proper selection and use of personal

protective equipment and evaluating its effectiveness.

2.3.8

Monitoring and providing input on other activities as

required to ensure proper response to accidental
occurrences, including the development of containment
and mitigation methods for liquid chemical spills or vapor
releases, conducting accident investigations and
recommending corrective measures.

February 1993 - 2.0 Saudi Aramco Loss Prevention Department Services Page 13
3.0 ACCIDENT INVESTIGATION, ANALYSIS AND
REPORTING
Much is learned through experience. A thorough investigation and
analysis of an accident can help to prevent future accidents. To learn by
experience, however, means that a system for the retrieval of information
must be set up and statistical records must be kept of injury, death and
property damage. With such a system operational, information can be
collated and analyzed to show accident patterns. The contractor can then
emphasize those areas in which safety education and training is needed
most.

The contractor is responsible for reporting accidents to Saudi Aramco and

in some cases to the Saudi Arab Government as required. This section
covers these reporting requirements and the principles behind accident
investigation and analysis.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 6.001 Notification Requirements for Incidents (Including Fires)

GI 6.003 Guide for Committees Investigating Major Incidents or

Engineering Reviews of Other Incidents

GI 6.029 Reporting and Recording Of Motor Vehicle Accidents

GI 7.026 Lifting/Elevating and Mobile Equipment Accident Reporting

Procedures

3.1 Reports Required by Saudi Aramco

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

Contractor shall ensure that an immediate report is made to the

Company Representative in the case of all:

February 1993 - Construction Safety Manual: Accident Investigation, Analysis And Reporting Page 14
 · Fatal injuries
· Injuries requiring medical attention which result in lost time
· Damage over SR 10,000 to contractor's plant or equipment
· Damage, in any amount, to Saudi Aramco's equipment or
property
· Fires
· Damage and near misses to cranes and heavy equipment (GI
7.026)

For accidents involving Contractor employee fatalities, serious

injury to two or more Contractor employees, or damage to Saudi
Aramco equipment or property, a preliminary written report
shall be submitted within 24 hours followed by a detailed written
report submitted within three days to the Company
Representative. In addition, Saudi Aramco may convene an
engineering review or investigation committee in accordance
with the requirements of GI 6.001 and GI 6.003 (see Figure I.1).

Contractor shall maintain, in a format approved by the Company

Representative, a current record showing all:

· Work injuries
· Fires
· Incidents of property damage over SR 10,000
· Motor vehicle accident
· Incidents involving damage to Saudi Aramco equipment and
property
· Damage and near misses to cranes and heavy equipment (GI
7.026)

The record shall be available for inspection at all times and shall
be submitted to Saudi Aramco on request. (See Figure I.2.)

A final written report shall be prepared and submitted to the

Company as per the provisions of GI 6.003. In the case of serious
accidents, however, a detailed account of the circumstances,
witnesses' statements and descriptive photographs are required.

February 1993 - 3.0 Accident Investigation, Analysis And Reporting Page 15

 In addition to the reports required above, the contractor must
keep a record of all injuries and damages on a form approved by
the Company (Figure I.2). A copy of this record shall be sent to
the proponent department and to the contractor's project
management. Monthly summary reports are required in
addition to the individual reports.

3.2 Accident Investigation

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

The main reasons for conducting an accident investigation are:

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

prevented;
2. To determine the point at which "unplanned" events took
over from the "planned" sequence of events;
3. To recommend what corrective action should be taken.

3.2.1 Responsibilities for Investigation

3.2.1.1 Supervisor/Safety Representative

The supervisor and/or safety representative shall

carry out an immediate investigation of any
accident which occurs within his area of
responsibility. The preliminary accident report
must be completed and submitted within 24
hours to the Saudi Aramco Company
representative with a copy to the Loss Prevention
Department. A final report on the incident shall
be submitted within three days detailing any
additional information and corrective action
needed.

February 1993 - 3.0 Accident Investigation, Analysis And Reporting Page 16

 3.2.1.2 Project Manager

The project manager shall review all accident

reports to ensure that all the necessary
corrective action has been taken and that he has
addressed any items that may require action on
his part.

3.3 Cases to be Investigated

Incidents that result in property damage or serious injuries to
personnel and hospitalization of two or more employees must be
fully investigated and reported. Unless the real cause is known,
the hazard cannot be controlled in the future. The near-miss
incident is equally important from the point of view of
prevention and should also be thoroughly investigated.

3.4 Accident Investigation Guidelines

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

1. Questioning the man in charge and finding out what was

planned.
2. Finding out the injured man's job or the normal configuration
and function of the damaged equipment or plant.
3. Questioning the injured man as soon as possible.
4. Questioning the witnesses separately as to what they
actually saw, not what they think happened.
5. Studying the equipment or plant layout and noting any signs
of misuse.

February 1993 - 3.0 Accident Investigation, Analysis And Reporting Page 17

 6. Finding the explanation of any irregularities.
7. From the information obtained, establishing the reason why
the "unplanned" events took over from those that were
"planned".
8. Recommending items of corrective action and methods of
implementing them to prevent the recurrence of the
incident.
9. Making a scaled drawing of the accident scene and
supplement that with supporting photographs.

3.5 Accident Analysis

3.5.1 Classification

Contractors can use nine main classifications to analyze

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

February 1993 - 3.0 Accident Investigation, Analysis And Reporting Page 18

 The nine classifications with their individual breakdowns
are:

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

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

1a. Falls (Of Persons on the Level) 6. Hand Tools

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

2. Handling Objects 7. Transportation

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

3. Striking Against Objects 8. Lifting Appliances

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

4. Struck by Objects 9. Hazardous Atmospheres

Falling objects Hydrogen Sulfide
Foreign bodies in eyes Others
Flying objects

February 1993 - 3.0 Accident Investigation, Analysis And Reporting Page 19

FIGURE I.1: PRELIMINARY ACCIDENT REPORT

Detailed Report Required Within 3 Days Control No_________________

Accident Location: Date Of Accident: Time Of Accident:

Company: Personnel Injured: Badge Number:

Type Of Injuries: Property Damage And Estimated

Cost Damage:

Description Of Accident:

Witness Statement(s)

What Caused The Accident:

February 1993 - 3.0 Accident Investigation, Analysis And Reporting Page 20

 What Corrective Action Has Been Taken

Signed:_______________________________________________________________
Badge No:________________________

Date Of Report:________________________________________________

Name
(Printed):______________________________________________________________
_______

Company:___________________________________________________ Job
Title:_________________________________

February 1993 - 3.0 Accident Investigation, Analysis And Reporting Page 21

FIGURE I.2: CONTRACTOR MONTHLY SAFETY REPORT

PROJECT TITLE:___________________________________
LOCATION:_________________________________

CONTRACTOR:__________________________________________________________
_____________________________

BUDGET ITEM No:._______________________________________ CONTRACT

No.:________________JOB No:_______

1. Work Injuries:

2. Fires:

3. Incidents Or Property Damage (Over SR 10,000):

4. Motor Vehicle Accidents:

5. Incidents Involving Damage To Saudi Aramco Equipment:

6. Crane, Heavy Equipment & Manlift Accidents:

7. Safety Meeting:

(A) Topics Discussed:

1.
2.
3.
4.
5.
(B) Attendance:

February 1993 - 3.0 Accident Investigation, Analysis And Reporting Page 22

 (C) Instructor(s):

Prepared By:_____________________________ Contractor Safety

Officer:_____________________________________

Signed By:____________________________________ Saudi Aramco

Representative:____________________________

Date:___________________________

February 1993 - 3.0 Accident Investigation, Analysis And Reporting Page 23

4.0 RESPONSIBILITIES FOR SAFETY
The Saudi Aramco proponent must ensure the company's safety and
accident prevention policies are clearly understood by all employees and
contractor personnel. The duties and responsibilities of employees,
supervisors, and management must be stated in writing by the company's
management. All employees should satisfactorily discharge the
responsibilities of their job, and be aware that their safety record will be
taken into account during performance appraisals.

The main responsibilities of various members of a construction team are

cited in the following:

4.1 Contractor Senior Management

1. Initiate the company's policy for the control of injury,
damage and fire.
2. Administer the policy himself or appoint a senior member of
staff to do so.
3. Know the requirements of Schedule 'D' and the relevant
parts of Saudi Arab Government Workmen's Regulations, and
ensure they are observed by his company.
4. Ensure that all supervisors are qualified and that they receive
adequate and appropriate training.
5. Make sure that in tendering, at planning stages and
throughout the contract, allowance is made for suitable and
sufficient equipment to enable the jobs to be done with
minimum risk.
6. Coordinate safety activities between Saudi Aramco,
subcontractors and any other individual contractors who may
be working on the same site.
7. Institute proper system for investigation, reporting and
estimating the cost of injury, property damage and fire loss.
Initiate analysis to discover accident trends and promote
action to prevent recurrence.
8. Reprimand any supervisor for failing to discharge
satisfactorily the responsibility allocated to him.

February 1993 - Construction Safety Manual: Responsibilities For Safety Page 24

 9. Set a personal example.
10. Ensure that a formal Hazard Identification Plan is prepared in
order to identify and correct hazards which may be
encountered during construction. (See Appendix A.4.)

4.2 Design Engineer

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

4.3 Contractor's Safety Officer

1. Advise management on the following:

· Ways to prevent injury to personnel, damage to plant

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

2. Carry out site surveys to see that only safe work methods are
in operation, that health and safety requirements are being
observed, and welfare and first aid facilities are adequate
and properly maintained.
3. Determine the cause of any accident (or dangerous
occurrence), and recommend means of preventing
recurrence of such an incident.
4. Supervise the recording and analysis of information on
injuries, damage and production loss. Assess accident trends
and review overall safety performance.

February 1993 - 4.0 Responsibilities For Safety Page 25

 5. Assist with training employees at all levels.
6. Take part in discussions on injury, damage and loss control.
7. Keep up-to-date with recommended codes of practice and
safety literature. Circulate information applicable to each
level of employees.
8. Foster within the company an understanding that injury
prevention and damage control are an integral part of
business and operational efficiency.
9. Attend job progress meetings where safety is an item on the
agenda. Report on job safety performance.

4.4 Construction Manager/Superintendent

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

· The most appropriate order and method of

performing the job.
· Allocation of responsibilities for Saudi Aramco, sub-
contractors, and other contractors.
· Storage areas, access, etc.
· Any hazards identified under the hazard identification
procedure described in Appendix A.4.
· Facilities for welfare, first aid and sanitation.
· Work permit procedures and requirements.
· Basic precautions for dealing with fire hazards.

5. Provide written instructions to establish work methods,

explain the sequence of operations, outline potential hazards
at each stage, and indicate precautions to be adopted.
6. Check over work methods and precautions with supervision
before work starts.

February 1993 - 4.0 Responsibilities For Safety Page 26

 7. Create safety awareness by promoting safety meetings,
presentations, open forum discussions and by implementing
safety training.
8. Set a personal example on site by wearing appropriate
protective clothing and equipment at all times.
9. Ensure that all accidents are reported to Saudi Aramco in
accordance with Section 3.

4.5 Site Safety Supervisor

(If different from contractor's safety officer)

1. Understand the requirements of Schedule 'D' and the

company's loss prevention policy.
2. Inspect the work site daily to report and correct unsafe
methods and conditions.
3. Keep a permanent record of all injuries, fires, motor vehicle
accidents (MVAs), property damage and crane/heavy
equipment accidents which have occurred at the site.
4. Keep a record of every weekly safety meeting on site
complete with subject discussed and a list of attendees.
5. Set a personal example.

4.6 Equipment Manager/Supervisor

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

February 1993 - 4.0 Responsibilities For Safety Page 27

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

4.8 Foreman
1. Be familiar with those parts of Schedule 'D' applicable to the
work on which subordinate workers are engaged.
2. Incorporate safety procedures in routine tasks and see that
they are obeyed.
3. Conduct weekly safety meetings with subordinates.
4. Conduct daily work site inspections to identify and correct
any existing unsafe conditions. Document and coordinate

February 1993 - 4.0 Responsibilities For Safety Page 28

 the safety inspection activities and findings with the job site
safety supervisor.
5. Correct unsafe acts, such as horseplay or the taking of
unnecessary risks.
6. Ensure that new employees are properly instructed in
precautions to be taken before they are allowed to start
work.
7. Commend men who, by action or initiative, eliminate
hazards.
8. Report accidents, unsafe conditions and defects in
equipment to immediate superiors.
9. Set a personal example.

4.9 Worker
1. Use the correct tools and equipment for the job. Use
protective clothing and equipment provided.
2. Do nothing to endanger self or work mates.
3. Keep tools in good condition.
4. Refrain from horseplay and abuse of safety devices,
equipment and welfare facilities.
5. Report any accidents, near misses or hazardous conditions to
immediate supervisor.
6. Read the Company safety rules and take note of special
safety precautions in restricted areas.
7. Obey all posted warning signs.

February 1993 - 4.0 Responsibilities For Safety Page 29

5.0 EMERGENCY PROCEDURES
Saudi Aramco departments and organizations have established disaster
and emergency response plans that are documented in general
instructions (GIs), department operating instruction manuals (OIMs),
terminal instruction manuals (TIMs), and refinery instruction manuals
(RIMs), etc. All managers and supervisors are expected to become
familiar with the emergency procedures of the plants and areas in which
any of their staff are working. Construction site-specific written
emergency procedures shall be prepared by the Contractor and submitted
as part of the Contractor's loss prevention program plan. Details of the
written procedures may be obtained from the Saudi Aramco
representative, operating supervisor, or loss prevention engineer.

General guidelines for preparing emergency response plans can be found

in the following Saudi Aramco Loss Prevention Department publication:

Guidelines For Preparing Emergency Response Plans, October

1989

5.1 Action to be Taken

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

1. All work is stopped at once.

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

Refer to the specific procedures established in each Company

operating area.

February 1993 - Construction Safety - Emergency Procedures Page 30

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

5.3 Help in an Emergency

5.3.1

In the event of an emergency situation (serious personal

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

1. By telephone: Dial the emergency telephone

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

5.3.2

When transmitting a message by telephone, radio, or

messenger, ensure that you clearly identify yourself by
giving:

· Your exact location

· Nature of emergency
· Service required and repeat the message
· Your name

February 1993 - 5.0 Emergency Procedures Page 31

 · Your badge number

Stay on the telephone until you are told to hang up. If

possible, post a lookout to direct the ambulance, fire
truck or helicopter to the right location.

February 1993 - 5.0 Emergency Procedures Page 32

6.0 SAFETY TRAINING
Good safety training is important to employees who are learning a new
trade but it is also necessary to keep supervisors and skilled operators up-
to-date with current safety technology and practices. Safe working
practices are learned when employees understand how an accident was
caused. Measures can then be taken to prevent a recurrence. People
who are trained to do their jobs correctly can also be expected to do
them safely.

INSTRUCTIONS AND STANDARDS

Schedule 'D':

Saudi Aramco Safety, Health and Environmental Requirements -

Loss Prevention Program

6.1 Safety Training for Supervisors

6.1.1

The immediate job of preventing accidents falls upon the

supervisor not because it has been arbitrarily assigned to
him, but because accident prevention and production
control are closely associated supervisory functions.

The most direct way to develop the desired attitudes and

to impart the necessary information about safety to
supervisors is to give them safety training.

6.1.2

The course for supervisors should include legal

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

February 1993 - Construction Safety Manual - Safety Training Page 33

6.2 Safety Training for Workmen
Accident prevention training for workmen should incorporate the
items listed in 6.3.2.

6.2.1 Integrated Practices

Safe working practices must be integrated into training for

specific skills.

It is expected that those who have attended recognized

training establishments will have received the necessary
safety instructions.

6.2.2 Specialized Training

Before their training is complete, new employees and new

entrants to industry are more susceptible to accidents.
Contractor's must provide safety orientation and training
for new employees.

Induction training should teach new workers to identify

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

Suitable induction courses together with job training

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

February 1993 - 6.0 Safety Training Page 34

 6.2.3 Use of Persuasion

The training providing skill and information should be

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

Posters can be useful provided that:

· They are designed with due regard for the industry

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

Posters can stimulate thought on accident prevention, but

they are no substitute for organized training. The most
effective posters are those that help to reinforce safety
training.

6.2.4 Course Requirements

An induction safety course for workmen should be aimed

at specific hazards which they could encounter at a
specific job site. A suggested outline of such a course is
given in 6.3.2.

February 1993 - 6.0 Safety Training Page 35

6.3 Scope of Training
Safety training needs to be ongoing if it is to accomplish optimum
results. The program material and presentation should cover the
safety subject and be interesting enough to hold the trainee's
attention. A limited training effort, such as an occasional safety
meeting, may prompt supervisors to do a better job for a short
time, but interest starts to lag unless an effective safety training
program is in place.

Good job safety instruction not only produces more skilled

workers, but also impresses upon them the high value that the
employer places on job safety. Frequent follow-ups and
attention by the supervisor to correct work practices also help to
create understanding and to eliminate resentment, which is a
source of some undesirable work attitudes. (See 6.3.1.)

February 1993 - 6.0 Safety Training Page 36

 6.3.1 Safety Training Topics For Supervisors

1. The Law and Safety 2. Policy and Administration

Statutory requirement Effect of incentive on accident
Appropriate regulations prevention
Duties of employer and employee Human relations
Schedule 'D' (Contractual Safety Consultation
Requirements)
Safety Officer: duties, aims,
objectives

3. Safety and the Supervisor 4. Principles of Accident

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

5. Site Inspection 6. Human Behavior

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

7. Site Tidiness 8. Health

Site organization Medical examination
Relationship of site housekeeping Hazard to health on site
to accident occurrence
Site access Sanitation and welfare
Equipment storage Protective clothing
Material stacking First Aid/CPR
Materials handling

February 1993 - 6.0 Safety Training Page 37

 9. Personal Protective Equipment 10. Electricity
Eye, face, hands, feet and legs Appreciation of electrical hazards
Respiratory protective equipment Power tools
Protection against ionizing radiation Arc welding
Low voltage system
Lighting and power system on sites
Grounding/Ground fault circuit
interrupters (GFCIs)

11. Oxygen and Acetylene 12. Equipment

Equipment
Cylinder storage and maintenance Accidents related to moving parts
of machinery
Condition and maintenance of Appreciation of principles of
valves, regulators, and gauges guarding
Condition and maintenance of Importance of regular maintenance
hoses and fittings
Pressures

February 1993 - 6.0 Safety Training Page 38

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

February 1993 - 6.0 Safety Training Page 39

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

17. Lifting Tackle 18. Fire Prevention and Control

Slings - single and multi-legged Principle causes determining fire
Safe working loads (SWLs) Understanding fire chemistry
Safety hooks and eyebolts Fire fighting equipment
Cause of failure Fire fighting training
Maintenance and examination

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

February 1993 - 6.0 Safety Training Page 40

 6.3.2 Induction Safety Topics For Workmen

1. Hazard Identification Procedure

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

2. Precautions Against the Above Hazards

· Simple precautions that can be taken by

workmen on site.

3. Personal Protective Equipment

· What is available
· How to obtain it
· Correct use and care

4. Health

· Site welfare facilities

· Potential health hazards
· First Aid/CPR

5. Duties of the Company

· Brief outline of the responsibilities of the

Company by law
· Details of Company's accident prevention
policy
· Saudi Aramco Safety and Loss Prevention
Requirements For Contractors (Schedule 'D')

February 1993 - 6.0 Safety Training Page 41

 · Saudi Arab Labor Law

6. Employee's Duties

· Brief outline of responsibilities of employee

under law
· Explanation of how new employees fit into
the Company's plan for accident prevention.

February 1993 - 6.0 Safety Training Page 42

7.0 SITE PLANNING AND HOUSEKEEPING
This section outlines the procedure to be followed prior to and during a
contract. It cannot claim to cover every type of contract that is likely to
occur, but it does provide a detailed logical process to serve as a guide in
deciding upon a plan of action.

INSTRUCTIONS AND STANDARDS

Saudi Aramco Standards:

GI 1021.000 Street And Road Closure And Excavations, Reinstatement

And Traffic Controls

SAES-P-123 Lighting; Illumination Requirements

SAES-B-007C Portable, Mobile and Auxiliary Fire-Fighting Equipment

Appendix C: Typical Construction Materials Store Yard.

Fire Safety Checklist for Evaluating Construction Materials
Store Yard

Schedule 'D':

Saudi Aramco Safety, Health and Environmental

Requirements (See Appendix A)

National Fire Protection Association:

NFPA 80-A Protection of Buildings from Exterior Fire Exposures

NFPA 231 - Appendix 'C'

Protection of Outdoor Storage

7.1 Initial Planning

Prior to the start of any contract, an analysis is made by the
contractor to ensure that construction will be conducted in a safe
manner. Similarly, accident prevention is analyzed, both at the

February 1993 - Construction Safety Manual: Site Planning And Housekeeping Page 43
 planning stage and throughout the contract, so that the
contractor will be able to eliminate or reduce accidents.
Accident prevention is a real factor in the economic success of all
contracts.

Among other factors that must be considered at the initial

planning stage are: results of a Hazard Identification Plan, loss
prevention program, protection of employees and equipment,
transportation, lifting equipment, excavation, scaffolding and
work in restricted areas requiring work permits.

7.1.1 Hazard Identification Plan

The contractor shall conduct a Hazard Identification tour

with the Company and Saudi Aramco Loss Prevention
representatives to identify potential hazards prior to
construction start-up.

7.1.2 Loss Prevention Program

A loss prevention program required in Schedule 'D' for

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

7.1.3 Protection of Employees and Equipment

Schedule 'D' details the requirements to be followed by

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

February 1993 - 7.0 Site Planning And Housekeeping Page 44

 7.1.4 Transportation

The contractor must provide transportation to and from

the site for his employees.

Saudi Aramco requires that employees must be

transported only in the passenger compartment of
vehicles. (See Section I.13.) The provision of buses for
larger sites will have to be considered. Inspection and
maintenance of vehicles and the selection and training of
drivers are other major considerations.

7.1.5 Lifting Equipment

Cranes, hoists and lifting equipment should be considered

well ahead of actual requirements both from the point of
view of economical use and the safety of personnel and
equipment. Lift plans shall be submitted as required.
(See Section III.1 and III.2.)

7.1.6 Demolition

Some contracts in existing plant areas may require

demolition before new work can begin. Only minor
demolition should be done by construction personnel.
Specialist contractors should be employed for the
demolition of larger structures. (See Section II.3.)

7.1.7 Excavations

Timber for shoring, steel sheet piles, etc. should be

present on site prior to starting excavation work. All
excavation work will be closely supervised by experienced
staff. (See Section II.2.)

7.1.8 Scaffolding
For all work carried out above ground level where no
permanent work place is available, temporary work places
in the form of scaffolding must be provided. An adequate

February 1993 - 7.0 Site Planning And Housekeeping Page 45

 supply of scaffold material must be on site. There must
be sufficient experienced men capable of erecting and
dismantling the scaffolding properly. Ladders, built to an
acceptable standard, must be supplied and readily
available for access to elevated work areas. (See Section
II.9.)

7.2 Site Layout

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

Items to be considered under site layout include the following:

7.2.1 Site Accommodation

This includes shacks, storage huts, compounds, racking

areas, lock-up boxes, office buildings, etc.

7.2.2 Adequate Access Roads

To be kept clear and unobstructed at all times.

7.2.3 Project Sign

Erect project sign at the main entrance to the

construction site and other sites, i.e., office, laydown yard,
fabrication yard, etc., as designated by the Company
representative.

The sign shall be a minimum of four feet in height, and

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

The sign shall list:

· PROJECT MANAGEMENT ORGANIZATION

February 1993 - 7.0 Site Planning And Housekeeping Page 46

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

The sign shall be erected within two weeks after the

contractor has started work on site. Contractor shall also
erect and maintain sufficient signs on or near the site to
direct delivery vehicles and visitors to the work site.

Example of Job Site Sign:

SAUDI ARAMCO/CENTRAL AREA PROJECTS

SAUDI ARAMCO BUILT GOVERNMENT SCHOOLS
BOYS SECONDARY - DAMMAM BI (2510) (ERC. 1990)
CONTRACTOR:
NAME
PO. BOX
LOCATION
TELEPHONE NUMBER
SAUDI ARAMCO REPRESENTATIVE
TEL. - OFFICE/TEL. - HOME

7.2.4 Safe Means of Access and Egress

To be provided on site wherever employees are likely to

go; these must be kept clear and unobstructed at all
times.

7.2.5 Parking Facilities

To be provided in clearly defined areas on site.

7.2.6 Drainage

The site should have good drainage and be graded in such

a way that water does not pool up during construction.

February 1993 - 7.0 Site Planning And Housekeeping Page 47

 7.2.7 Vehicle / Heavy Equipment Paths On Site Vs Pedestrian
Paths

Pathways for workmen must be clearly marked and

distinct from vehicular travel routes on site.

7.2.8 Sand

In sand dune areas that might lie adjacent to or around a

construction site, consideration should be given to the
movement or build up of sand.

7.2.9 Fire Prevention

Suitable fire extinguishers must be readily available on

site. The area around fire extinguishers or hydrants must
be kept clear so that they are readily accessible in case of
emergency. They must be regularly inspected and
maintained. Site personnel must be trained in the use of
fire fighting equipment. (See Section I.11).

7.2.10 Site Illumination

Adequate lighting must be provided in all areas of the job

site in accordance with SAES-P-123.

The National Electric Code and National Fire Protection

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

7.3 Storage Areas

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

February 1993 - 7.0 Site Planning And Housekeeping Page 48

 7.3.1

Storage areas must be adequate for all material and

equipment to be stored.

7.3.2

They should not be within 15 meters (50 feet) of

permanent or temporary structures.

7.3.3

Storage areas should be clearly marked.

7.3.4

They should have directional signs to facilitate speedy

delivery.

7.4 Welfare Facilities

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

7.4.1

Canteen or eating area adequate for total work force

must be provided. This area shall be clean of refuse and
meet Saudi Aramco Sanitary Code requirements.

7.4.2

Rest area must be provided.

7.4.3

Adequate toilet and washing facilities must be provided.

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

February 1993 - 7.0 Site Planning And Housekeeping Page 49

 7.4.4

An adequate supply of drinking water must be available.

Common drinking cups or dips are prohibited.

7.4.5

First aid facilities must be supplied and arrangements

made for medical care and for emergency situations.

7.4.6

Where necessary, safe smoking areas must be provided,

with the concurrence of the responsible area Loss
Prevention office.

7.5 Good Housekeeping

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

Covered containers, drums, etc., should be provided at various,

clearly marked locations throughout the work site. The
containers should be emptied daily at approved rubbish dumps.

7.6 Construction Sites and Materials Storage Yards

(See Appendix C)

7.6.1

The contractor's engineer shall establish the perimeter of

the site by agreement with the proponent department.
He may consult the Loss Prevention Department for
assistance.

February 1993 - 7.0 Site Planning And Housekeeping Page 50

 7.6.2

The perimeter fence for construction sites and materials

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

7.6.3

The fence shall be frequently inspected by a

representative of the contractor's engineer.

7.6.4

Any access paths through the proposed site shall be

rerouted outside the perimeter. Loss Prevention
Department is to be consulted on any such rerouting.

7.6.5

Where a fence crosses existing roads, red and white, blue

and white, or black and reflective yellow (or white) flags
shall be fastened to the fence. If access is blocked, a
dead-end sign will be erected on the approach to the
fence with the distance of the obstruction marked below
the sign. However, if there is a temporary by-pass, a
"DIVERSION AHEAD" sign shall be erected on the
approach to the fence and diversion arrows showing the
route shall be displayed on the fence in black and yellow
(or white) reflective material.

7.6.6

A suitable number of soundly constructed access gates

shall be provided. The number of access gates will be
kept to a minimum on main thoroughfares (See NFPA 231
Appendix 'C'). A minimum of two fifteen-foot wide gates
are required.

February 1993 - 7.0 Site Planning And Housekeeping Page 51

 7.6.7

Standard Saudi Arab Government stop signs will be fixed

to the inside of the vehicle access gates.

7.6.8

Temporary signs should be erected to route traffic in the

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

7.6.9

While not in use all power driven construction equipment

must have the ignition locked and key removed. If there
is no lock for the cab and access can be readily made into
the engine compartment, then the machine must be
made immobile by disconnecting the battery or by any
other means especially if the equipment is left outside the
perimeter. This must be carried out before leaving the
equipment unattended.

7.6.10

Crane booms, bulldozer blades, and front end loader

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

7.6.11

Job site electrical power must be de-energized at night

unless required for specific lighting facilities or used by a
night watchman.

7.6.12

February 1993 - 7.0 Site Planning And Housekeeping Page 52

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

7.6.13

Any excavation or obstruction of any kind likely to create

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

7.6.14

If large pools of water are formed which cannot be

adequately drained, these shall be separately fenced or
barricaded if they constitute a safety hazard.

February 1993 - 7.0 Site Planning And Housekeeping Page 53

 7.6.15

There shall be no indiscriminate dumping of excavation

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

7.6.16

All manhole covers will be replaced or the manhole

properly barricaded.

7.6.17

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

7.6.18

Refuse must be disposed of at a job site approved for such

purposes and the contractor must have permission to use
the site. Approved disposal sites can be those of Saudi
Aramco or local municipalities. It is forbidden for
contractors to dump refuse in any unauthorized area.

7.6.19

Clock stations can be requested from Industrial Security

provided sufficient notice is given to ensure their
availability.

7.6.20

The Saudi Aramco Project Representative shall notify the

Loss Prevention Department representative and also the
area Industrial Security Department about the time and
place for the pre-construction meeting and also the first
weekly site meeting which these departments should plan
to attend.

February 1993 - 7.0 Site Planning And Housekeeping Page 54

 7.6.21

It is the responsibility of the Company representative to

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

February 1993 - 7.0 Site Planning And Housekeeping Page 55

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

It is the responsibility of all contractors to ensure that proper first aid is

available to their employees on all job sites.

Provisions shall be made prior to start-up of the project for prompt

medical attention in case of medical emergencies.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 1321.015 Request for Air Medical Evacuation

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

Schedule 'D':

Saudi Aramco Safety, Health and Environmental

Requirements -

Injury and Damage Reporting

First Aid Facilities

8.1 Provision of First Aid Facilities

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

February 1993 - Construction Safety Manual - First Aid Page 56

 8.1.1

First aid supplies shall be kept readily available in a

cabinet designated for those supplies only. (See 8.3 for a
recommended list of cabinet contents.)

8.1.2

This cabinet shall be placed under the charge of a first aid

attendant, who shall ensure the cabinet is well stocked at
all times.

8.1.3

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

February 1993 - 8.0 First Aid Page 57

 8.1.4

Contractors shall post notices indicating the following:

1. The name of the person who is in charge of the first

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

8.1.5

Contractors on pipeline and power line work or who are

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

8.1.6

A site register shall be maintained by all contractors listing

all injuries treated. (See Figure I.3 Example.)

8.2 First Aid Attendants

8.2.1

When more than 50 persons are employed within a radius

of 15 kilometers, first aid facilities run by a nurse familiar
with first aid cardiopulmonary resuscitation (CPR)
requirements and exclusively assigned to medical duties.

February 1993 - 8.0 First Aid Page 58

 8.2.2

Those persons in charge of first aid supplies on smaller

sites with less than 50 workers should be trained in first
aid procedures.

8.2.3

The contractor shall provide, or make arrangements to

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

Each ambulance shall be equipped, as a minimum, with

the following supplies:

· Stretcher and blankets

· Portable oxygen
· Splints for bone fractures
· Bandages/rubber tourniquet
· Sterile wash water

8.2.4 Medical Evacuation Capabilities

Saudi Aramco has the ability to provide air medical

evacuations (Medevac) for both onshore and offshore
medical emergencies with helicopters or fixed wing
aircraft. The procedures to initiate a Medevac are
covered in GI 1321.015 and shall be incorporated in the
Contractor's Loss Prevention Program plan.

8.3 First Aid Facilities At Work Site

(Originally Published in Umm al-Qura, No. 2534 July 26, 1974)
Decision No. 404 Based on Articles 245 of Labor Law

Article I

February 1993 - 8.0 First Aid Page 59

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

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

size finger dressings.
2. A sufficient number of not less than 6 sterile
medium-size hand dressings.
3. A sufficient number of not less than 6 sterile large-
size hand dressings.
4. A sufficient supply of absorbent cotton wool for
packing and firming up splints. Such supply shall not
be less than 200 grams of cotton wool in small 25-
gram packages and two 500-gram packages.
5. A sufficient number of not less than 12 gauze
bandages 7 cm. in width.
6. A sufficient number of not less than 12 gauze
bandages 11 cm. in width.
7. Not less than 4 yards of adhesive tape in rolls, 1 cm.
in width.
8. Not less than 100 grams of Mercurochrome in
aqueous solution.
9. Two 10-gram shakers of sulfa powder for sterilization
of wounds.
10. 100 grams of aromatic ammonia solution in a glass
bottle with a glass stopper.
11. A medium-sized Thomas' thigh splint, a wooden
posterior leg splint, a wooden elbow splint, a wooden
Carr splint for the forearm, a wooden palm splint,
and other types of ready-to-use splints.
12. A minimum of 6 triangle bandages.
13. A minimum of safety pins.
14. Ointment for burns containing a disinfectant and an
analgesic.
15. A minimum of ten 70 x 70 bandages for burns.
16. A pair of scissors with blunt ends.

February 1993 - 8.0 First Aid Page 60

 17. A sufficient number of stretchers for moving injured
persons.

If work is carried out in scattered locations which are more than

300 meters apart, a separate cabinet shall be provided for every
group consisting of more than ten workmen.

Article II

The employer shall assign one or more persons to be responsible

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

Article III

An employer who employs 50 or more laborers shall provide at

the work site a first aid room which meets the following
standards:

(a) It shall meet all sanitary specifications.

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

Article IV

February 1993 - 8.0 First Aid Page 61

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

Article V

The first aid cabinet shall be of hard wood or sheet metal,

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

Article VI

An employer who employs less than fifty workmen shall assign an

appropriate number of his workmen to receive first aid training
in accordance with Article II.

Article VII

The Director General of the Department of Labor Inspection shall

be charged with implementing this decision. He is authorized to
increase the contents of the first aid cabinets or rooms in those
industries and trades requiring such an increase, to stipulate
special first aid procedures to implement the above articles, to
determine the placing (if he deems it necessary) of first aid
cabinets for any group comprising less than ten workmen, and to
fix the number of stretchers and the number of workmen to be
trained.

February 1993 - 8.0 First Aid Page 62

8.4 Labor And Workmen Law
Saudi Labor And Workmen Law
Chapter 7
Protection An Social Services
Labor And Workmen Law
Articles 134-6

Article 134

The employer shall provide first-aid services for the workmen in

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

February 1993 - 8.0 First Aid Page 63

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

Article 135

Every employer who employs more than fifty workmen shall

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

Article 136

Every employer shall prepare for each workman a medical file

showing the result of the medical examination performed on the
workman upon his employment, a description of the cases of his
illness, the stages of his treatment, and the periods of his
absence from work, provided that mention shall be made in the
file of the kinds of ordinary and occupational diseases and labor
injuries.

February 1993 - 8.0 First Aid Page 64

FIGURE I.3: INJURY SUMMARY

Injury Summary (Page ___of___)

Project:__________________________________Project No.:________________________Month &
Year:____________________
Contractor:__________________________________File No.:_________________________

Injur Name Of Badg Craft Date Of Carry Days Nature Of Injury Brief Description Of Accident
y No. Injured e Accide Over Lost And Part Of Body State What, Where, How, Why
Num nt Yes/No This Affected
ber Mon
th

February 1993 - First Aid Page 65

 Total Lost Time Total Total Man-hours
Injuries This Days Worked This Month:
Month: Lost:

Report Prepared By:________________________________

Signature:_________________________________
Title And Telephone:__________________________________________________________________

February 1993 - 8.0 First Aid Page 66

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

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

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

GI 7.027 Personnel Work Platform Operations

GI 8.002 Prescription Safety Glasses

GI 8.003 Breathing Apparatus

GI 8.005 Protective (Safety) Footwear

Saudi Aramco Engineering Standards:

SAES-A-105 Noise

SAES-H-102 Safety Requirements For Painting

Schedule 'D':

Saudi Aramco Safety, Health and Environmental

Requirements

OSHA:

Code Of Federal Regulations 1910, 1915 and 1926

February 1993 - Construction Safety Manual - Personal Protective Equipment Page 67

ASTM D120.E1-87

Standard Specifications For Rubber Insulating Gloves

ANSI Z 41-83 Personnel Protection - Protective Footwear

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

Face Protection

ANSI Z 89.1-86 Personnel Protection - Protective Headgear For

Industrial Workers - Requirements

9.1 Head Protection

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

9.1.1

Employees working in areas where there is danger of

head injury from impact; from falling or flying objects; or
from electrical shock and burns, shall be protected by
protective helmets as per ANSI referenced standards or
equivalent.

9.1.2

The suspension cradle gives a helmet its impact

distribution qualities. It is therefore essential that it be
properly adjusted to the wearer's head so there is a gap of
at least one and a half inches between the top of the
suspension cradle and the helmet shell.

9.1.3

Ancillary equipment such as ear muffs, welders shields,

etc. can be obtained to fit on helmet shells. Holes should
not be drilled into helmet to facilitate use of such

February 1993 - 9.0 Personal Protective Equipment Page 68

 equipment as this can seriously impair both the
mechanical strength and the electrical resistance of the
helmet.

9.1.4

Safety hats or helmets shall not be painted.

9.1.5

The complete helmet should be cleaned regularly with

soap and water. Helmets should be scrapped following
any penetration, high impact, or subjection to extreme
heat.

9.1.6

A safety helmet should be worn by all persons at all times

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

9.2 Eye and Face Protection

Protection of the eyes and face from injury by physical or
chemical agents or light radiation, is of prime importance in an
industrial environment. The type of protection selected will
depend on the hazard, but it should be borne in mind that all eye
protection and most face protection devices must be considered
as optical instruments. They must be selected, fitted, and used
with regard to both the type of hazard and the optical condition
of the user. (See Figures I.9 and I.9A.) The wearing of contact
lenses is not recommended in areas where eye protection is
required.

February 1993 - 9.0 Personal Protective Equipment Page 69

 9.2.1 Eye Protection from Impact

Factors to be considered in selecting impact resistant eye

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

1. Spectacles used for protection against frontal impact.

When fitted with side shields, they afford limited
protection against side impact and should not be
worn while driving if they interfere with peripheral
vision.
2. Flexible fitting goggles. A flexible frame surrounding
the lens gives protection against flying objects.
3. Cushion fitting goggles. A rigid plastic frame
surrounding the lens and a separate cushioned fitting
surface on the facing contact area gives protection
against flying objects.
4. Chipping goggles. Separate rigid plastic eyecups with
lens. Designed in two shapes, one for individuals
who do not wear spectacles and one to fit over
prescription spectacles.
5. Chemical goggles.

9.2.2 Eye Protection from Radiant Energies

In addition to damage from physical and chemical agents,

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

9.2.3 Face Protection

Face shields protect the face and neck from flying

particles, sprays of hazardous liquids, splashes of molten
metal, and hot solutions. Where required, safety

February 1993 - 9.0 Personal Protective Equipment Page 70

 spectacles and chemical goggles shall be worn under the
face shield.

9.3 Hand Protection

The kind of gloves used depends primarily upon the material or
equipment being handled and can be resistant against one or
more of the following: heat, acid, caustic, slipping, wear, fire, oil,
sharp edges, general wear and tear, cold, etc. (See Figure I.5.).
Gloves should not be used near moving machinery as they can be
caught and trap the hand before it can be withdrawn from the
glove.

9.4 Foot Protection

Foot protection used must be manufactured to the referenced
ANSI standard Z41-83 (or its equivalent). Safety footwear is
available in many styles, with special soles to resist oil, abrasion,
heat, and other abuses to which the footwear may be subjected.
Comfort is particularly important for the wearer, so safety
footwear must fit properly.

Approved safety footwear are sturdy work shoes with leather

uppers and/or leather composition with steel toe caps. Soles and
heels are "non"-slip type. Fashion type safety "toe" shoes with
canvas, nylon and/or other soft composition uppers or soles are
not considered safety shoes and are not approved by Saudi
Aramco.

9.5 Hearing Protection

Increasing attention is being paid to the problem of excessive
noise in industry. Noise can be defined as "any unwanted
sound". The intensity of noise is commonly expressed in terms of
decibels (dBA) and measured by a sound level meter. Medical
authorities state that continual exposure to noise levels above 90
dBA for an eight hour day, five day work week may endanger a
person's hearing. The safe period of exposure to a noise level is

February 1993 - 9.0 Personal Protective Equipment Page 71

 inversely proportional to the level of the noise. (See reference
SAES-A-105, Noise.)

Hearing loss will result from over-exposure to excessive noise

levels. Only after engineering and mechanical methods of
reducing noise levels have been explored, should consideration
be given to providing hearing protection to individual workmen.

Exposure to impulsive or impact noise shall not exceed the

requirements of SAES-A-105, Noise.

Whenever it is infeasible to reduce the noise levels or duration of

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

9.5.1 Ear Plugs

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

9.5.2 Ear Muffs

Ear muffs cover the external ear to provide an acoustic

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

February 1993 - 9.0 Personal Protective Equipment Page 72

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

9.6 Fall Restraining/Arresting Devices

There are several types of fall restraining devices used
throughout the construction industry. The two most commonly
used ones are the full body safety harness and the safety belt.
Harnesses are used for above ground work, where fall restraining
and arresting protection is required. Safety belts are used to
restrain the wearer at his place of work. Safety belts should not
be used as part of the fall arrest system. (See Figure I.6.)

9.6.1

Full body harnesses are required when working in areas

with no guard rails at heights above 1.82 meters (6 feet)
or for potential falls of six feet or greater. Exceptions shall
require the review and concurrence of the Loss
Prevention Department.

9.6.2

Special attention should be given to achieve a snug fit of

the safety harness as it is easy for a man to slip through
sound but badly adjusted equipment and fall.

9.6.3

No fall restraining or arresting device is any stronger than

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

9.6.4

Fall restraining/arresting devices must be stored in clean

and dry conditions away from sunlight, and must be

February 1993 - 9.0 Personal Protective Equipment Page 73

 thoroughly inspected both on issue and at the start of
each shift.

9.6.5

Fall protection devices shall be capable of supporting a

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

The maximum length of standard lanyards shall be limited

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

All fall arresting/restraining devices and hardware shall be

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

9.6.6

During all operations conducted from a personnel

platform (man basket) at any height above ground level,
fall protection devices (lanyards) shall be secured to an
anchorage point or a structural member located on the
basket which can support a minimum dead weight of
2,450 kilograms (5,400 pounds).

February 1993 - 9.0 Personal Protective Equipment Page 74

TABLE I.1: BASIC PERSONAL PROTECTIVE EQUIPMENT

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

Typical Job Classifications Basic Personal Protective

Equipment To
Be Worn (see key below)
Abrasive blast cleaner See Section II.11, Table II.7
Boiler maker 1, 8, 9, 10D, 15B
Carpenter 1, 8, 9, 10C, 15A
Electrician 1, 2, 8, 9, 10B, 15A, or B
Iron worker - structural 1, 8, 9, 10D, 12/13, & 14 A/B, 15A
Lineman 1, 8, 9, 10C, 12/13 & 14 A/B, 15A
Mason 1, 8, 9, 10C/A, 15A
Material Control Man 1, 8, 9, 10C, 15A
Mechanic/Machinist 1, 8, 9, 10C/A, 15A
Painter See Section II.11, Table II.7
Pipe fitter 1, 8, 9, 10 C/D, 15A
Plumber 1, 8, 9, 10C, 15A
Rigger 1, 8, 9, 10C, 15A
Roof worker 1, 8, 9, 10C, 12/13 & 14 A/B, 15A
Scaffold erector 1, 8, 9, 10C, 13 & 14 A/B, 15A
Sheet metal worker 1, 8, 9, 10 C/D, 15A
Welder 1A &B, 4, 8, 9, 10D,/E, 15B

Key To Personal Protective Equipment

1. Safety glasses with side shields (1A=Clear, 1B=Shaded)
2. Face shield
3. Goggles, safety impact (3A=Clear, 3B=Shaded)
4. Welding hood and skull guard (Lens shaded to suit work)
5. Respirable air fed hood with filter

February 1993 - 9.0 Personal Protective Equipment Page 75

6. Respirator, chemical cartridge
7. Respirator dust
8. Safety hat helmet
9. Safety foot wear (9A=shoes, 9B=boots)
10. Gloves. (10A= Rubber coated, 10B= Rubber molded, 10C = General purpose, 10D=
Leather, 10E=Heat resistant)
11. Ear protection (11A=Ear plugs, 11B=Ear muffs)
12. Standard safety belt
13. Full body harness
14. Lanyard 1.82m (6FD). (14A=Standard, 14B=Shock Absorbing)
15. One piece coverall (15A=Standard, 15B=Fire Resistant)

Notes: All personal protective equipment shall meet ANSI/OSHA or their

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

February 1993 - 9.0 Personal Protective Equipment Page 76

FIGURE I.4: PROTECTIVE GOGGLES, SPECTACLES, FACE SHIELDS AND HELMETS

A. Typical safety glasses/side shields B. Safety glasses/side shields

(others) C. Face shields

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

goggles (soft)

G. Typical safety goggles H. Safety goggles (others) I.

Welding helmet
TYPICAL EYE PROTECTION APPLICATIONS

Operation Hazards Protection

Acetylene-welding, Sparks, molten metal, D, E, F
cutting burning harmful rays, flying
particles
Electric arc welding Sparks, molten metal, I
intense rays, flying
particles
Chemical handling Splash, acid burns, G, H (Severe +C)
fumes
Chipping Flying particles A, B, C, E, F, G

February 1993 - 9.0 Personal Protective Equipment Page 77

 Furnace operations Glare, heat, molten D, E, F
metal
Grinding (light) Flying particles A, B, C, G
Grinding (heavy) Flying particles C, D, E, G
Laboratory Chemical splash, glass G, H (A or B +C)
breakage
Machining Flying particles A, B, C, G
Molten metals Heat, glare, sparks, D, E (A or B tinted + C)
splash
Spot welding Flying particles, sparks A, B, C, G

February 1993 - 9.0 Personal Protective Equipment Page 78

FIGURE I.4A: PROTECTION AGAINST RADIANT ENERGY

Protection against radiant energy requires the selection and use

of the proper shades of welding filter lens or plate.

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

FILTER LENS SHADE NUMBERS FOR PROTECTION AGAINST RADIANT ENERGY

Welding Operation Comfort Shade number

Shielded metal-arc welding 1/16-, 10

3/32-, 1/8-, 5/32-inch diameter
electrodes
Gas-tungsten arc welding and gas- 11
metal arc welding (nonferrous)
1/16-, 3/32-, 1/8-, 5/32-inch
diameter electrodes
Gas-tungsten arc welding and gas- 12
metal arc welding (ferrous) 1/16-,
3/32-, 1/8-, 5/32-inch diameter
electrodes
Shielded metal-arc welding 3/16-, 12
7/32-, 1/4-inch diameter
electrodes
Shielded metal-arc welding 5/16-, 14
3/8-inch diameter electrodes
Atomic hydrogen welding 10-14
Carbon-arc welding 14
Soldering 2
Torch brazing 3 or 4

February 1993 - 9.0 Personal Protective Equipment Page 79

 Light oxy fuel gas cutting, up to 1 3 or 4
inch
Medium oxy fuel gas cutting, 1 inch 4 or 5
to 6 inches
Heavy oxy fuel gas cutting, over 6 5 or 6
inches
Gas welding (light), up to 1/8-inch 4 or 5
Gas welding (medium), 1/8-inch to 5 or 6
1/2 inch
Gas welding (heavy), over 1/2-inch 6 or 8
Air-carbon arc cutting 12

February 1993 - 9.0 Personal Protective Equipment Page 80

FIGURE I.5: SPECIALIZED HAND PROTECTORS

Heat Resistant Gloves

These gloves are made from materials that provide insulation to hot or cold objects.
The purpose of this material is to give the user enough time to perform his task or to
stop handling the object before his hand is injured.

Rubber Molded Gloves Rubber Coated Gloves

These gloves are made from materials that Similar to the rubber
molded glove in performance. These
are resistant to penetration by many chemicals. gloves also have an inner
lining that improves wear ability.

(A & B) Leather Gloves

February 1993 - 9.0 Personal Protective Equipment Page 81

 These gloves are used to protect the
wearer from abrasions. They also
provide some resistance to hot/cold
surfaces, but minimal protection from
most chemicals.

(C) Welding Glove

Generally made from leather, these
gloves provide the user with
protection from hot sparks/slag during
welding. They also provide some heat
resistance.

A B C

February 1993 - 9.0 Personal Protective Equipment Page 82

Figure I.6: Typical Self-Powered Platform For Building Maintenance

February 1993 - 9.0 Personal Protective Equipment Page 83

February 1993 - 9.0 Personal Protective Equipment Page 84
10.0 BREATHING APPARATUS
Where industrial processes create hazardous atmospheric contaminants,
the first consideration should always be the application of engineering
measures to control the contaminants. In those cases where engineering
control measures are not possible, affected personnel must be supplied
with personal respiratory protective equipment.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 6.021 Safety Requirements For Abrasive Blast Cleaning

GI 8.003 Air Supplied Breathing Apparatus

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

Protection Program (Saudi Aramco Medical Services
Organization, Dhahran, Saudi Arabia)

Schedule 'D':

Saudi Aramco Safety, Health and Environmental

Requirements - Personal Protective Equipment

American National Standards:

ANSI Z88.2. - 1980

Practices for Respiratory Protection

US. Bureau of Mines:

Respiratory Protection (See 30 CFR Part II)

10.1 Selection of Equipment

A wide variety of respiratory protective equipment is available.
As each type is suitable for certain applications, it is necessary to

February 1993 - Construction Safety Manual - Breathing Apparatus Page 85

 develop an orderly method for determining the appropriate
device to be employed.

Persons should not be assigned tasks requiring the use of

respirators unless it has been predetermined by medical
examination that the worker is physically able to perform the
work and use the breathing apparatus properly.

Each user must receive instructions on the proper use and

limitations of the device, as well as demonstrations and practice
in how to fit and wear it. Personnel shall not be placed in a
hazardous environment for which the respirator is not designed,
such as a location where there is a lack of sufficient oxygen.

Consider the following factors when selecting a suitable

respiratory protective device:

1 The nature of the hazardous operation or process.

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

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

10.1.1 Requirements For Use

As with all personal protective equipment, respirators

only work if you use them correctly. For face mask

February 1993 - 10.0 Breathing Apparatus Page 86

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

10.1.2 Misuse

Workers sometimes consider respiratory equipment a

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

Common misuses of respiratory protection equipment

include:

a. Using air-purifying (chemical cartridge type)

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

February 1993 - 10.0 Breathing Apparatus Page 87

 10.1.3 Hazardous Substances

Protection is required against those hazardous substances

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

· Asbestos
· Creosol (cresylic acid)
· Hydrogen cyanide (hydrocyanic acid)
· Tetraethyl lead and its compounds
· Mercury and its compounds
· Nitroglycerine
· Organic phosphate insecticides
· Solvents

10.1.4 Contaminants

Air supplied to respiratory equipment must be free from

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

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

2 Carbon monoxide, not more than 10 parts per million
(ppm)
3 Carbon dioxide, not more than 0.10% vol.
4 Oil mist, not more than 5 mg/m3 @ NTP
5 Water vapor, not more than 0.76 mg/l
6 Particulates, none

The above standards are based on Compressed Air Gas

Association (Table No. 1) and referred to as Grade 'D'
breathing air. Respirable air quality must meet this
standard, at a minimum.

February 1993 - 10.0 Breathing Apparatus Page 88

 The air delivered to the user must be less than 100 oF
(38oC) and supplied at 6 standard cubic feet per minute (6
SCFM). Air cooling devices (e.g. vortex tubes) may be
necessary.

10.2 Respiratory Protective Devices

Respiratory protective devices can be classified as follows:

1 Air purifying respirators

2 Supplied air respirators
3 Self-contained breathing devices

10.2.1 Air Purifying Respirators

10.2.1.1 Gas Masks

The gas mask type of respirator consists of a face

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

10.2.1.2 Chemical Cartridge Respirators

Chemical cartridge respirators consist of a face
piece (usually half mask) connected directly to
one or two small containers of filters/chemicals.
The chemicals used are similar to those found in
gas mask canisters, but cartridge respirators are
for use only in atmospheres not immediately
dangerous to life or health. An area where the
chemical cartridge respirator works very well is in

February 1993 - 10.0 Breathing Apparatus Page 89

 spray painting. It is critical that the cartridge be
matched to the specific application.

10.2.1.3 Particulate Filter Respirators (Dust Respirators)

A particulate filter respirator protects against the

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

1 The resistance to breathing offered by the

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

10.2.2 Supplied Air Respirators

A supplied air respirator permits the user to breathe

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

10.2.2.1 Air Line Respirators

The air line respirator (see Figure I.8) is suitable

for respiratory protection in atmospheres not
immediately hazardous to life. Equipping the
respirator with a small cylinder of compressed air
to provide an emergency air supply qualifies the
respirator for use in immediately hazardous
atmospheres. It is particularly suited to some
types of jobs because it is light and may be worn
for long periods of time without appreciable
discomfort. For example, it is often used for

February 1993 - 10.0 Breathing Apparatus Page 90

 spray painting, insecticide spraying, welding,
metalizing and prolonged production work in
hazardous areas.

There are two basic types of air line respirators:

1 the continuous flow,

2 the pressure demand flow.

The continuous flow respirator may be

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

1 In the continuous air line respirator, a set

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

2 The pressure demand flow air line respirators

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

10.2.2.2 Abrasive Blasting Respirators

Abrasive blasting respirators are used to protect

personnel engaged in sand or other abrasive
blasting operations.

February 1993 - 10.0 Breathing Apparatus Page 91

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

10.2.2.3 Air Supplied Suits

The most extreme condition requiring respiratory

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

For these conditions, full suits of impervious

clothing with respirable air supplies are available.
This equipment must be used only by well-
trained and qualified personnel. Consideration
must be given for the clearance of safety
equipment through manholes and other
accessways. (See Figure I.9.)

10.2.3 Self Contained Breathing Apparatus (SCBA)

When entry into a hazardous atmosphere is necessary,

self contained breathing apparatus shall be used. This
equipment typically consists of a high pressure cylinder of
air, a cylinder valve, a regulator, a face piece and tube
with an exhalation valve. The need to have the mask
properly fitted before use is important. A person who
wears glasses or who has a beard cannot wear this type of
breathing apparatus as a proper seal cannot be obtained
between the mask and face.

SCBAs must be used in lieu of airline respirators when the

distance from the source of fresh air supplied via the air
line hose is greater than 91 meters (300 ft) per ANSI

February 1993 - 10.0 Breathing Apparatus Page 92

 Z88.2-1980. However, an exception from this
requirement is made in an emergency situation where use
of such equipment is necessary to escape from a
hazardous condition.

February 1993 - 10.0 Breathing Apparatus Page 93

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

10.4 Safety Precautions

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

1 Breathing air compressors shall have:

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

10.4.1 Air Compressors

February 1993 - 10.0 Breathing Apparatus Page 94

 · Air compressors shall operate at 245oF and 150 psig
maximum. (See manufacturers' specifications.)
· Intake air filters to compressors and outlet filters to
operator mask/hood are required.
· Air supplied respirator's maximum intake
temperature and pressure are 140oF (60oC) and 125
psig respectively. Filter outlet temperature to
operator's mask/hood is 100oF maximum. The
air.supply rate is 6 CFM for hoods without vortex
tube and 25 CFM for hoods with vortex tube.

February 1993 - 10.0 Breathing Apparatus Page 95

FIGURE I.7: RESPIRATORY PROTECTION

Self Contained Breathing Apparatus Airline Respirator

(SCBA)

Chemical Cartridge
Respirator

February 1993 - 10.0 Breathing Apparatus Page 96

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

February 1993 - 10.0 Breathing Apparatus Page 97

FIGURE I.8: CLEARANCE CONSIDERATIONS FOR SAFETY EQUIPMENT

Deck-mounted hatch
dimension. As angle X
increases, depth of hatch must
increase

February 1993 - 10.0 Breathing Apparatus Page 98

11.0 FIRE PREVENTION
This section covers measures to prevent fires and protect against all their
possible harmful effects, in order to avoid injury to personnel and loss of
time and materials.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 2.100 Work Permit System

GI 2.711 Fire and Safety Watch

GI 1781.001-1 Inspection/Maintenance - Fire Protection Equipment

GI 1787.000-1 Fire Reports

Abqaiq Plants Operations Instruction Manual:

No. 2.102 Fire Fighting Dispatching Procedure

Refinery Instruction Manual:

No. 1.806 Fire Watch

Saudi Aramco Engineering Standards:

SAES-B-7A Fire Water System and Design

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

Saudi Aramco Sanitary Code

Schedule 'D':

Saudi Aramco Safety, Health and Environmental

Requirements - Fire Extinguishers

National Safety Council Accident Prevention Manual for Industrial

Operations

February 1993 - Construction Safety Manual - Fire Prevention Page 99

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

11.1 Before the Job Starts

Construction within a petroleum industry complex requires
careful planning since plants and support facilities being
constructed are frequently next to those already in operation.
An accident at a construction site can have serious effects on a
nearby oil or gas facility and vice-versa, because of a large
amount of fuel present at both locations. The factors which must
be considered before the job starts include site preparation,
work permit schedules, types of work permits required and
type/quantity of equipment required on-site.

As part of this process, the contractor must take into account the
potential hazards that can be encountered on site; protection of
machinery and equipment; control of ignition sources; storage of
flammable and combustible materials; housekeeping; staff
training; and end-of-shift checks. These subjects are addressed
in the Hazards Identification Procedure prior to construction
start-up in Appendix A of this manual. This section focuses on
means of avoiding and controlling fires.

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

11.2.1

Avoid congestion around machinery and equipment

where there is a high level of activity and traffic.

February 1993 - 11.0 Fire Prevention Page 100

 11.2.2

Operations having a high fire risk, such as welding and

spray painting, should be isolated from flammable and
explosive materials or specially protected.

11.2.3

Be sure to provide adequate emergency access and

egress.

11.2.4

Storage of flammable and explosive materials in the plant

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

11.3 Equipment Protection

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

February 1993 - 11.0 Fire Prevention Page 101

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

11.4.1

Electrical equipment should be checked regularly for

defects.

11.4.2

Smoking is permitted only in designated areas.

11.4.3

Welding equipment, asphalt kettles, heating appliances

and other open flames or hot surfaces should be
segregated from combustible materials.

11.4.4

Beware of indirect sources of ignition: hot welding slag

dropped from a height for example, or sparks from a fire
under an asphalt kettle are familiar examples of this.

11.4.5

Open fires and/or open burning of materials are strictly

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

11.4.6

Proper bonding and grounding techniques shall be used

for any operation where static electricity could become an
ignition source.

February 1993 - 11.0 Fire Prevention Page 102

11.5 Flammable Liquids
Flammable liquids are those that can produce a flammable
mixture in air at ambient temperature. In Saudi Aramco, this is
defined as a fluid (liquid or gas) having a flash point of 55 oC
(130oF) or lower. Care in handling flammable fluids is of prime
importance.

11.5.1 Storage

All flammable liquids must be kept in securely capped

metal containers or steel drums on which the contents
are clearly marked. Gasoline, acetone, spirits and other
volatile liquids with flash points below 32oC (90oF) should
be kept in strong metal lockers located in well-ventilated,
non-combustible huts or sheds. Drums containing
flammable fluids shall be provided with proper bung
vents. Flammable storage areas must be securely locked
(or fenced), posted with a warning sign "Danger:
Flammable Area" and must be located at least 15 meters
(50 feet) away from the nearest building or storage area
for combustibles. No other materials should be stored
with flammable liquids.

Flammable gases in cylinders (acetylene, propane, etc.)

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

February 1993 - 11.0 Fire Prevention Page 103

 11.5.2 Handling of Flammable Liquids
(Reference NFPA 30)

In handling, the following precautions should be

observed:

1 Transportation must always be in (closed) metal

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

11.5.3 Ventilation

Gasoline and diesel powered equipment should only be

used in well-ventilated areas. Exhaust pipes should be
kept away from combustible materials. Engines must be
stopped before refueling takes place.

11.6 Combustible Materials

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

February 1993 - 11.0 Fire Prevention Page 104

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

11.8 Emergency Equipment

The Fire Protection Department area offices can assist in training
Saudi Aramco employees in the proper use of fire fighting
equipment. (See GI 1781.001. Inspection and Maintenance of
Fire Protection Equipment.)

Each contractor has a contractual obligation to provide and

maintain adequate, easily accessible fire extinguishers on the job
site (Schedule 'D'). The contractor should consult with the local
Fire Protection Unit for advice on selection of such equipment.
There are three types of fire extinguishers normally found on
construction sites: water, carbon dioxide and dry chemical types.
Contractor personnel should be aware of the fire fighting
equipment available on site and be familiar with its use.

11.8.1 Water-Type Fire Extinguisher

Water extinguishers should be available around sites

where there will be Class "A" material, such as wood,
paper, waste material, or packing crates. The typical
portable water extinguisher comes in a 9.5 liters (2-1/2
gallon) size. On construction sites within Saudi Aramco
facilities a pressurized system of fire water hydrants and
hoses will normally be available, so this type of
extinguisher will have limited use.

February 1993 - 11.0 Fire Prevention Page 105

 11.8.2 Carbon Dioxide Type Extinguisher

The carbon dioxide (CO2) type extinguisher is normally

used for controlling electrical fires. These fires take place
in motors, switch-gear, and so forth and are usually very
easily controlled by de-energizing the circuits that supply
the power. The advantage of using CO 2 in this particular
instance is that it leaves no residue in the mechanisms of
the electrical equipment and, therefore, does not further
contribute to the damage.

11.8.2.1 CAUTION

A CO2 extinguisher should never be used in

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

11.8.3 Dry Chemical Type Extinguisher

A dry chemical type extinguisher is normally used in

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

February 1993 - 11.0 Fire Prevention Page 106

 11.8.4 Pressurized Water

Where a pressurized water system is available on site, the

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

11.9 Reporting a Fire

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

The emergency telephone number used for reporting a fire or

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

11.10 End-of-Shift Checks

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

February 1993 - 11.0 Fire Prevention Page 107

 · Clean-up and removal of rubbish and waste
materials.
· Switch off electrical equipment at the mains.
Separate circuits should be provided for security
lights and other equipment that has to be left turned
on.
· Cover valuable equipment to protect it against dirt
and against the effects of water that might be used in
an emergency.
· Make a special check of smoking areas, hot
equipment, welding areas, etc. to be sure there is no
possibility of delayed ignition resulting in a fire.
· Return flammable liquids and gas cylinders to
designated storage areas.

February 1993 - 11.0 Fire Prevention Page 108

FIGURE I.9: KNOW YOUR FIRE EXTINGUISHER
Dry Chemical
Water Type Carbon Dioxide Sodium or Multi-Purpose
C02 Potassium ABC
Bicarbonate

Stored Pressure Stored Pressure

Cartridge Cartridge
Operated Operated
CLASS A FIRES - Yes No No Yes
Ordinary Combustibles
Wood, paper, trash

CLASS B FIRES - No Yes Yes Yes

Flammable Liquids and Gases
Gasoline, oil, paints, grease, etc.

CLASS C FIRES - No Yes Yes Yes

Energized electrical equipment

February 1993 - Fire Prevention Page 109

 Pull pin, unclip Pull pin, unclip Unclip hose to Unclip hose to
METHOD OF OPERATION nozzle, squeeze discharge horn, break seal and break seal and
handle and direct squeeze handle strike actuator; strike actuator;
at base of fire and blanket fire squeeze nozzle squeeze nozzle
with CO2 and direct at base and direct at base
of flames, of flames,
sweeping from sweeping from
side to side. side to side.
RANGE 30'-40' 3'-8' 5'-20' 5'20'
STOCK NUMBER 21-104-550 21-102-223 21-102-820 21-102-775

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

November 1992 Construction Safety Manual - 11.0 Fire Prevention Page 110
12.0 RADIO COMMUNICATIONS
In a widespread area such as that covered by Saudi Aramco operations, it
is not cost effective to lay down telephone lines and establish subsidiary
installations for communication. It is more feasible to develop a radio
communications network instead. The continuous development of the
Saudi Aramco radio communications system has enabled us to convey
messages to the most remote corner of the Company's operational area.

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

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 70.500 Disaster Contingency Plan - Dhahran Area

GI 80.500 Disaster Control - Refinery and Terminal - Ras Tanura

GI 1600.003 Destruction Of Obsolete/Damaged, Unneeded

Communication Equipment

GI 1601.002 Radio Asset Control And Accountability Program (RACAP)

GI 1602.001 Residential Telephone Service

GI 1602.002 Business Telephone Service Inside Aramco Communities And

Facilities

GI 1602.003 Business Telephone Service Outside Aramco Communities

And Facilities

GI 1603.001 Data Circuits, Message Switch And Facsimile Terminals

See also OIMs, RIMs, and TIMs.

February 1993 - Construction Safety Manual: Radio Communications Page 111

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

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

Manual)

No. 554.001 Disaster Control Plan - Udhailiyah Area

No. 554.002 Disaster Control Plan - Qurayyah Seawater Treatment Plant

Radio Telephone Procedure Guide:

Communications Department - Dhahran

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

12.1.1 Remote Control Unit

The remote control units located in offices are used to

control radio equipment at some other location. The unit
controls used by operating personnel are the volume
control, hand set switch, and the frequency switch. All
other controls must be set by technical personnel.

12.2 Safe Operation

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

Under certain circumstances, radio waves can cause ignition of

electric blasting caps. Radio equipment must be shut down

February 1993 - 12.0 Radio Communications Page 112

 within 91 meters (100 yards) of any blasting operations or where
electric detonators are used or stored.

Water Damaged Equipment:

Vehicle drivers and maintenance personnel are requested to

exercise great caution when washing vehicles containing radio
equipment.

12.3 Radio Phrases

AFFIRMATIVE: This means Yes

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

CORRECTION: This means that An error has been made; the

correct message is ...

DISASTER: When used on Company communications systems,

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

DISASTER DRILL: This is an exercise for training personnel to

handle disaster situations.

HOW DO YOU READ?: This means that the operator is trying to

determine if the message is being received well.

MAYDAY: This is an international radio distress signal which is

primarily intended for ships and aircraft requiring assistance to
save human lives or property.

NEGATIVE: This means No.

February 1993 - 12.0 Radio Communications Page 113

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

OVER: This means that the transmission of a message has ended,

but one station is waiting for the other to transmit.

OVER AND OUT: Do not use this phrase.

PRIORITY TRAFFIC: This is a message having preferential rating

over the routine. The expression "I have priority traffic" means
the operator has listened to the messages being transmitted and
has determined that his message is of greater urgency.

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

RESUME TRAFFIC: All stations are free to transmit routine

messages.

ROGER: This means that the operator has received and

understood the message and accepts responsibility to carry out
any instructions therein.

SAY AGAIN: Do not use the word "repeat". If a message is to be

repeated, the operator shall instruct the station to "say again
your message".

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

SPEAK SLOWLY: This phrase is used mostly in cases where

technical difficulties are causing the circuit to cut in and out.

STANDBY: Any or all operators told to STANDBY shall cease

further use of the communications circuit until further notice.

TRAFFIC: The information or signals transmitted over a

communications systems.

February 1993 - 12.0 Radio Communications Page 114

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

VERIFY: Check with originator and make certain the message is

correct.

12.4 Phonetic Alphabet

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

February 1993 - 12.0 Radio Communications Page 115

PHONETIC ALPHABET

Letter Word Pronunciation

A ALPHA AL fah
B BRAVO BRAH vo
C CHARLIE CHAR lee
D DELTA DELL ta
E ECHO ECK oh
F FOX-TROT FOKS trot
G GOLF GOLF
H HOTEL hoh TELL
I INDIA IN dee ah
J JULIET JEW lee ETT
K KILO KEY loh
L LIMA LEE mah
M MIKE MIKE
N NOVEMBER No VEM ber
O OSCAR OSS car
P PAPA Pah PAH
Q QUEBEC keh BECH
R ROMEO ROW me oh
S SIERRA See AIR rah
T TANGO TANG go
U UNIFORM YOU nee form
V VICTOR VIC tor
W WHISKEY WISS key
X X-RAY ECKS ray
Y YANKEE YANG key
Z ZULU ZOO loo

February 1993 - 12.0 Radio Communications Page 116

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

All stations must be established and operated in such a manner

as not to result in harmful interference to associated members or
members of recognized private operating organizations.

NOTE: All stations are forbidden to carry out the following:

unnecessary transmissions; the transmissions of superfluous
signals; or false (or deceptive) distress, safety, or identification
signals.

Use of profane or obscene language is a violation of the

International Agreement.

Tampering with equipment is highly dangerous because of the

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

12.5.1 Monitoring of Circuits

Most voice transmissions are transmitted by radio waves

and can easily be monitored by outside agencies. It is
forbidden to disclose or divulge any information
intercepted over the Company communications systems.

February 1993 - 12.0 Radio Communications Page 117

 12.5.2 Secrecy Act

All member nations of the ITU bind themselves to the

Secrecy Act which states: "They will take the necessary
measures to prohibit and prevent:

* The unauthorized interception of radio

communications not intended for public use.

* The divulgence of the contents, simple disclosure of

the existence, publication, or any use whatever,
without authorization, of information of any nature
obtained by the interception of radio or telephone
communications."

Supervisors should be especially alert for violations of this

kind and use maximum disciplinary action toward
violators.

12.5.3 Penalties

All persons operating the communications systems will be

held responsible for any improper operation and will be
held subject to disciplinary action.

12.6 Message Priorities for Company Operations

1 MAYDAY

2 PAN/DISASTER

3 DISASTER DRILL

4 SAFETY SIGNAL (Number 3 Priority - International

Frequencies)

5 PRIORITY TRAFFIC

6 ROUTINE

February 1993 - 12.0 Radio Communications Page 118

 12.6.1 MAYDAY

(Broadcast to all stations)

When MAYDAY is spoken three times and followed by the

words: "this is (the call station, station identification, or
other identification of the mobile station)", indicates that
a ship, aircraft, or other vehicle is threatened by grave and
imminent danger and requires immediate assistance to
save human life or property.

The message has absolute priority over all other

messages. When the message is heard, all stations shall
stop transmitting and listen to the message. The nature
of distress may be such that the operator may not be able
to complete the message or repeat.

International Search and Rescue Monitor Stations shall

'fix' the bearings of the signal and alert ships and aircraft
in the area to assist with the rescue.

All persons operating radio equipment must be

thoroughly acquainted with this type of priority message.

12.6.2 URGENCY SIGNAL

(International PAN; Company DISASTER)

This message is usually directed to a particular station.

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

Messages of this nature carry priority over all messages

except MAYDAY. Company operators use the word
DISASTER. Within Company operations DISASTER has the

February 1993 - 12.0 Radio Communications Page 119

 same priority as the word PAN for those operating on
international circuits or frequencies.

12.6.3 DISASTER DRILL

At various times the Company conducts training exercises

which are associated with familiarization and
indoctrination programs. At the beginning of such a drill,
radio stations will announce "A DISASTER DRILL is being
conducted", followed by the name of the area. When a
DISASTER DRILL is in progress, all stations whether mobile
or fixed must standby, except those having MAYDAY,
URGENCY, or DISASTER messages. The difference
between DISASTER and DISASTER DRILL must be
thoroughly understood.

12.6.4 SAFETY SIGNAL

No. 3 Priority - International Frequencies

This need only be understood by those operating on

international circuits or frequencies. The French
pronunciation of SECURITE will be spoken three times and
followed by the station identification. The SAFETY SIGNAL
is used

when a station is going to broadcast a message

concerning the safety of navigation or giving important
meteorological warnings.

12.6.5 PRIORITY TRAFFIC

Repairs to facilities involved in disasters should be

classified as PRIORITY TRAFFIC.

12.6.6 ROUTINE

All messages except those classified above should be

ROUTINE.

February 1993 - 12.0 Radio Communications Page 120

12.7 Distress Messages
(Forms and Examples)

12.7.1 MAYDAY

1 Distress Signal

The distress signal is MAYDAY, MAYDAY,

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

Give location, first.

Give the nature of the distress, second.

Give the kind of assistance required.

Complete message with any other information

which can be of assistance to rescue operations.

2 Stations Receiving Message

From the location given, the receiving stations

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

This station assumes the full responsibility of a

control station for all further radio transmissions
and all other stations remain off the air unless
directed to transmit by the control station.

February 1993 - 12.0 Radio Communications Page 121

 By virtue of acknowledging the MAYDAY
message, the receiving station assumes control
and becomes fully responsible. It may use any
means at its disposal to carry out the rescue
operation.

3 End of Mayday Distress

When the distress traffic has ceased or when

silence is no longer necessary on a circuit or
frequency which has been used for distress
traffic, the control station shall transmit the
following message:

"To all stations, to all stations, to all stations -

This is (control station identification, repeated
three times) distress traffic has ended with
(station in distress identification). All stations
resume normal traffic."

The message should be repeated at intervals in

order to assure that all stations standing by
receive the message.

IMPORTANT: The transmission of MAYDAY

messages for the purpose of training is not
permitted under any circumstances.

12.7.2 Urgency Signal

This signal indicates that the calling station has a very

urgent message to transmit concerning the safety of a
person, ship, or aircraft.

1 Signal

Radio operators, operating on international

circuits or frequencies, shall be alert for the
urgency signal which is PAN, repeated three

February 1993 - 12.0 Radio Communications Page 122

 times followed by the station call letter or
identification. The Company equivalent to
urgency signal is DISASTER.

2 Response

All stations shall cease transmitting and listen to

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

3 Procedures

All persons operating Company communications

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

4 Return to Normal

When the disaster has ended, the responsible

parties outlined in the General Instruction shall
clear the radio circuits for normal traffic.

12.7.3 Priority Traffic

Repairs to facilities involved in disasters would be

classified as priority traffic and the priority would depend
on the situation.

February 1993 - 12.0 Radio Communications Page 123

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

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 1183.215 Transporting Explosives in Company Owned/Leased/Rented

Motor Transport Vehicles

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

GI 6.025 Control of Remote Area Travel and Search/Rescue

Procedures

GI 6.029 Reporting and Recording Of Motor Vehicle Accidents

GI 6.030 Traffic and Vehicle Safety

GI 1321.015 Request for Air Medical Evacuation

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

Schedule 'D':

Saudi Aramco Safety, Health and Environmental

Requirements - Transportation.

13.1 Driver Requirements

All contractors must employ only qualified personnel as drivers
of motor vehicles. It is the responsibility of the driver's
supervisor, foreman, or superintendent to verify the driver's

February 1993 - Construction Safety Manual: Transportation Page 124

 credentials prior to his employment. It is Saudi Arab
Government law and a Company rule, that each person driving a
motor vehicle must possess and have on his person a valid Saudi
Arab Government driver's license.

13.2 Driver's Responsibilities

13.2.1

It is the responsibility of the driver to ensure that his

vehicle is safe to operate.

13.2.2

It is the responsibility of each driver to take his vehicle to

the proper facility for servicing and repairs when they are
required or scheduled.

13.2.3

The driver of the vehicle is fully responsible and

accountable for the mechanical and physical condition of
the vehicle. He must report any damage, beyond normal
wear and tear, immediately.

13.2.4

The driver is responsible for transporting materials

properly and ensuring that a load does not exceed the
manufacturer's design load capacity. All loads must be
properly secured and tied down. Materials should not
extend over the sides of the truck. Loads extending
beyond the front or rear shall be marked with a red flag.
Also such loads must be equipped with visible brake and
tail lights at their rear end points.

13.2.5

Tires which have breaks in the casing, or with exposed

fabric, shall not be used.

February 1993 - 13.0 Transportation Page 125

 13.2.6

Sand tires present a hazard if used on vehicles which are

operated at excessive speed especially when they are not
properly inflated. It is the driver's responsibility to ensure
that Saudi Aramco Transportation Department tire
inflation standards are maintained. Proper inflation
pressures are posted at the Department's tire shops.

13.2.7

Drivers shall not transport unauthorized persons in

Company vehicles. The driver's supervisor shall authorize
all passengers in the vehicle.

13.2.8

The driver and all passengers of a Company vehicle shall

wear seat belts at all times while the vehicle is in motion.

13.2.9

Drivers have full authority to refuse to transport any

passenger who refuses to use seat belts. Conversely,
passengers may refuse to ride with a driver who refuses
to wear his seat belt.

13.2.10

Passengers shall not be transported in the rear of pickups

or on truck beds.

13.2.11

Drivers should not transport more passengers than the

number of seat belts provided in the vehicle.

February 1993 - 13.0 Transportation Page 126

 13.2.12

All drivers shall be familiar with what the Company

considers unsafe driving practices and avoid them at all
times.

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

13.3 Motor Vehicle Regulations: Saudi Arab Government

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

13.3.1

Where there is no sign post indicating the maximum

speed limit, no vehicle may be driven at a speed greater
than the following:

1. 100 kilometers per hour for light motor vehicles

outside city limits. (See GI 6.030.)

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

To drive safely, speed must be reduced below the

allowable speed limit at night, or during fog, rain or sand
storm.

13.3.2

Drivers shall comply with all Saudi Arab Government and

Saudi Aramco traffic signs.

February 1993 - 13.0 Transportation Page 127

 13.3.3

All vehicles shall be parked correctly and/or in

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

13.4 Vehicle Condition

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

Vehicle Inspection Checklist:

1. The vehicle number, company name, current inspection

stickers and license plate (front and back) must be in place.

2. Seat belts are mandatory for all vehicle occupants.

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

4. Windows and windshield must be clean and free of cracks or

damage. The glass must be in good condition. The windows
must open and close properly.

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

6. All brakes (foot and hand brakes) must be in good working

order. Check the foot and hand brake mechanism for correct
operation.

February 1993 - 13.0 Transportation Page 128

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

8. Springs and shock absorbers must be in good condition with

no alignment or control problems.

9. There should be no excessive movement of the steering

wheel and no signs of damage. Steering knobs and loose
coverings are prohibited.

10. Tires should have no breaks in the tire casing or exposed

fabric and must be inflated to correct air pressure as
specified by the Transportation Department.

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

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

12. If the vehicle is fitted with a trailer, the coupling must be

intact and working correctly. The trailer should have safety
coupling chains, rear brake lights, turn signals, tail lights and
rear license plate lights.

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

14. Check that the windshield wiper blades are in good

condition, and operate properly. Inspect the rear window
wiper, if fitted.

The windshield washer should work properly and there

should be water in the washer container.

15. The speedometer should be in good working order.

February 1993 - 13.0 Transportation Page 129

 16. Test the exhaust system by starting up the engine of the
vehicle, listening for sounds and spotting any leaks associated
with it. Check to see if the tail pipe extends at least three
inches from the body of the vehicle. The tail pipe emissions
should be released from a point where they do not directly
come into contact with the driver of the vehicle or its
occupants, thereby causing any adverse health affects to any
of them.

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

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

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

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

19. The vehicle's horn must be operational.

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

Each driver must conduct a vehicle inspection whenever

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

February 1993 - 13.0 Transportation Page 130

 Passengers will be carried only in the passenger
compartment of a vehicle. All vehicle occupants must wear
seat belts. Drivers shall insist that all passengers wear seat
belts before starting the vehicle. Drivers can receive a
moving violation for not adhering to this regulation.

Loose materials are to be kept out of the driving

compartment. Do not place materials (hard hats, etc.) on
rear window shelf.

13.5 Driver Training

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

13.6 Enforcement of Safe Driving Practices

The Industrial Security Organization issues "Unsafe Driving
Practice Warning" notices.

13.6.1

Saudi Aramco drivers who commit traffic offenses are

given penalty points. Repeat offenders may receive
disciplinary action. (See GI 6.030.)

13.6.2

Contractors driving on Saudi Aramco facilities or in the

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

February 1993 - 13.0 Transportation Page 131

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

The Main Gate/Security Control Center telephone numbers are:

Dhahran: 874-
2055
Ras Tanura: 673-
5231
Abqaiq: 572-
5291
Udhailiyah: 577-
8114
Yanbu: 321-
4284
Mubarraz: 577-
2344
Abu Ali: 678-
2228
Berri: 678-
7226

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

13.7.1 Emergencies

In the event of serious injury, fire or hazardous road block

caused by an accident on Saudi Aramco facilities, the
emergency telephone number 110 should be used. For
emergencies occurring off Saudi Aramco facilities, a Main
Gate/Security Control Center telephone number can be
used (see above). This will allow both the Main
Gate/Security Control Center and Medical Controller to be

February 1993 - 13.0 Transportation Page 132

 informed and they will ensure that the proper unit will
respond to assist. When reporting any accident, make
sure the message is understood before hanging up.

13.7.2 Remain at Scene

A driver shall not leave the scene of an accident or move

his vehicle after an accident unless he needs to take an
injured person to a hospital. This is a Saudi Arab
Government law and the Traffic Department investigating
officer is the only one delegated the authority to release
vehicles involved. The Saudi Aramco Government Affairs
Representative will advise you of this release. If a
damaged vehicle is blocking traffic or is stopped on the
highway, reflective triangles must be used to warn
approaching traffic of the vehicle's presence.

13.8 Passenger Seating and Seat Belts

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

Seat belts shall be worn by the driver and passengers in all

vehicles except buses with more than 14 seats, where seat belts
are only required for drivers.

13.9 Desert Driving

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

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

that:

February 1993 - 13.0 Transportation Page 133

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

13.9.1 Stay With Vehicle

A person lost or stranded in the desert must stay with the

vehicle as it provides shelter and to make it easier for
searchers to locate him.

13.9.2 Sand Tires

Sand tires are hazardous to use when they are not

properly inflated, when they are driven at high speeds or
when the roads are wet. It is the driver's responsibility to
ensure the following requirements are met for sand tires:

VEHICLE TYPE TIRE SIZE RECOMMENDED

TIRE PRESSURE
MIN MAX
Carryall, 4x4 9.00x16 15 35
Pickup, 4x4,1/2 Ton 9.00x15 15 35
Pickup, 4x4,3/4 Ton 9.00x16 15 35
Pickup, Crewcab, 4x4, 1 11.00x16 15 35
Ton
Utility, 4x4,3/4 Ton 9.00x16 15 35
Utility, Crewcab, 4x4, 1 11.00x16 15 35
Ton

February 1993 - 13.0 Transportation Page 134

 Stake Truck, 4x4, 1 Ton 11.00x16 15 35
Welder's Truck, 4x4, 1 11.00x16 15 35
Ton

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

· 70 KPH at maximum sand tire pressure

· 20 KPH at minimum sand tire pressure

Since sand tires have a larger diameter than standard

tires, speedometer readings will not be accurate. Unless
the vehicle speedometer has been corrected to account
for the oversize tires, the driver should remember that he
is traveling approximately 10-15% faster than the
speedometer reading.

13.10 Vehicle Admittance to Restricted Areas

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

13.11 Operation of Motor Vehicles Within Saudi Aramco

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

February 1993 - 13.0 Transportation Page 135

 13.11.1 Seat Belts

All vehicles shall be equipped with seat belts for each

passenger seat in accordance with Saudi Arabian
Standards Organization (SASO).

13.11.2 Traffic Regulations

All posted speed limits shall never be exceeded and all

local traffic signs shall be obeyed.

February 1993 - 13.0 Transportation Page 136

14.0 AIRCRAFT OPERATION
This section will deal with both passenger and cargo transportation for
which Saudi Aramco aircraft are used.

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

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 1310.00 Transportation of Dangerous Articles Onboard Saudi Aramco

Aircraft

Aircraft Guidelines For Crew Managers And Aviation Remote Airfield

Operations Personnel (February 1988)

IATA Dangerous Goods Regulations (33Rd Edition, 1992)

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

14.1 General Operating Responsibilities

14.1.1 Captain/Pilot

The Captain/Pilot is in command of the aircraft at all times

and is responsible for the safety of his passengers and
cargo. He is the sole judge and will make all decisions in
determining if the weather is acceptable for flight or if
landing and take off conditions are within Company
minimum standards.

No one is allowed to "pressure" the pilot into carrying

more weight than the pilot states is acceptable.

February 1993 - Construction Safety Manual: Aircraft OperationPage 137

 The Captain/Pilot is authorized to follow any course of
action which he judges requires immediate decision or
action in the interests of safety.

14.1.2 Camp Supervisors

All camp supervisors in remote areas will familiarize

themselves with all the relevant instructions on the
movement of aircraft to and from their areas as detailed
in the "Saudi Aramco Aviation Department Policy and
Guidelines for Camp Managers".

It is to the mutual advantage of the user department and

the pilots of the Aviation Department that rules of
Aviation Safety be reviewed and applied to all operations
in remote areas. Complete cooperation and
understanding between pilots and camp supervisors is
essential for the safe and efficient operation of all
inbound and outbound aircraft.

14.2 Passenger Briefing/Instructions, General (All Aircraft

Types)
14.2.1

The pilot shall either orally brief his passengers or direct

their attention to the aircraft safety instructions.

14.2.2

Passengers should never approach fixed-wing aircraft for

boarding from the front, and they must keep well clear of
props and engines at all times.

14.2.3

A flight crew member or designated safety observer

should monitor passenger movement while they are
boarding or leaving an aircraft.

February 1993 - 14.0 Aircraft Operation Page 138

 14.2.4

Smoking is prohibited on all Saudi Aramco aircraft and on

all ramp and apron areas.

14.2.5

Seat belts must be fastened during all flights. Do not

unfasten the seat belt until the aircraft has come to a
complete stop and you are instructed to do so.

14.2.6

Passengers will comply with all flight crew or flight

attendant instructions.

14.2.7

Ear protection is supplied by Saudi Aramco where

appropriate.

14.2.8

All Saudi Aramco aircraft carry US registration. The

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

14.2.9

Other areas of briefing may include the use and handling

of special material or equipment which must be declared
and will be shipped only at the Captain's discretion.

February 1993 - 14.0 Aircraft Operation Page 139

 14.2.10

In the event of forced landing, the pilot and passengers

will stay with the aircraft. The Captain will direct
rescue/survival activities. The Aviation Department will
conduct a day and night search for the disabled aircraft.

14.3 Transportation of Dangerous Goods

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

Any questions on Dangerous Goods Transport should be

addressed to Central Area Loss Prevention Department, Aviation
Safety Officers, or the Terminal Supervisor of the nearest Saudi
Aramco airfield terminal.

14.4 Hours of Operation for Single-Engine Helicopters

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

By permission from the area supervisor, a helicopter may fly

overland up to 30 minutes after sunset if warranted by
extenuating circumstances. Operations may also authorize short
flights to continue until sunset if rescue facilities are immediately
available.

14.5 General Precautions for Helicopters

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

February 1993 - 14.0 Aircraft Operation Page 140

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

When visibility is reduced by dust or other conditions, personnel

shall exercise special caution to keep clear of the main and
stabilizing rotors.

14.5.1 Life Vests

In the event of a forced landing at sea, the float gear is

capable of supporting the helicopter. Life vest must be
worn on all over-water flights. Only the vests provided in
the helicopter should be used.

February 1993 - 14.0 Aircraft Operation Page 141

II. General And Civil

February 1993 - Construction Safety Manual: II. General And Civil Page 142
1.0 WORK PERMIT SYSTEM
The Work Permit System incorporates procedures commonly used in
industrial facilities to ensure that necessary communication takes place
and hazards are controlled.

Saudi Aramco's restricted areas are potentially hazardous. However,

knowledgeable people using proper procedures can perform work tasks
efficiently and safely. The Saudi Aramco work permit procedure is
important in maintaining a safe work environment and is a requirement
for all Saudi Aramco jobs in restricted areas.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 2.100 Work Permit System

GI 2.708 Gas Testing Procedures

GI 2.711 Fire & Safety Watch

GI 6.012 Isolation, Lockout And Use Of Hold Tags

Power Distribution Instruction:

No. 3.0 Definitions of Terms and Approved Abbreviations

No. 10.0 Power Distribution Operations

No. 11.0 Hold Orders, Clearances and Permission to Test

1.1 Definitions
1.1.1 Restricted Areas

Restricted areas are those areas or activities which have

been designated by department managers as requiring
the work permit system. These include (but are not
limited to) all areas where hydrocarbons, flammable

February 1993 - Construction Safety Manual: Work Permit System Page 143
 liquids or gases, or oxidizing agents are handled, stored,
piped, or processed in significant quantities; and critical
non-hydrocarbon operations.

The following are examples of restricted areas:

petroleum processing plants; pump stations; tank farms;
loading piers; hydrocarbon pipelines; oil wells; gas plants;
specified locations on marine vessels; gasoline service
stations; areas where explosives and industrial X-ray or
radioactive materials are used or stored; work areas
under or near power lines; confined space entry; and
material supply storage areas.

1.1.2 Issuer (Operation Supervisors)

Operation supervisors are those supervisors who are

certified by their division or department head to issue and
approve work permits in restricted areas under their
supervision.

1.1.3 Receiver (Authorized Craftsmen)

Authorized craftsmen are the craft supervisors, craftsmen,

or others who have been certified by their division or
department head to sign and receive work permits in the
case of Company employees and by sponsoring
organization heads in the case of contractors.

1.1.4 Work Permit

There are four work permits:

1 Release of Hazardous Liquids or Gases, Form 924-1

(yellow) -

This form is required when opening lines or vessels

that may release hazardous or toxic materials.

2 Hot Work, Form 924-2 (red) -

February 1993 - 1.0 Work Permit System Page 144

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

3 Cold Work, Form 924-3 (blue) -

This form is for work that will not produce sufficient

energy to ignite flammable atmospheres/materials.

4 Confined Space Entry, Form 924-4 (green) -

This form is required for tank cleaning, tank

inspection, work in sewers or excavations of 4 feet or
deeper.

All work in restricted areas must have at least one of the

listed work permits. Work must be performed according
to the instructions and precautions specified in the work
permit.

1.2 Issuance and Approval

The authorized receiver (authorized craftsman) must request a
work permit from a certified issuer (operation supervisor) before
doing any work in a restricted area.

The issuer will grant the work permit after he has visited the site
with the receiver, reviewed the hazards applicable to the
particular job, and is satisfied that the work can be done safely.
If the work contemplated involves any change, addition, or
deletion in the facility, the work should be reviewed by an
engineer and appropriate authorization is necessary.

Both the issuer and the receiver must hold valid work permit
certificates issued by Saudi Aramco.

February 1993 - 1.0 Work Permit System Page 145

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

Usually clearance receivers are PDD employees. Non-PDD

employees and contractors should request PDD Electric
System operators for assistance.

The following instructions apply to PDD clearances:

PDD 3.0: Definitions of Terms and Approved

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

1.3 Precautions
1.3.1 Checklist

Each permit contains a checklist of precautions against

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

1.3.2 Clear Area

One specific precaution applying to all work is to clear the

area of people not required for the job to avoid their
being exposed to unnecessary hazards. If people enter an
area where they could be exposed to undue danger, the

February 1993 - 1.0 Work Permit System Page 146

 work should be stopped until they are cleared from the
area.

1.3.3 Work Stoppage

If conditions change or become unsafe during the course

of work, the issuer or local supervisor may stop the work
and cancel the permit.

The receiver has the responsibility to stop the work and

advise the issuer or supervisor any time he feels the
safety of the job does not meet the conditions of the work
permit.

1.4 Handling of Issued Work Permit

A work permit is valid for only one shift, but it may be extended
for one additional shift with proper approval. Exceptions in
excess of 16 hours may be granted in special cases, provided
certain precautions are taken. (See GI 2.100 for details.)

The receiver of the work permit must keep the permit posted at
the job location at all times.

The receiver of a work permit must keep a copy in his possession

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

1.5 Closing Out and Filing the Permit

When the job is completed or at the end of the shift, each work
permit must be closed out by both issuer and receiver. The only
exception shall be when the distance and remoteness make
signing impractical, and it is so stated when the work permit is

February 1993 - 1.0 Work Permit System Page 147

 issued. The work permit will be filed and kept by the issuing
department for three months.

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

The superintendent of the construction organization will assure

Saudi Aramco by his signature that his employee knows both the
general instruction and his job. Contact the local Loss Prevention
office for work permit certification information.

Records of current certificate holders, with their names and the

dates issued, must be kept by each superintendent or
organization head.

1.7 12 Rules on Work Permit Procedure

(See below)

1.8 Hold Tags and Multiple Lockouts

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

1.8.2 The purpose for the Lockout System is to render controllers

inoperative, i.e., circuit breakers, disconnect switches,
valves, etc. on any systems (electrical, steam, hydrocarbon,
water, acid, etc.), where the operation of the control device
could be hazardous to personnel working on the system.

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

February 1993 - 1.0 Work Permit System Page 148

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

February 1993 - 1.0 Work Permit System Page 149

TWELVE RULES ON WORK PERMIT PROCEDURE

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

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

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

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

5) Job description and equipment used must be clearly stated on the

work permit. Be specific, issue permits for a single pump, drum,
etc.

6) All tick boxes must be correctly filled in and gas readings indicated.

7) Proper lockouts, hold tags, and blinds must be used where

applicable (multiple clips with lock, and/or chains with padlocks).

8) Work permits should be issued for the specific period of time

required to complete the job.

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

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

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

February 1993 - 1.0 Work Permit System Page 150

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

February 1993 - 1.0 Work Permit System Page 151

LOCK OUT AND TAG

Workers may be injured while working on equipment when the controls

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

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

When more than one man is going to work on a system or on a number of

pieces of equipment within the system, the multiple lockout clip enables
each man to lock out the circuit or machine control. If your man can't get
his lock on the clip, work should not proceed until a suitable clip is found.
Clips may be ordered under stock number 21-350-487; locks under stock
number 08-323-261; tags under stock number 39-378-419. Locks
belonging to contractor personnel must have one key only and should be
compatible with the Saudi Aramco system. Contractors will establish
their own lock issuing procedure complete with logging and a numbering
system.

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

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

February 1993 - 1.0 Work Permit System Page 152

FIGURE II.1: HOLD TAG

Front View

Back View

February 1993 - 1.0 Work Permit System Page 153

FIGURE II.2: LOCKOUT CLIP (TYPICAL)

February 1993 - 1.0 Work Permit System Page 154

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

Other types of excavation accidents are caused by contact with

underground pipes and cables, by falls of equipment and persons, by
persons being struck by excavating equipment, and by hazardous
atmospheres.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 1021.000 Street and Road Closure, Excavation Reinstatement and

Traffic Controls
(See Appendix D)

GI 2.100 Work Permit System

Saudi Aramco Engineering Standard:

SAES-A-111 Borrow Pit Requirements

OSHA Safety And Health Standards:

29 CFR 1926
Subpart P Excavations

DEFINITIONS:

1. Excavation

Any man-made cavity or depression in the earth's surface,

including its sides, walls, or faces, formed by earth
removal and producing unsupported earth conditions by
reason of the excavation.

February 1993 - Construction Safety Manual - Excavations, Trenching And Shoring Page 155
 2. Trench Excavation

A narrow excavation made below the surface of the

ground. In general, the depth is greater than the width,
but the width of a trench is not greater than 4.5 meters
(15 feet).

3. Accepted Engineering and Construction Practices

Plans for excavations and protective system methods shall

be submitted to Loss Prevention before work start up.

4. Protective Systems

Methods used to protect employees from cave-ins, from

materials that could fall or roll into the excavation onto
the workers or from collapse of adjacent structures.
Protective systems include supports, sloping and
benching, shields and other means to protect workers.

5. Shoring

Hydraulic, timber or mechanical systems that support the

sides of an excavation, designed to prevent cave-ins.

6. Hydraulic Shoring

A pre-engineered support system of aluminum hydraulic

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

7. Benching

A method of protecting employees from cave-ins by

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

February 1993 - 2.0 Excavations, Trenching And Shoring Page 156

 8. Sloping

A method of excavating in which the sides of an

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

9. Soil Classification System

A method of categorizing soil and rock deposits as types

A, B, and C in decreasing order of stability. Soil type is
determined by analysis of the soil's properties and how it
performs under exposure to the elements and
superimposed loads.

Type A:

Cohesive soils with an unconfined compressive strength

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

(i) The soil is fissured.

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

February 1993 - 2.0 Excavations, Trenching And Shoring Page 157

 Type B:

Soils classified as Type B are:

(i) Cohesive soils with an unconfined compressive
strength greater than 0.5 tsf (48 kPa) but less than
1.5 tsf (144 kPa).
(ii) Granular cohesionless soils including angular gravel
(similar to crushed rock), silt, silt loam, sandy loam
and, in some cases, silty clay loam and sandy loam
clay.
(iii) Previously disturbed soils except those which would
otherwise be classed as Type C soil.
(iv) Soil that meets the unconfined compressive strength
or cementation requirements for Type A, but is
fissured or subject to vibration.
(v) Dry rock that is not stable.
(vi) Material that is part of a sloped, layered system
where the layers dip into the excavation on a slope
less steep than four horizontal to one vertical (4H:1V)
but only if the material would otherwise be classified
as Type B.

Type C:

Soils classified as Type C are:

(i) Cohesive soils with an unconfined compressive
strength of 0.5 tsf (48 kPa) or less.
(ii) Granular soils including gravel, and loamy sand.
(iii) Submerged soil or soil from which water is freely
seeping.
(iv) Submerged rock that is not stable.
(v) Material in a sloped layered system where the layers
dip into the excavation or a slope of four horizontal
to one vertical (4H:1V).

February 1993 - 2.0 Excavations, Trenching And Shoring Page 158

 10. Trench Boxes:

A structure that is able to withstand the forces imposed

on it by cave-ins, and in the process, protects employees
inside the structure. (Plans for trench boxes are to be
submitted to Loss Prevention.)

2.1 Before Work Starts

In order to begin excavation work with minimum risk to men,
plant and equipment and to enable the work to proceed without
interruption, the following factors must be considered well
before the job starts:

1.) Size and purpose of the excavation.

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

Consideration of these factors will indicate the safety measures

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

February 1993 - 2.0 Excavations, Trenching And Shoring Page 159

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

All protective shoring systems and configurations, such as timber

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

2.2.1 Excavation near Saudi Telephone Cables

To avoid disruptions of service and unnecessary costs

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

February 1993 - 2.0 Excavations, Trenching And Shoring Page 160

 Saudi Aramco proponent inquiries may be addressed to
the Contractor Liaison Division of Government Affairs,
telephone 874-1461 (Corporate Advisor, Contractor
Liaison/GAO).

2.3 Underground Obstructions

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

2.4 General Precautions

2.4.1 Shoring Protective Systems

As soon as an excavation reaches a depth of 1.2 meters (4

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

The determination of the angle of slopes, benches, (See

Figure II.3) or the choice and design of other protective
systems shall be based on evaluation of pertinent factors
such as: type of soil (Type A, B, or C), depth of cut;
possible variations in water content of the material while
the excavation is open; anticipated changes in materials
from exposure to air, sun, or water; loading imposed by
structures, equipment, overlying material, or stored
material; and vibrations from equipment, blasting, traffic,
or other sources.

Excavations shall not be sloped at an angle greater than

one and one-half horizontal to one vertical (34 0 measured

February 1993 - 2.0 Excavations, Trenching And Shoring Page 161

 from the horizontal). Plans for sloping and benching
systems shall be sent to Loss Prevention for review. (See
Figures II.3, II.4, II.5.)

Shoring systems shall be designed by a qualified person

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

2.4.2 Personnel Protection

Portable trench boxes or sliding trench shields may be

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

Trench boxes shall be designed, constructed and

maintained to provide protection equal to or greater than
the sheeting or shoring required.

Shields shall be installed in a manner to restrict lateral or

other movement of the shield and be capable of
withstanding any sudden application of lateral loads.

Shields shall be extended above the excavation to protect

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

Employees shall not be allowed inside the shielded areas

whenever shields are being installed, removed or moved
(see Figure II.7).

2.4.3 Inspection

All parts of an excavation, including the shoring, shall be

inspected every day by a competent person to ensure that

February 1993 - 2.0 Excavations, Trenching And Shoring Page 162

 there is no danger of collapse and all observations shall be
noted in the site safety log book.

2.4.4 Clearance

In order to provide a safe footing at the edge, and to

prevent spoil falling into an excavation, a clear space at
least 0.6 meter (2 feet) wide shall be maintained on all
sides. (See Figure II.8: Guide to Safe Distance Back From
Top Of Slope For Storage of Materials / Equipment
Placing.)

2.4.5 Mechanical Excavator

Men shall not be permitted to work underneath loads or

in places where they could be struck by any part of a
mechanical excavator.

2.4.6 Walkways

Where employees, equipment, or members of the public

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

2.5 Access and Egress

Safe means of getting into and out of an excavation shall be
provided at intervals not exceeding 7.5 meters (25 feet). Ladders
shall conform to the requirements set out in Section 9.2, be
placed at an angle of 75o, and extend at least 0.9 meter (3 feet)
above the stepping-off point. Ladders shall be securely fixed.

February 1993 - 2.0 Excavations, Trenching And Shoring Page 163

2.6 Hazardous Atmospheres and Materials
2.6.1 Ventilation

Where there is reason to suspect oxygen deficiency or the

presence of a hazardous atmosphere in an excavation, gas
tests must be carried out by a qualified person. Where
necessary, mechanical ventilation shall be used, or other
appropriate precautions shall be taken before men enter.

Note: Toxic, oxygen and flammable gas tests are to

be conducted before entering hazardous excavations
in Restricted Areas (as mentioned in GI 2.100).

2.6.1.1 Hazardous Atmospheres

Prior to entry into excavations greater than four

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

· Precautions shall be taken to prevent

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

· For an atmosphere with a concentration of

any flammable gas below its lower explosive

February 1993 - 2.0 Excavations, Trenching And Shoring Page 164

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

· Above 0.0 LEL - No hot work permitted

· 0.05 LEL to 0.5 LEL - Breathing apparatus
must be used
· Above 0.5 LEL - No entry permitted

· When controls are used that are intended to

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

2.6.1.2 Emergency Rescue Equipment

(i) Emergency rescue equipment, such as

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

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

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

2.6.2 Exhaust Gases

Where an internal combustion engine is used in an

excavation, special precautions must be taken to ensure

February 1993 - 2.0 Excavations, Trenching And Shoring Page 165

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

2.6.3 Organic Lead

Where the presence of buried organic lead (TEL) sludge,

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

2.7 Edge Protection, Markers and Fixed Lighting

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

2.8 Roads, Streets, and Sidewalks

Excavation work in roads, streets, and sidewalks shall not be
undertaken without the prior approval of the relevant authorities
(See Section II.1, Work Permit System). Excavation work on
public highways will have to be cleared in advance with
Government Affairs and any special measures that they might
specify must be implemented (See Section II.8, Roadworks).

February 1993 - 2.0 Excavations, Trenching And Shoring Page 166

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

2.10 Borrow Pits

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

2.10.1 A separate traffic flow plan is required to keep pedestrian

traffic away from vehicle traffic areas. Traffic is strictly
prohibited in borrow pit areas. Signs in Arabic and
English shall be posted in roped-off areas, warning
personnel to stay out of borrow pits.

2.10.2 Dust concentration, noise levels, and security fencing

associated with borrow pit operations shall be in
accordance with Saudi Aramco Safe Operating
Procedures.

2.10.3 Hydraulic Shoring For Trenches

Hydraulic shoring is provided as a method of protection

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

It is not intended that the aluminum hydraulic

specifications apply to every situation that may be

February 1993 - 2.0 Excavations, Trenching And Shoring Page 167

 experienced in the field. These data were developed to
apply to the situations that are most commonly
experienced in current trenching practice. Situations that
are not covered require specific designs for specific
applications and will be subject to Loss Prevention review.
(See Figures II.9, II.10, II.11, and II.12.)

2.10.4 Timber Shoring For Trenches

Timber shoring is provided as a method of protection

from cave-ins in trenches that do not exceed 20 feet
(6.1m) in depth. Loss Prevention requirements must be
used when timber shoring protective systems are
designed. (See Figures II.13, II.14, II.15 and II.16.)

February 1993 - 2.0 Excavations, Trenching And Shoring Page 168

TABLE II.1: MAXIMUM ALLOWABLE SLOPES

SOIL OR ROCK TYPE MAXIMUM ALLOWABLE SLOPES

(H:V) [1] FOR EXCAVATIONS
LESS THAN 20 FEET DEEP [3]

STABLE ROCK VERTICAL (90O)

TYPE A [2] 3/4 : 1 (53O)
TYPE B 1:1 (45O)
TYPE C 1-1/2 : 1 (34O)

NOTES:

1. Numbers shown in parentheses next to

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

2. A short term maximum allowable slope of

1/2H : 1V (63O) is allowed in excavations in
Type A soil that are 12 feet (3.67 m) or less in
depth. Short-term maximum allowable
slopes for excavations greater than 12 feet
(3.67 m) in depth shall be 3/4 H : 1V (53O).

3. Sloping or benching for excavations greater

than 20 feet deep shall be reviewed by Loss
Prevention.

Slope Configurations

(All slopes stated below are in the horizontal to

vertical ratio)

February 1993 - 2.0 Excavations, Trenching And Shoring Page 169

FIGURE II.3: EXCAVATIONS MADE IN TYPE A SOIL

February 1993 - 2.0 Excavations, Trenching And Shoring Page 170

FIGURE II.3A

February 1993 - 2.0 Excavations, Trenching And Shoring Page 171

FIGURE II.3B

February 1993 - 2.0 Excavations, Trenching And Shoring Page 172

FIGURE II.4: EXCAVATIONS MADE IN TYPE B SOIL

February 1993 - 2.0 Excavations, Trenching And Shoring Page 173

FIGURE II.4A

February 1993 - 2.0 Excavations, Trenching And Shoring Page 174

FIGURE II.5: EXCAVATIONS MADE IN TYPE C SOILS

February 1993 - 2.0 Excavations, Trenching And Shoring Page 175

FIGURE II.6: EXCAVATIONS MADE IN LAYERED SOILS

February 1993 - 2.0 Excavations, Trenching And Shoring Page 176

FIGURE II.6A: EXCAVATIONS MADE IN LAYERED SOILS

February 1993 - 2.0 Excavations, Trenching And Shoring Page 177

FIGURE II.7: EXAMPLES OF TRENCH SHIELDS

February 1993 - 2.0 Excavations, Trenching And Shoring Page 178

FIGURE II.8: GUIDE TO SAFE DISTANCE BACK FROM TOP OF SLOPE FOR STORAGE
OF MATERIALS OR PLACING EQUIPMENT

February 1993 - 2.0 Excavations, Trenching And Shoring Page 179

FIGURE II.9: EXAMPLES OF SCREW TRENCH JACKS

February 1993 - 2.0 Excavations, Trenching And Shoring Page 180

FIGURE II.10: ALUMINUM HYDRAULIC SHORING TYPICAL INSTALLATIONS

February 1993 - 2.0 Excavations, Trenching And Shoring Page 181

FIGURE II.11: ALUMINUM HYDRAULIC SHORING

Vertical Shores for Soil Type A

Hydraulic Cylinders
Width Of Trench

Depth of Maximum Maximum Up to 8 Over 8 up Over 12

Trench Horizontal Vertical to 12 up to 15
Feet Spacing Spacing
Over 5 8 4 2 inch 2 inch 3 inch
up to 10 diameter diameter diameter
Over 10 8 4 2 inch 2 inch 3 inch
up to 15 diameter diameter diameter
Over 15 7 4 2 inch 2 inch 3 inch
up to 20 diameter diameter diameter

Over 20 Loss Prevention Review

Vertical Shores for Soil Type B

Hydraulic Cylinders
Width Of Trench

Depth of Maximum Maximum Up to 8 Over 8 up Over 12

Trench Horizontal Vertical to 12 up to 15
Feet Spacing Spacing
Over 5 8 4 2 inch 2 inch 3 inch
up to 10 diameter diameter diameter
Over 10 6.5 4 2 inch 2 inch 3 inch
up to 15 diameter diameter diameter
Over 15 5.5 4 2 inch 2 inch 3 inch
up to 20 diameter diameter diameter

Over 20 Loss Prevention Review

February 1993 - 2.0 Excavations, Trenching And Shoring Page 182

FIGURE II.12: ALUMINUM HYDRAULIC SHORING WALER SYSTEMS FOR SOIL TYPE B

February 1993 - 2.0 Excavations, Trenching And Shoring Page 183

FIGURE II.13: EXAMPLE OF TIMBER SHORING PROTECTIVE SYSTEMS

February 1993 - 2.0 Excavations, Trenching And Shoring Page 184

FIGURE II. 14: TIMBER TRENCH SHORING - MINIMUM TIMBER REQUIREMENTS*

February 1993 - 2.0 Excavations, Trenching And Shoring Page 185

FIGURE II.15: TIMBER TRENCH SHORING - MINIMUM TIMBER REQUIREMENTS*

February 1993 - 2.0 Excavations, Trenching And Shoring Page 186

FIGURE II.16: TIMBER TRENCH SHORING - MINIMUM TIMBER REQUIREMENTS*

February 1993 - 2.0 Excavations, Trenching And Shoring Page 187

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

Many problems are peculiar to the demolition of tanks, vessels, and

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

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 2.100 Work Permit System

GI 2.711 Fire and Safety Watch

GI 6.012 Isolation, Lockout And Use Of Hold Tags

GI 8.001 Safety Requirements For Scaffolds

GI 150.001 Asbestos Regulation

GI 402.001 Operational Chemical Cleaning of Boilers

Refinery Instruction Manual:

No. 10.185 Precautions for Working in Leaded Product Tanks

American National Standards Institute:

ANSI A 10.6-83

Safety Requirements for Demolition

ANSI Z 88.2-80

February 1993 - Construction Safety Manual: Demolition Page 188

 Standard Practice for Respiratory Protection

ANSI Z 117.1-89

Safety Requirements for Working in Tanks and Confined

Spaces

American Petroleum Institute:

API 2217-84 Guidelines for Confined Space Work in Petroleum Industry

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

3.1 Before Work Starts

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

3.1.1 Responsible Supervisor

Before any demolition work is started, a competent

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

3.1.2 Original Drawings

The original drawings of the structure to be demolished

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

February 1993 - 3.0 Demolition Page 189

 3.1.3 Disconnections

All utility services such as electricity, gas, and water must

be shut off and the main supplies disconnected outside
the line of the demolition work. Tanks, vessels, and
paperwork must be completely disconnected from inlet,
outlet, and overflow points.

3.1.4 Adjacent Structures and Public Areas

Adjacent structures, public buildings, pedestrian

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

3.1.5 Barricades/Signs

Barricades must be erected around the work area. Signs

bearing the words "Danger - Demolition in Progress" in
Arabic and English must be erected at each approach to
the barricade.

3.2 Method of Demolition

The method of demolition to be used should be decided upon in
consultation with the Saudi Aramco representative, Loss
Prevention and all contractors involved. The re-use of salvage
materials should be considered prior to this decision. It should
be remembered that the safest and most efficient method is to
start at the top and dismantle in the reverse order of
construction. There are, however, cases where such a method is
impractical or uneconomical and where other methods have to
be considered. Any portion of the job which contains asbestos
insulation should be cleared under the general procedures (See
Section II.4), and Industrial Hygiene Services, Preventive
Medicine Services Division, shall be contacted.

February 1993 - 3.0 Demolition Page 190

 3.2.1 Demolition of Equipment Containing PCB:
Polychlorinated Biphenyl (ASKAREL)

Before equipment containing or suspected of containing

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

3.2.2 Demolition Of Buildings With Asbestos / Insulation

Materials

Before demolition of buildings with asbestos and

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

3.3 Stability During Demolition

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

3.3.1

Lateral support should not be removed from more than

one story of wall at any time before starting to demolish
it. When a wall from which support has been removed
must be left standing at anytime, including overnight and
off-shift work hours, adequate bracing (guying) must be
provided to prevent collapse and to guard against wind
pressures.

February 1993 - 3.0 Demolition Page 191

3.4 Working Place Clearance
3.4.1 Access

A safe means of access to and egress from all working

places must be provided. Work places and the areas
around ladders and stairways must be kept clear of
material and debris.

3.4.2 Glass Removal

Nails in timber must be removed or bent over, or the

timber must be stacked where it will not be a source of
danger. All glass in windows, doors, partitions, etc. should
be completely removed prior to structural demolition.

3.5 Structural Steel Removal

All steel construction should be demolished column length by
column length and tier by tier. A structural member being
removed must not be under any stress other than its own
weight. Members being cut or dismantled should be chained or
lashed in place to prevent uncontrolled swinging or dropping.

3.6 Tanks, Vessels and Pipe Work (Explosion Prevention)

3.6.1 Welding and Hot Cutting

No tank, vessel, or pipe work which has contained

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

3.6.2 Cold Cutting

The use of cold cutting techniques for the dismantling of

tanks, vessels, and pipe work, can substantially reduce the

February 1993 - 3.0 Demolition Page 192

 risk of explosion. Although this is often more costly and
laborious, there are times when it is the only safe method
which can be used.

3.6.3 Steaming and Ventilation

In the case of vessels and tanks up to about 22,712 liters

(6000 gallons) capacity, both vapors and residues can
usually be removed by steaming out; however, with larger
tanks the problems are somewhat different. Because of
the high capacity of a large tank, steaming cannot be
relied on to volatilize all residues unless very large
quantities of steam are available. It is, however, relatively
easy to eliminate explosive concentrations of vapor within
the tank by forced ventilation using a blower or eductor
system approved for hazardous locations.

3.6.4 Residue Cleaning

With volatile materials, use of such methods as in 3.6.3

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

3.7 Protective Clothing and Equipment

All demolition workers should be provided with and make use of
the following protective equipment:

1 Safety helmet
2 Goggles
3 Heavy duty gloves

February 1993 - 3.0 Demolition Page 193

 4 Appropriate respiratory equipment (whenever necessary to
prevent inhalation of dust and fumes)
5 Safety boots with steel toe caps and preferably with
penetrant resistant soles.

Safety belts or harnesses (with lifelines where required) shall be

used by men working in isolated or dangerous locations where
there is the possibility of them falling and where other
preventive measures are impractical.

3.8 Mechanical Equipment Guards

Mechanical equipment such as cranes and bulldozers should be
equipped with wire mesh guards over windows and with solid
protection over the driving position so that there is no danger of
the operator being struck by flying debris.

February 1993 - 3.0 Demolition Page 194

4.0 ASBESTOS AND OTHER FIBERS
Asbestos is the generic name given to a number of naturally occurring
inorganic fibrous silicate minerals. Asbestos materials have been widely
used in the construction industry and may be present in a number of
manufactured products such as cement sheeting, molded insulation,
gaskets, ropes, blocks, fire resistant boards, etc. For the purpose of these
regulations, asbestos is defined as any of the minerals crocidolite,
amosite, chrysotile, fibrous anthophyllite or any mixture containing any of
these minerals.

The use of asbestos is restricted. At present, the Saudi Aramco Industrial

Hygiene Unit must approve the use of asbestos materials, under GI
150.001.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 2.100 Work Permit System

GI 8.003 Breathing Apparatus

GI 150.001 Asbestos Regulations

American National Standards:

ASTM C460-88

Standard Definitions of Terms Relating to Asbestos - Cement

4.1 Types of Asbestos

These exist in two main rock-forming mineral groups: 1)
Serpentine group, which includes chrysotile (white asbestos);
and, 2) Amphibole group, which includes crocidolite (blue
asbestos) and amosite (brown asbestos). These two main groups
were the most widely used asbestos minerals. However, fibrous
anthophyllite has also been used in industry in a few

February 1993 - Construction Safety Manual: Asbestos And Other Fibers Page 195
 applications. Chrysotile was commonly used as the reinforcing
material in asbestos-cement products. Because crocidolite has
high resistance to acids, it has been extensively used in chemical
plants. Due to the superior heat resistance of amosite it has
been used principally for the manufacture of fire-resistant
insulation boards. The majority of asbestos products has been
made of white asbestos, but some products contain blue
asbestos (crocidolite). Of the asbestos products manufactured
blue asbestos has the higher health risk. Blue asbestos can
usually be recognized by its dark lavender blue color; however,
its presence could be masked by other materials. Since
prolonged exposure to heat, as would be the case with boiler or
hot-pipe lagging, may change the characteristic blue color of
crocidolite to a white or fawn color.

4.2 Health Risks

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

The maximum allowable concentration of airborne asbestos dust

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

4.3 Before Work Starts

The contractor shall submit a Hazard Identification Plan to Loss
Prevention Department and to the Industrial Hygiene Service,

February 1993 - 4.0 Asbestos And Other Fibers Page 196

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

4.3.1 Air Sampling

Where the contractor knows that some part of an

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

4.3.2 Job Details

The contractor shall then inform the Industrial Hygiene

Services of details of the work involved, the number of
persons employed, the anticipated duration of the
operation, the type of asbestos being used, and the type
of equipment being used to work the asbestos material.

4.3.3 Chest X-rays

It is the contractor's duty to ensure that each man

employed on asbestos work be given a chest X-ray prior to
commencement of the job and thereafter at two-year
intervals. Detailed records shall be kept by the contractor
of all persons employed in the process. These records
shall be available to Saudi Aramco upon request.

February 1993 - 4.0 Asbestos And Other Fibers Page 197

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

Approved containers shall be used during the transportation of

asbestos materials. All such containers that contain asbestos
shall be clearly marked in English and Arabic: "Caution: Health
Hazard - Contains Asbestos".

4.5 Work Area

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

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

Only persons directly concerned with the operation shall be

permitted inside the area.

4.6 Handling and Use

4.6.1 Wetting/Ventilation

The handling, mixing, applying, removing, cutting, and

spraying of asbestos materials shall be done in a wet state
so as to prevent the emission of harmful fibers in excess
of allowable concentration.

February 1993 - 4.0 Asbestos And Other Fibers Page 198

 Before removing asbestos cement mortar, coating,
grouting, plaster, or similar material containing asbestos
from bags, cartons, or shipping containers, the material
shall be wetted or enclosed, or the operation shall be
carried out under total exhaust ventilation.

Work practices for using or removing asbestos are given in

Section 4, GI 150.001.

4.6.2 Cutting

Shearing or punching shall be used in preference to

sawing or drilling of asbestos. Where it is necessary to cut
or saw materials containing asbestos using hand or power
tools, it shall be done in a separate cordoned off area with
an approved exhaust and dust collection system.

4.6.3 Protective Equipment

Protective equipment shall be required for all instances

where asbestos is used regardless of ventilation, wetting,
etc.

4.7 Protective Clothing

4.7.1 Types

The contractor shall provide approved disposable overalls,

head covering, foot protection, and gloves to prevent any
airborne asbestos fibers from coming into contact with
the body.

The contractor shall provide a sufficient amount of

clothing to each employee working with asbestos to
ensure that a complete change of clean protective
clothing is available for the start of each shift.

February 1993 - 4.0 Asbestos And Other Fibers Page 199

 4.7.2 Contamination

At the end of each shift, contaminated personal

protective equipment shall be collected and disposed of in
accordance to GI 150.001. Under no conditions shall
contaminated clothing be worn from the work site.
Employees shall be careful to prevent contamination of
street clothes from work clothes.

Asbestos-contaminated clothes shall be packed and

carried in sealed impermeable bags or containers and
disposed of in accordance to Section 6, GI 150.001.

4.7.3 Review

The Loss Prevention Department and Industrial Hygiene

Services shall review the types and applications of
contractor's protective clothing for its' acceptability to
Saudi Aramco.

4.8 Respiratory Equipment

Where there is an unavoidable emission of asbestos dust, the
contractor shall supply a respirator approved by Industrial
Hygiene Services and Loss Prevention Department to each
employee.

4.8.1 Type

In normal circumstances, an approved filter type dust

respirator will be adequate protection; however, dusty
jobs (e.g. stripping, delogging, demolition, etc.) involving
asbestos materials require air-supplied positive pressure
respiratory equipment.

4.8.2 Use

February 1993 - 4.0 Asbestos And Other Fibers Page 200

 All employees shall be properly trained in the use of
respiratory equipment before being engaged in any work
with asbestos. Also, it is the contractor's responsibility to
make sure that each worker be supplied with equipment
that provides the level of protection required and of the
proper fit.

4.8.3 Care

All respiratory equipment shall be thoroughly checked,

cleaned, disinfected and stored at the end of each work
period and before use by other persons.

4.9 Washing and Changing Facilities

The contractor shall provide showering/washing facilities for all
employees engaged in asbestos work.

The contractor must ensure that employees use these facilities

before leaving the job site at the end of each shift.

The contractor shall provide suitable changing accommodations,

disposal facilities for protective clothing worn during asbestos
work and separate accommodations for street clothing not worn
during working hours.

4.10 Disposal of Waste Asbestos Materials/Clothing

All waste asbestos materials and disposal clothing shall be
disposed of in sealed impermeable bags or containers.

All bags and containers shall be marked in both English and

Arabic: "Caution: Health Hazard - Contains Asbestos". The bags
and containers shall be handled and disposed of in accordance to
Section 6, GI 150.001.

4.11 Cleanliness of Work Areas and Equipment

February 1993 - 4.0 Asbestos And Other Fibers Page 201

 The contractor shall ensure that all machinery, equipment, work
areas, and adjacent areas are kept free from asbestos dust and
waste as provided in Section 5, GI 150.001.

February 1993 - 4.0 Asbestos And Other Fibers Page 202

5.0 WELDING, CUTTING, AND BRAZING
This section outlines the principles involved and the precautions to be
taken in gas welding, cutting, and brazing and electric arc welding
operations.

Welding/cutting are safe operations if carried out in the correct manner.

Where equipment is defective or there is no well-arranged, well-lit, or
properly ventilated working place, hazards can arise.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 2.100 Work Permit System

GI 355.020 Control of Compressed Gas Cylinders

GI 401.081 Performance Qualifying Tests Of Welders And Welding

Operations

Saudi Aramco Engineering Standards:

SAES W-4 Welding Alloy Steels

SAES W-5 Field Stress Relieving

Saudi Aramco Bottled Gas Manual:

Section 6 Safe Handling of Compressed Gases

Schedule 'D':

Saudi Aramco Safety, Health and Environmental

Requirements - Oxygen and Acetylene Equipment and
Electric Arc Welding Equipment

American National Standards:

ANSI Z49.1 Safety In Welding and Cutting

February 1993 - Construction Safety Manual: Welding, Cutting, And Brazing Page 203
ANSI Z87.1 Practice For Occupational And Educational Eye And Face
Protection

NFPA 70 National Electrical Code

5.1 Gas Welding: Oxy-Acetylene Equipment and Use

Personnel working with welding equipment shall be trained,
competent, and provided with personal protection equipment.
Welding goggles, helmets, screens, forced ventilation and similar
equipment shall be provided to all workers and to trainees in the
immediate area.

5.1.1 Gases

Oxygen (O2) is odorless. It can promote rapid

combustion, therefore, grease and oil must never be used
near oxygen as this could cause fire.

Oxygen cylinders or apparatus shall not be handled with

oily hands or gloves. A jet of oxygen must never be
permitted to strike an oily surface, greasy clothes or enter
fuel, oil or other storage tanks.

Acetylene (C2H2) has a distinct odor often likened to that

of garlic or sour apples. It is combustible when mixed
with air over a wide range (2.5% - 81%). Acetylene
burned with oxygen can produce a higher flame
temperature than any other commercial gas.

Acetylene becomes unstable at pressures above 103 kPa

(15 psig) which means it may explode. Under no
conditions shall acetylene be generated, piped (except in
approved cylinder manifolds) or utilized at a pressure in
excess of 15 psi gauge pressure. Inside the cylinder,
acetylene is dissolved in acetone to prevent internal
explosion; therefore, it is essential that acetylene
cylinders be stored, handled, and used in the vertical

February 1993 - 5.0 Welding, Cutting, And Brazing Page 204

 position to prevent the liquid acetone from escaping and
damaging the valves and other equipment.

Warning: Regulated Acetylene pressures must never be

allowed to exceed 103 kPa (15 psig) or it may
explode.

5.1.2 Color Coding of Cylinders

Color coding can be of great help but also a potential

source of danger as there is no internationally recognized
standard color code. Refer to GI 355.020-4, Control of
Compressed Gas Cylinders, for Saudi Aramco color coding
requirements.

5.1.3 Storage Of Cylinders

5.1.3.1

Cylinders should be stored in a safe, dry, well-

ventilated place prepared and reserved for that
purpose. Flammable substances such as oil and
volatile liquids or corrosive substances should not
be stored in the same area. Oxygen cylinders and
flammable gas cylinders shall be stored
separately, at least 6.6 meters (20 feet) apart or
separated by a fire proof, 1.6 meters (5 feet) high
partition.

All storage areas shall have Arabic and English

"No Smoking Permitted" signs prominently
displayed.

All cylinders should be chained or otherwise

secured in an upright position. To prevent
rusting, cylinders stored in the open should be
protected from ground contact, extremes of
weather, or contact with water. Valve caps shall
be kept in place when cylinders are not in use.

February 1993 - 5.0 Welding, Cutting, And Brazing Page 205

 Flammable substances shall not be stored within
50 feet of cylinder storage areas. (See GI
355.020.)

5.1.3.2

Cylinders shall not be stored at temperatures

exceeding 54oC (130oF). Accordingly, they
should not be stored near sources of heat such as
radiators, furnaces, or near highly flammable
substances like gasoline. Cylinders shall be
stored out of the direct rays of the sun, in
protective enclosures or sun shelters.

5.1.3.3

Cylinder storage should be planned so that

cylinders will be used in the order in which they
are received from the supplier. Empty and full
cylinders must be stored separately with empty
cylinders plainly marked as such, to avoid
confusion. Empty cylinders should be segregated
according to the type of gas they have held.

5.1.3.4

All cylinder storage rooms shall be ventilated

sufficiently so that explosive concentrations of
gas cannot accumulate. Smoking or any other
source of ignition shall be prohibited near
storage areas, and appropriately marked "No
Smoking" as in Section 5.1.3.1 above. All wiring
shall be in conduit and electric switches shall be
located outside the room. All electrical
installations shall meet the National Electrical
Code (NFPA 70) for hazardous areas.

February 1993 - 5.0 Welding, Cutting, And Brazing Page 206

 5.1.4 Handling of Cylinders

Serious accidents may result from the misuse, abuse, or

mishandling of cylinders.

5.1.4.1

Cylinders should never be lifted by their valves

since the valves are not designed to take such
stress. When the cylinder is not in use, the valve
shall be protected with the valve cap.

5.1.4.2

All valves must be fully closed before a cylinder is

moved. Unless a trolley or special carrier is used,
regulators and hoses should be detached from
the cylinders, for moving.

February 1993 - 5.0 Welding, Cutting, And Brazing Page 207

 5.1.4.3

If cylinders are to be lifted by a crane, specially

designed bottle holders with lifting eyes should
be used. Chain and wire rope slings can allow
cylinders to slip. Where a trolley is to be used for
slinging, its base should be strong enough to take
the weight of the cylinders. Do not lift a cylinder
with an electromagnet.

5.1.4.4

Cylinders in transit on vehicles shall have valve

caps in place and be firmly secured to prevent
movement. Cylinders shall be secured to avoid
any violent contact. Loading and unloading shall
take place carefully. Cylinders shall not be
dropped, thrown, dragged, used as rollers, or as a
support. No damaged or defective cylinder shall
be used.

5.1.4.5

When in doubt as to the proper handling of a

compressed gas cylinder or its contents, the
supplier of the gas, the Bottled Gas Coordinator
(Central Area Storehouse Department), or Loss
Prevention Department should be consulted.
Depleted cylinders shall be returned to the
supplier with the valves closed and the valve
protection caps in place. Cylinders, even those
marked empty, should be treated as a possible
hazard and handled with great care as they still
contain some gas.

February 1993 - 5.0 Welding, Cutting, And Brazing Page 208

 5.1.5 Inspecting Equipment

All equipment should be examined immediately before

use and regularly maintained. All welding operations shall
be conducted in well ventilated areas.

5.1.5.1

Only soapy water should be used to check for

leaks. Presence of a leak is often indicated by a
hissing sound or unusual changes in the torch
flame. Cylinders and valves should be kept clean.
Valve sockets shall be kept free of grit, dirt,
grease or oil.

5.1.5.2

Hoses should be used for one type of gas only

and color coded for identification. They should
be examined before use for any signs of splitting
which might give rise to leakage. All connections
should be made by clips or crimps. The hoses
used for acetylene and for oxygen shall not be
interchangeable.

5.1.5.3

Connections and check valves should be regularly

examined. Equipment should be fitted with the
correct pressure regulators and a regular check
should be made to ensure that the regulator is
working properly. The torch nozzle should be
kept closed.

An acetylene cylinder valve wrench shall be

available at all times for the cylinder in use.

5.1.5.4

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 Means of torch ignition should be readily
available. A friction lighter shall be used for this
purpose.

5.1.5.5

Acetylene can form explosive compounds in

contact with certain metals or alloys, particularly
unalloyed copper or silver. Joint fittings or lines
made of copper should not be used and
acetylene should not be allowed to come into
contact with copper pipe work or tubing. Only
approved materials shall be used for acetylene
systems.

5.1.5.6

It is dangerous to let the torch flame come into

contact with gas cylinders or for the lighted torch
itself to be left unattended. Torches shall never
be sat down while lit. It is equally dangerous to
rest blowpipes, even extinguished ones, on old
drums. "Empty" drums which have contained
low flash point liquids are known to have become
lethal bombs when a hot welding torch was laid
down on them.

5.1.5.7

Cylinders in use should be kept upright on a

custom-built stand fitted with a bracket to
accommodate the hoses and equipment or
otherwise secured. The metal cap should be kept
in place to protect the valve when the cylinder is
not connected for use.

February 1993 - 5.0 Welding, Cutting, And Brazing Page 210

 5.1.6 Faults

It is not uncommon for minor "explosions" to occur during

welding or cutting. Most are more frightening than
harmful, but some can lead to very dangerous conditions.

There are four general groupings of these faults:

1 Snapout can occur during use when:

· Both regulators are set at an incorrect

pressure
· Torch nozzle obstructed
· Nozzle held too close to the work

Corrective action:

· Completely shut both torch valves

· Check regulator setting
· Check cylinder pressures
· Check nozzles
· Re-light
· Ensure adequate gas flow

2 Backfire can occur on lighting up when:

· Regulators not set to correct pressure

· Light applied before flow of gas mixture
properly established

Corrective action:

· Close both torch valves, oxygen first

· Check cylinder pressures
· Check and adjust regulator settings
· Cool torch and check nozzle orifice for
obstruction
· Re-light

February 1993 - 5.0 Welding, Cutting, And Brazing Page 211

 3 A flashback is very dangerous. Flashback is caused by
gases being mixed in the hose(s). Usually this mixing
of gases occurs when the hoses have been
disconnected from regulators or torches or when a
new hose is being used for the first time. Sometimes
it is due to loose connections. Usually one of the
hoses will have burst and possibly ignited.

Preventive action:

· Use flashback flame arrestors for regulator

and torch
· Ensure all connections are tight
· Ensure cylinder valves are open and torch
valves closed
· Set regulators to the required pressures
· Purge each hose separately and consecutively
by opening the torch valve and allowing gas to
flow for sufficient time to ensure only pure
gas remains in the hoses
· Close the valve for each gas as the purge is
completed
· This purge should be carried out only in the
open or in extremely well-ventilated areas

Corrective action:

· Close both torch valves

· Close both cylinder valves
· Extinguish hose if alight
· Repair equipment and hoses

5.1.7 Fuel Gas and Oxygen Manifolds

Fuel gas and oxygen manifolds shall bear the name of the
substance they contain in English and Arabic letters at
least 1-inch high which shall be either painted on the
manifold or on a sign permanently attached to it.

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 Fuel gas and oxygen manifolds shall be placed in safe, well
ventilated, and accessible locations. They shall not be
located within enclosed spaces.

Manifold hose connections, including both ends of the

supply hose that lead to the manifold, shall be such that
the hose cannot be interchanged between fuel gas and
oxygen manifolds and supply header connections.
Adapters shall not be used to permit the interchange of
hose. Hose connections shall be kept free of grease and
oil.

When not in use, manifold and header hose connections

shall be capped.

Nothing shall be placed on top of a manifold, when in use,

which will damage the manifold or interfere with the
quick closing of the valves.

5.2 Electric Arc Welding

Arc welding is a process for joining metals by heating with an
electric arc. For arc welding, two welding leads, the electrode
lead and the work lead, are required.

5.2.1 Voltage

The voltage across the welding arc is normally within the

range 20-40V. The voltage supplied, however, needs to
be somewhat higher so that means of stabilizing and
regulating the arc current can be introduced into the
circuit. Using DC, a 60-80V supply will usually suffice.
Using AC, an 80-85V supply will suffice although some of
the latest techniques need an open circuit voltage of up to
100V between electrode and work. It should be
remembered that a nominal 100V supply has, in fact, a
peak voltage of 141V.

February 1993 - 5.0 Welding, Cutting, And Brazing Page 213

 For these reasons, DC should be used for welding
operations in any situation where the effect of electric
shock is likely to be extreme, such as in damp and
confined spaces (tanks, boilers, etc.).

5.2.2 Welding Connections

In each welding circuit there are three main connections:

1) the welding lead;

2) the welding return;
3) the welding ground.

5.2.2.1

The welding lead is the conductor carrying the

welding current from the point of supply to the
electrode holder.

5.2.2.2

The welding return is the conductor carrying the

current back from the work to the point of
supply. Its conductivity should at least equal that
of the welding lead. The welding return should
be used to ground the metal case of the welding
machine. This high current capacity is essential,
because all the current fed to the arc has to be
conducted back to the supply point. The current
involved could be as high as 300 amperes on a
hand welding operation.

February 1993 - 5.0 Welding, Cutting, And Brazing Page 214

 5.2.2.3

A continuous welding ground is essential and

indispensable for conductors since electric
currents as low as 50 milliamperes can be fatal.
The ground should be of low impedance so that
there can be no rise in the potential of the work
and so that sufficient fault current passes quickly
enough to cut off the supply if necessary. It is
recommended that the welding ground be
bonded to the ground of the main supply system
by a separate substantial conductor.

The frames of all fixed arc welding and cutting

machines shall be grounded either through a
third wire in the cable containing the circuit
conductor or through a separate wire which is
grounded at the source of the current.

Welding grounds and returns should be securely

attached to the work by cable lugs, by clamps in
the case of stranded conductors, or by bolts for
strip conductors. Bolts are unsatisfactory for
stranded conductors, since the strands can
loosen under the bolt head and become
detached (see Manufacturers Grounding
Specifications for Electrically Powered Equipment
and Engine Powered Equipment).

February 1993 - 5.0 Welding, Cutting, And Brazing Page 215

 5.2.2.4

Welding cable insulation needs to be abrasion

resistant to withstand normal treatment over
rough ground and the wear inflicted by foot and
vehicular traffic. Where feasible, cables should
be additionally protected by stringing overhead
or by using cable covers. They should be
regularly examined for cuts or abrasions to the
insulation; damaged cable shall not be used. If
joints become necessary, standard plug and
socket coupling shall be used. Holders should be
unplugged when not in use. If joints become
necessary, standard plug and socket couplings
shall be used. Splices are not allowed in welding
cables.

5.2.2.5

Electrode holders shall be constructed to

accommodate all sizes of electrodes and with an
ejector for hot, spent stubs.

5.2.2.6

A shield should be fitted between electrode

holder and handle to prevent live elements from
being touched. The handle itself shall be made of
non-flammable insulating material and be free
from joints or holes.

February 1993 - 5.0 Welding, Cutting, And Brazing Page 216

 5.2.2.7 Auxiliary Power Outlets

Most welding machines are furnished with an

alternator which produces 3 KVA of 115 and 230
volts. As a safety factor, all power hand tools
which are not double insulated should be
grounded to the welder frame. Ground Fault
Interrupters are required, where power output
exceeds 5 KV. Placards must be placed on the
welding machine.

5.3 Protective Measures

5.3.1

The need for the operator to take safety precautions and

preventive measures during the operation of welding
machines to ensure that no safety-related incident occurs
cannot be overemphasized. The following is a list of
precautions and operating considerations to take into
account when operating a 400 amp arc welding machine,
for example. All users are strongly encouraged to read
the equipment's operating manual to ensure reliable and
safe operation.

1. Keep all doors, covers and panels in place when

operating the machine: the arc welding machine is
designed to operate with all its doors, covers and
panels in place. They ensure the optimum flow of
cooling air, and removal of these covers and panels
will reduce the cooling of the engine and generator,
resulting in overheating and premature failure of the
unit.

2. Ensure that the engine protection push button 'pops

out' when the engine is switched off. Under normal
circumstances, this button will 'pop out' once the
engine is switched off. However, if the unit becomes

February 1993 - 5.0 Welding, Cutting, And Brazing Page 217

 clogged with dirt, dust or sand, it may not return to
its 'off' position without assistance. If the button
remains depressed, it will quickly drain the unit's
battery. The resulting failure to start will delay your
work while a new battery is fitted, a 'jump start'
arranged, or a recharge cycle is completed.

3. Maintain welding and ground cables and connections

in good condition. A major source of safety hazards,
poor and inconsistent welding performance, and loss
of point-of-use welder capacity is a set of welder
leads in poor condition, or of the wrong size for the
length of cable being run. Other sources of safety
hazards related to cables and connections are:

· cracked insulation is an obvious source of hazard

producing shorts to ground eventually leading to
increase of conductor resistance. With no-load
voltages approaching 100+ volts, significant hazard of
electrocution to personnel exists, especially in wet
areas or when working on metal structures.
· combining sets of low capacity cables to reach a
distant welding site can greatly reduce the effective
welding power available to the welding machine.
Larger-capacity cables must be used to reach distant
sites, because of the buildup of resistance from the
extra length of the leads. Inadequate or weak cable
connections can also introduce sparking hazards,
potential shorts to ground, and extra resistance
which reduces effective welding machine capacity.
Cable sizes and lengths must be as recommended by
the manufacturer, as follows (for 400 amp machine):

Combined length of Minimum Cable

electrode and work cable Size
up to 150 feet 2/0
150-200 feet 3/0

February 1993 - 5.0 Welding, Cutting, And Brazing Page 218

 200-250 feet 4/0

4. When welding is in progress, the full length of cable

must be stretched out on the ground. Leaving the
cable coiled on the machine alters the current flow
and disrupts the welding process.

5. Do not adjust the 'current control' while welding is in

progress. This can damage the control.

5.3.2

Sparks and molten or hot metal coming from the work

area can easily set fire to combustible materials near or
below the working area. Wherever possible, all
combustible material should be removed from the work
area. If it cannot be removed, it should be covered with
fireproof material. Gas cylinders should be protected
from falling sparks.

5.3.3

Operators of arc welding equipment must always switch

off the current to the electrode holder and remove the
electrode whenever it is to be set down and is not actually
in use.

5.3.4

When welding or cutting material that is supported by a

crane, a shield or an effective screen should be provided
to protect the suspension ropes or chains. Grounding
cables shall only be connected to the work, not to the
crane or rigging.

5.3.5

February 1993 - 5.0 Welding, Cutting, And Brazing Page 219

 Forced ventilation shall be arranged wherever work is to
be carried out in a confined area. Suitable metal bins shall
be provided for spent electrode stubs as they are usually
hot when discarded and can easily cause a fire. Dry
chemical fire extinguishers should be kept available while
work is in progress. All completed work should be marked
"HOT".

5.4 Welding and Cutting: Tanks, Vessels and Drums

Careful tests should be made to establish that the tank, vessel or
drum is free from explosive flammable vapors or substances.
The responsible supervisor should make a check before
permitting any work to begin. It is essential that past contents of
the tank, vessel or drum be identified. If there is any doubt or if
the tank is known to have had any kind of flammable or explosive
content, it should be cleaned and purged thoroughly prior to
welding or cutting. Extreme care should be taken in considering
methods of tank welding and cutting as these jobs are hazardous
operations unless correct safety measures are taken. (See
General And Civil II.1, Work Permit System.) Welding and cutting
on drums is strictly controlled and, in most cases, prohibited.
Contact area Loss Prevention for guidance and information.

Note: The use of oxygen for blowing out containers and small
tanks is forbidden.

5.5 Confined Spaces

It is vital that forced ventilation be maintained in confined spaces
at all times. Air line respirators may be needed for men working
inside such places. No gas cylinders should ever be allowed into
such an area. The hoses and equipment used inside must be in
excellent condition.

February 1993 - 5.0 Welding, Cutting, And Brazing Page 220

 Where work in confined spaces has to take place over several
days, the hoses and equipment shall be taken outside overnight
in case of any leakage that could occur, resulting in a build up of
gas. (See General And Civil II.1, Work Permit System. )

5.6 Personnel Protection

5.6.1

Helmets, welding hoods, and goggles are necessary to

protect eyes and face against heat and the effect of the
intense light emitted by welding operations.

5.6.2

Goggles are required to protect the eyes of the welder

from pieces of flying slag chips during electric arc welding.
They should be fitted with opaque side pieces. These
goggles should also be worn under the regular welding
hoods.

5.6.3

Electric welding operations must be effectively screened

to prevent nearby personnel from being affected by
harmful radiation. Screens should be made from fire
resistant materials or should be suitably treated with a
fire resistant compound. Screens should be designed and
placed so as not to restrict the flow of air for ventilation
purposes.

5.6.4

February 1993 - 5.0 Welding, Cutting, And Brazing Page 221

 Gloves are necessary protection to the hands against
heat, sparks, molten metal, and radiation. Leather,
suitably reinforced at points of maximum wear, is the
material most generally worn. Gloves should be long
enough to protect wrists and forearms. When gloves are
not long enough, protective sleeves of similar materials
should be worn.

5.6.5

Safety boots and leggings are essential to provide

effective protection against heat, flying sparks, and falling
metal. Pant cuffs shall never be worn inside of the safety
boot.

5.7 Health Hazards

Apart from the obvious hazards of physical burns, health hazards
in welding operations fall into two classes: hazards from radiant
energy and hazards from dusts and fumes.

5.7.1 Radiant Energy

The process of welding produces radiant energy in the

form of visible light, ultra-violet rays, and infrared rays.
The risk of this energy harming the operator or other
personnel can be minimized by the proper use of
protective clothing and shielding. Exposure of the skin to
infrared and ultraviolet rays can result in irritation and
burning. The risk of exposure is lessened by wearing
protective clothing, shielding, and distance.

Arc-eye or flash burn is a well known condition in welding

operations and is due to the eyes being exposed to
ultraviolet rays. This condition is a superficial burn on the
outer layer of the eye.

The effects normally wear off within two days, and

generally no permanent damage is caused. The condition

February 1993 - 5.0 Welding, Cutting, And Brazing Page 222

 is, however, extremely painful and can easily be avoided
by the use of eye protective lens or shields.

Welding protective lens shall be tempered glass. Lens

shall be distinctively marked to identify approved lens
shade.

Lens Shade Guide:

1. Arc Welding- 10 to 14
2. Torch Brazing-3 to 6
3. Gas Welding- 4 to 8

5.7.2 Respiratory Effects

The risk of being gassed in normal welding operations is

slight; however, when working in confined areas, a forced
ventilation system should be in operation to remove any
build up of hazardous gases.

5.7.2.1

Oxy-acetylene welding operations can cause the

oxygen and nitrogen of the air to unite to form
nitrogen oxides. In well ventilated areas this
does not cause any problems; however, in
confined areas or where the welder is working
very close to the job, the amount of nitrogen
oxides breathed can rapidly reach toxic levels.
The main problem with this gas is that the welder
does not appear to be affected at the time; the
real effects take place some 6 to 24 hours after
exposure.

February 1993 - 5.0 Welding, Cutting, And Brazing Page 223

 5.7.2.2

All welding operations produce quantities of

ozone, a highly toxic gas. In oxy-acetylene and
electric arc welding, the amount produced is
small and providing adequate ventilation is used,
the risk is negligible. Significant and sometimes
dangerous amounts of ozone can be formed
when inert gas shielded welding is being carried
out.

There are many other dangers which can arise

when welding or cutting under specific conditions
or on particular metals. Hazardous operations
include: welding on manganese steel, galvanized
material, material which has been degreased or
on material which has been painted with lead,
copper-bearing, or chromate-containing paint.
These problems must be recognized before the
job starts, and safe practices for dealing with
them must be established.

Although welding cannot be regarded in general

as an extremely hazardous occupation, exposure
to concentrated fumes may be irritating and in
some cases dangerous. It is essential that each
operation be analyzed before work starts and
that the control measures are correctly applied.

February 1993 - 5.0 Welding, Cutting, And Brazing Page 224

6.0 EXPLOSIVE MATERIALS
The use of explosive materials within construction is extensive and,
whether large or small quantities are handled, the responsibilities falling
upon supervisory staff are considerable. Those responsible must consider
the acquisition, storage, transporting, handling and use of explosive
materials, as well as the emergency procedures to be adopted in the case
of misfire, accident, fire, etc. The acquisition and use of explosive
materials in Saudi Arabia are strictly controlled by the Saudi Arab
Government, whose requirements must be adhered to at all times. All
blasting operations in Saudi Aramco are strictly controlled and the use of
explosive materials by contractors is prohibited without prior written
approval by Company representatives. For contractor In-Kingdom
blasting operations, contact the Resources Planning Department, Project
Support Services Division, Blasting Services Unit for all blasting
requirements.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 2.100 Work Permit System

GI 355.015 Requisitioning, Receiving, Storing and Issuing Explosives

GI 475.001 Blasting Near Existing Facilities

GI 475.002 Use Of Explosives In Construction

GI 610.001 Special Regulations for the Use of Explosives in Seismic

Operations

GI 1183.215 Transporting Explosives on Company Owned/Leased/Rented

Motor Transport Vehicles

GI 1310.00 Transportation Of Dangerous Articles Aboard Saudi Aramco

Aircraft

Schedule 'D':

February 1993 - Construction Safety Manual: Explosive MaterialsPage 225

 Saudi Aramco Safety, Health and Environmental
Requirements

American National Standards:

ANSI A10.7-89 Safety Requirements for Transportation, Storage,

Handling, and Use of Commercial Explosives and Blasting
Agents in Construction and Demolition

NFPA 495-90 Explosive Materials Code

National Safety Council Industrial Data Sheets:

I-644-90 Treatment Of Extraneous Electricity In Electric Blasting

I-730-86 Ammonium Nitrate / Fuel Oil Mixtures As Blasting Agents

February 1993 - 6.0 Explosive Materials Page 226

7.0 PILING OPERATIONS
Piling operations attract many of the problems associated with other types of
construction work: access, unguarded machinery, housekeeping, etc. Heavy
equipment and the stress and vibration imposed upon that equipment give rise to
hazards peculiar to piling operations. The standard of supervision should be high,
as well as the standard and maintenance of equipment.

Piling operations fall into two categories: driving load-bearing piles, which may be
driven vertically or raked; and, driving sheet piles. Piles may be of steel, concrete,
timber or any combination of the three. Piling equipment can vary from a simple
air-operated hand-held hammer to a large complex rig.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 2.100. Work Permit System

GI 7.025. Mobile Heavy Equipment Operator Testing and Certification

GI 7.026. Crane and Heavy Equipment Accident Reporting Procedures

GI 7.029. Inspection, Testing and Maintenance of Wire Rope Slings

GI 7.030. Inspection And Testing Requirements Of Elevating / Lifting Equipment

Schedule 'D':

Saudi Aramco Safety, Health and Environmental Requirements -

Excavations

Crane Safety Handbook (Page 99)

National Safety Council Data Sheet:

Special Hazard Bulletin X128. Property Damage from Blasting, Pile

Driving, and Similar Sources

ASME Standard:

February 1993 - Construction Safety Manual: Piling Operations Page 227

 Section I Power Boilers
Section VII Pressure Vessels

7.1 Before Work Starts

In order that piling operations may be undertaken with the minimum risk
to men and equipment, the following factors should be considered before
work starts.

· The nature and purpose of the operation.

· Soil investigation reports of the area.

· Location and nature of any underground services in the area, which

should be checked with the various departments through the Saudi
Aramco Construction Engineer; then, precisely located by careful hand
digging, under competent supervision.

Where piling operations are within a restricted area, the proper Work
Permits should be obtained before any work is undertaken.

Competent supervision, experienced in piling operations, is essential for

piling work.

Equipment of adequate capacity to perform the operation should be

assembled. All equipment must be carefully inspected before being used
with particular attention to the following. (See GI 7.030.)

7.1.1 Cranes

Cranes used for both lifting and piling operations should be of an

adequate size and capacity to perform the work safely. Where
cranes are to be used for driving raking piles with a drop hammer
or driving piles below the level of the crane using extended leaders,
the hammer will be suspended from the crane at a greater radius
than the boom angle indicator will show. In all such cases, the
distance of the hammer from the center point of the crane must be
calculated and this distance used to ascertain the safe working
load.

February 1993 - 7.0 Piliing Operations Page 228

 Outriggers, counterbalances, etc., shall be provided to maintain
stability of the pile driver rig.

7.1.2 Pile Gates

Sufficient timber or steel must be available for the construction of

pile gates. Proper ladder access must be provided to the pile gates,
and where they are over 1.8 meters (6 feet) high, handrails or
rigger's belts must be provided.

7.1.3 Inspection

Air compressors or steam boilers must be carefully examined and

all hoses and couplings checked both for leaks and general
condition. All steam and air hoses should be fitted with a regulator
valve and a quick acting shut-off valve for emergency.

7.1.4 Wedges

An adequate supply of hardwood wedges should be obtained for

adjusting piles while pitching. Softwood wedges are likely to split
and must not be used.

7.1.5 Timber Block

Stop blocks shall be provided for the leads to prevent the hammer
from being raised against the head block.

Guards shall be provided across the top of the head block to

prevent the cable from jumping out of the sheaves.

Fixed leads shall be provided with ladder and adequate attachment

points so that the loft worker may engage his safety belt lanyard to
the leads. If loft platforms are provided, they shall be protected
with standard guardrails.

Steam/air hose leading to the hammer or jet pipe and all hoses
shall be securely attached with 1/4" chain or cable to prevent whip
lash.

February 1993 - 7.0 Piliing Operations Page 229

 7.1.6 Ground Support

The ground upon which the crane or rig will stand should be firm
and level. Digger mats or a hard-core standing should be provided
if the ground is likely to subside under the high ground loading
imposed by driving or extracting piles.

7.2 Driving Piles

7.2.1 Pitching

Piles should only be lifted and positioned in the pile gate or onto
the leaders or rig with sound lifting gear adequate for the purpose.
Quick release shackles should be examined before each use.
Where hollow section or concrete piles are lifted with chains or
wire slings, timber or burlap packing should be placed between the
lifting gear and the pile. Adequate access, such as a cradle or a
properly secured ladder, must be provided for the topman when
pitching sheet piles. The topman must wear stout gloves when
pitching.

7.2.2 Driving

Workmen should stand clear of the operation while driving is in

progress. The emergency shut-off valve and the crane or winch
controls must be manned at all times during driving. The foreman
must be present and so positioned that he can be seen by the crane
or winch operator and the man standing by the valve. When
driving raking piles, the pile, leaders, and machine must all be in the
same line. Under no circumstances should any man touch the
hammer until all valves are closed. A system of signals must be
arranged between the foreman, the winch or crane operator, and
the valve operator, so that the emergency shutdown does not
depend on verbal communication. Where the head of a pile
becomes distorted through driving, no attempt should be made to
clear it from the leaders by lifting or booming up. The pile head
should be cut off and the debris cleared from the leaders.

February 1993 - 7.0 Piliing Operations Page 230

7.3 Pile Extraction
No attempt should be made to extract piles which have been hammer-
driven by lifting or booming up with a crane. A steam, air, or electric
operated extractor should be used. Particular attention should be paid to
the extractor wedges and the condition of the gripping faces, which should
not be smooth. Workmen must not walk under piles that are suspended
from extractors.

7.4 General Precautions

7.4.1

Men handling piles or working on piling operations should always

wear safety helmets, safety shoes, safety glasses, stout gloves, and
be equipped with ear protection, preferably of the muff type.

7.4.2

At the start of each shift, hammers and extractors should be

carefully checked for loose bolts, etc.

7.4.3

All other equipment should be inspected daily for defects.

7.4.4

Piling operations should never be undertaken except under

competent supervision and with a crew experienced in this class of
work. Crane operators shall have a valid Saudi Arab Government
heavy equipment license and a valid Saudi Aramco certificate (See
GI 7.030).

7.4.5

Piling operations are a construction process with special hazards. In

addition to these special hazards, men are exposed to the hazards
commonly associated with all types of construction work, and
precautions against these general hazards must not be neglected.

February 1993 - 7.0 Piliing Operations Page 231

8.0 ROADWORKS
A contractor engaged in roadwork is not only responsible for the safety of
his own men, he also has an obligation to protect the public from
potential construction hazards, during the day, at night and in all weather
conditions. Consequently, the marking of construction sites and the safe
and efficient diversion and control of traffic must be properly planned and
executed. Road closure plans must be submitted to Loss Prevention
before roads are closed.

Failure to do this can have disastrous results.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 1021.000 Street and Road Construction, Excavation, and Maintenance

of Traffic Controls (Appendix D)

GI 2.100 Work Permit System

8.1 General
8.1.1

Saudi Aramco organizations can obtain barriers, lights,

etc. from the Maintenance Department during normal
working hours. Contractors shall provide their own
barriers, lights, etc..

8.1.2

To avoid creating a traffic hazard, warning devices must

not be put in place until they are needed. They must be
promptly removed when work is complete.

8.1.3

Activities which produce dust shall be kept to a minimum.

February 1993 - Construction Safety Manual: Roadworks Page 232

 8.1.4

Permanent road signs and striping shall be restored

before the roadway is returned to service.

8.1.5

The surface of any highway, street, or sidewalk shall be

level and in good condition before any barriers and
markers are removed.

8.1.6

Should there be any doubt as to the type of marking and

protection required for roadwork in any location, the Loss
Prevention engineer for the area should be consulted.

8.1.7

A flagman, equipped with a safety vest and a red flag,

shall be posted at least 50 meters (165 feet) from the
work site at the entrance barricade and another flagman
at the exit barricade. It shall be the duty of the flagmen to
control the flow of traffic in a safe manner. Both flagmen
shall be in sight of each other. If conditions do not permit
this, then a third man shall be positioned where he can
see and be seen by the other two men in order to signal
them to start or stop traffic. Traffic control signals shall be
in accordance with GI 1021.000. At night, flagmen shall
wear light-reflecting vests and gloves, and use reflective
signs or flags. Flagmen shall be stationed in an
illuminated area.

8.1.8

During darkness, the work area will be marked by lights

spaced 10 meters (30 feet) apart. Warning lights used in
oil operations, industrial, or company housing areas shall

February 1993 - 8.0 Roadworks Page 233

 be weather proof and positioned 0.6 meter (2 feet) and
0.9 meter (3 feet) above grade.

8.1.9

In addition to the foregoing, excavation work in

residential areas shall be entirely enclosed, covered over,
or roped-off.

8.1.10

Excavations in sidewalks or areas of expected pedestrian

traffic shall be provided with close-planked walkways or
bridges 0.9 meters (3 feet) wide and equipped with
standard guardrails.
8.2 Street and Road Construction, Excavations, and
Maintenance Traffic Controls
See Appendix D (GI 1021.000).

February 1993 - 8.0 Roadworks Page 234

 9.0 WORKING PLACES, LADDERS, AND
SCAFFOLDING
Every contractor and every employer of workmen has a legal
and contractual responsibility to ensure that each place at which
his men work is safe and that it remains safe so long as men
work there. Similarly, each supervisor is responsible for
ensuring that every man working under his direction or control
has a safe working place and a safe means of getting to and from
every working place.

Where work cannot safely be done on the ground or from part

of a building or permanent structure, scaffolds, ladders, or other
means of support shall be provided and properly maintained.

INSTRUCTIONS AND STANDARDS

The Standards used for guidance in this section of the

Construction Safety Manual are those of the American National
Standards Institute, Inc. (ANSI) and US Code of Federal
Regulations (CFR) 1910.28. Where scaffold manufacturers
products meet other scaffold standards that are equivalent to
or higher than ANSI requirements, then those products can be
used. Scaffold products from different manufacturers shall not
be mixed on a scaffold, unless they are specifically designed to
be used together.

Saudi Aramco Instructions and Standards:

GI 2.100. Work Permit System

GI 6.020. Personal Flotation Devices for Work Over, On or Near Water

GI 8.001. Safety Requirements For Scaffolding (formerly 1009.006)

SAES-P-123. Lighting Utilization

Schedule 'D':

February 1993 - Construction Safety Manual: Working Places, Ladders, and Scaffolding Page 235
 Saudi Aramco Safety, Health and Environmental
Requirements - Ladders; Scaffolding; Personal Flotation
Devices for Work Over, On or Near Water.

American National Standards Institute:

Uniform Building Code

ANSI A10.8 - 1988

Scaffolding-Safety Requirements

ANSI A14.1 - 1982./ANSI A14.1a- 1985

Ladders - Portable Wood Safety Requirements

ANSI A14.2 - 1990

Portable Metal Ladders

ANSI A14.3 - 1984

Ladders - Fixed-Safety Requirements

ANSI A92.2 - 1990

Vehicle - Mounted Elevating and Rotating Aerial Devices

US. Code of Federal Regulations, 29. CFR Part 1910.28, Safety

Requirements for Scaffolding

National Safety Council Data Sheets:

Data Sheet 568. Job-Made Ladders

NFPA 70 - 90 National Electrical Code (NEC)

9.1 Working Places, General

9.1.1 Falls

Within Saudi Aramco, every working place shall be safe

and of adequate dimensions. Where men, tools, or
materials could fall 1.8 meters (6 feet) or more, a
guardrail system (consisting of toprails and midrails) and
toeboards shall be provided. Should the provision of

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 236
 these safeguards be impracticable, other means of
preventing falls, such as safety belts, etc. shall be used.
For further information, see Personal Protective
Equipment, Section I.9, (9.6.5 and 9.6.6) of this Manual.

9.1.2 Access and Egress

A safe means of getting to and from a working place shall

be provided and used. Ladders shall conform to the
requirements set out in 9.2.

9.1.3 Lighting

Every working place and every means of getting to and

from a working place shall be provided with adequate
lighting which shall be properly maintained. (See SAES-P-
123)

9.1.4 Prevention of Falls

Permanent decking, parts of a structure, walkways,

footbridges, etc., which men use in the course of their
work or for a permanent or temporary access, shall be
provided with a guardrail system and toeboards
(permanent or temporary) at all edges from which men,
tools, or materials could fall 1.8 meters (6 feet) or more.
Holes and gaps shall be guarded or securely covered.
Stairs (permanent or temporary) shall have all treads
properly secured and shall be fitted with handrails
throughout their length and conform to the Uniform
Building Code.

9.1.5 Ramps

Where the slope of a ramp exceeds 1 vertical to 4

horizontal, the ramp shall be fitted with stepping cleats
at 0.3 meter (1 foot) intervals. When a ramp is to be
used by the general public, its slope shall not exceed 1
vertical to 4 horizontal. Handrails shall be provided.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 237
 9.1.6 Falling Material

Where there is danger of men being struck by falling

material, protective coverings shall be erected or No. 18
gauge wire, 1/2 inch mesh or equivalent, shall be
securely fixed between the toeboard and midrail to
prevent falling objects.

9.1.7 Hot Surfaces

Suitable precautions shall be taken to prevent men

coming into contact with any hot surface.

9.1.8 Slipping and Tripping

Contractors are responsible for maintaining good

housekeeping to prevent slipping, tripping, and falling.
Oil spills, mud, scrap, and other debris must be cleared
up immediately. Men shall not be permitted to walk or
work on steel work or other surfaces on which paint or
cement wash is still wet.

9.1.9 Roof Work

Where work is done on or from the roof of a building or

structure, or where men have to cross, work on, or work
from fragile roofs or surfaces, adequate protection in the
form of crawling boards, roof ladders, or other suitable
covering must be provided to prevent men and materials
falling from or through the roof. Temporary guardrails
shall be placed to prevent workers from falling. If roof
work is accomplished on pitched roofs with a slope
greater than 1:4, workers shall be equipped with safety
belts that are securely anchored to the structure. During
storms or high winds, workers shall not be working on a
roof or scaffold that is exposed to the weather.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 238
 9.1.10 Insecure Structures

Unstable or weak structures shall be supported by guys,

stays, supports, or other fixings where necessary. If work
being done is likely to reduce the stability of an existing
structure or building, bracing or other means of support
shall be used. Unstable structures shall not be left
unsupported over night.

No wall sector which is more than one story in height,

shall be permitted to stand alone without lateral bracing,
unless such wall was originally designed to do so and is in
a safe condition to be self-supporting. All walls shall be
left in a stable condition at the end of each shift by
bracing support jacks, timbers and/or guy-wired, taking
wind force and storm conditions into consideration.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 239
 9.1.11 Work Over Water

9.1.11.1

Where men work on, over or near water, a

guardrail system and toeboards, fencing or other
suitable barriers shall be provided for the
protection of the worker.

9.1.11.2

Wherever the provision of a guardrail system and

toeboards, fencing or other suitable barriers is
impracticable, or if for any reason men are
outside the protection of these safeguards,
suitable life vests shall be worn and a safety belt
or harness securely fixed to a dropline.

9.1.11.3

Approved rescue equipment that meets the

requirements of GI 6.020 in the form of life rings
with life lines, etc.; where necessary, a suitably
equipped rescue boat shall be readily available,
and properly maintained. Men shall be
thoroughly trained in the use of all protective and
rescue equipment, first aid and cardiopulmonary
resuscitation (CPR).

9.2 Ladders and Stepladders

The safety of a ladder depends on four important factors:
selection, condition, position and use. Ladders shall comply with
the referenced ANSI or equivalent codes.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 240
 9.2.1 Selection

9.2.1.1

A ladder must be of the proper length for the job

to be done. If it is to be used for access or as a
working place, it shall rise to a height of 36 inches
to 42 inches above the landing place or above the
highest rung to be reached by the feet of the
man using the ladder.

9.2.1.2

Metal ladders, ladders with metal reinforced side

rails, and ladders which are wet shall not be used
near electrical equipment with exposed live
conductors. Such ladders shall have a warning
notice attached to guard against use near
electrical equipment.

9.2.1.3

Aluminum ladders shall not be used where there

is a likelihood of contact with materials harmful
to aluminum, such as caustic liquids, damp lime,
wet cement, etc.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 241
 9.2.2 Condition

9.2.2.1

Each ladder shall be examined before use. Those

with split or broken side rails, missing, broken,
loose, decayed or damaged rungs or cleats, or
with other faulty equipment shall be tagged and
removed from service.

9.2.2.2

Rungs shall be properly mortised into side rails.

Cleats shall be inset by 2.25 centimeters (7/8
inch), or filler blocks used on the side rails
between the cleats. Cleats shall be uniformly
spaced 30.5 centimeters (1 foot) between
centers.

9.2.3 Position

9.2.3.1

The side rails of a ladder shall be equally

supported on a firm level surface. Boxes, blocks,
barrels, etc. shall not be used as a means of
support. The area at the base of a ladder must
be kept clear. Ladders shall not be used in a
horizontal position as platforms, runways or
scaffolds.

9.2.3.2

Ladders shall not be supported on their rungs or

cleats. Rungs or cleats shall not be used to
support planks.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 242
 9.2.3.3

Whenever possible, ladders shall be set at an

angle of 75o to horizontal ground (i.e., one meter
out to four meters up).

9.2.3.4

Metal reinforcing shall be on the underside of the

rungs and where reinforcing is on only one side
of the side rails, that too shall be on the
underside.

9.2.3.5

Both side rails of a ladder shall be evenly

supported at the upper resting place. Side rails
must be securely tied off to prevent movement.
Where secure fixing is impracticable, other
measures must be taken to prevent movement
by securing at the base, using side guys, or
stationing a man at the base. It must be
understood, however, that a man stationed at
the base will be unable to control a ladder more
than 6 meters (20 feet) in length.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 243
 9.2.3.6

Where there is a possibility of a ladder being

struck by moving vehicles or equipment, a man
should be placed on guard or a space at the base
should be securely fenced off. If a ladder is
erected close to a doorway, the door should
either be locked, shut, or be secured in the open
position with a man on guard or properly
barricaded.

9.2.3.7

Ladder landing places shall be provided at least

every 9 meters (30 feet) of height and shall be
fitted with a guardrail system and toeboards.
Holes in decking through which ladders pass shall
only be enough to permit passage of the man
using the ladder.

9.2.3.8

A ladder should always be placed so that there is

space behind each rung or cleat for a proper
foothold. There should be no obstruction in the
way of a man's foot, particularly at the landing
platform. Here the rung or cleat should be level
with the platform.

9.2.3.9

Where ladders have to be suspended, both side

rails shall be lashed top and bottom so as to
provide equal support. Where long ladders are
used, they shall also be lashed at the center to
prevent lateral movement.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 244
 9.2.4 Use

9.2.4.1

Where an extension ladder is used fully

extended, the minimum overlap depends on the
extension ladder length, and overlap should be as
follows (examples):

9.75 to 10.97 meters (32 to 36 feet) = 1.22

meters (4 feet) overlap

10.97 to 14.63 meters (36 to 48 feet) = 1.52

meters (5 feet) overlap

Splicing or lashing ladders together shall not be

permitted.

9.2.4.2

Before mounting a ladder, personnel shall check

their shoes for freedom from grease, oil or mud.
They shall always step through, not around, the
rail extensions at the top of the ladder.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 245
 9.2.4.3

Single rung and single cleat ladder should be

used by only one man at a time. When ascending
or descending personnel shall face the ladder and
keep both hands on the ladder. Personnel shall
not run up or down or slide down a ladder at any
time. The width of single cleat ladders shall be at
least 38.1 centimeters (15 inches) but not more
than 50.8 centimeters (20 inches) between rails
at the top.

9.2.4.4

Men ascending or descending ladders shall not

carry tools and materials in their hands. Tools
may be carried in pockets or on special belts
provided there is no risk of injury and movement
is not impaired. Materials shall be raised or
lowered using a handline after being securely tied
or placed in a basket.

9.2.4.5

A man working on or from a ladder must always

have a secured handhold and both feet on the
same rung or cleat. If the work to be done
requires the use of both hands, a safety belt is
required, securely fixed to a dropline (life line).
Only one person shall be on a ladder at a time.

9.2.4.6

Job-made ladders shall be constructed for

intended use. If a ladder is to provide the only
means of access or exit from a working area for
25 or more employees, or if simultaneous two-
way traffic is expected, a double cleat ladder shall
be installed.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 246
 Double cleat ladders on Saudi Aramco
construction sites shall not exceed 4.5 meters (15
feet) in length.

Single cleat ladders shall not exceed 4.5 meters

(15 feet) in length between supports (base and
top landing). If ladders are to connect different
landings, or if the length required exceeds this
maximum length, two or more separate ladders
shall be used, offset with a platform between
each ladder. A guardrail system and toeboards
shall be erected on the exposed sides of the
platforms.

5.08 by 10.16 centimeters (2 by 4 inches) lumber

shall be used for side rails of single cleat ladders
up to 4.5 meters (15 feet) long.

5.08 by 10.16 centimeters (2 by 4 inches) lumber

shall be used for side and middle rails of double
cleat ladders up to 3.6 meters (12 feet) in length;
5.08 by 15.24 centimeters (2 by 6 inches) lumber
for double cleat ladders from 3.6 by 4.5 meters
(12 to 15 feet) in length.

Wood cleats shall have the following minimum

dimensions when made of woods that meet ANSI
requirements for ladders:

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 247
 LENGTH OF CLEAT THICKNESS WIDTH
Up to and including 1.9 cm (.75 in) 7.62 cm (3 in)
50.8 cm (20 inches)
Over 50.8 cm (20 in.) 1.9 cm (.75 in.) 9.52 cm (3.75
and up to in.)
and including 76.20
cm (30 in.)

Cleats may be made of species of any other

group of wood provided equal or greater
strength is maintained.

Cleats shall be inset into the edges of the side

rails one-half inch, or filler blocks shall be used on
the rails between the cleats. The cleats shall be
secured to each rail with three 10d common wire
nails or other fasteners of equivalent strength.
Cleats shall be uniformly spaced, 30.48
centimeters (12 inches) between centers.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 248
 9.2.4.7

Metal ladders shall not be used for work on

electrical systems unless the ladders are
specifically designed for that application.

9.2.5 Stepladders

Generally, the foregoing remarks on selection, condition

and use of ladders apply equally to stepladders. The
following requirements also apply:

9.2.5.1

To ensure stability, stepladders shall be spread to

their fullest extent limited by manufacturer's
braces when in use. Whenever possible, they
should be placed at right angles to the work with
either the front or back facing the work.

9.2.5.2

Do not stand, climb or sit on the stepladder top,

pail shelf, braces or back section.

9.2.6 General

9.2.6.1

Ladders and stepladders shall be maintained in

good condition at all times. Joints shall be tight,
all hardware and fittings shall be securely
attached, and movable parts shall operate freely
without binding or undue play.

9.2.6.2

Ladders and stepladders must not be painted.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 249
 9.2.6.3

Where a ladder is carried by one man, the front

end should be kept high enough to clear men's
heads and special care shall be taken at corners
and blind spots.

9.3 Scaffolding Components

9.3.1

All scaffold structures shall be erected with metal

components approved per ANSI requirements or
equivalent. Scaffolds shall be stored to prevent damage
and to permit easy access for use. Scaffold erection plans
(drawings) shall be submitted to Loss Prevention
Department for review prior to men being allowed to
work on the scaffold.

9.3.2 Tubing

Ordinary scaffold tubing is 4.8 centimeters (1-29/32

inches) in diameter and nominal wall thickness 0.4
centimeter (5/32 inch) and is referred to as two-inch
nominal diameter tubing. It is mild steel and normally
supplied in lengths of 6.4 meters (21 feet). Tubes must
meet ANSI or equivalent requirements and must be free
from cracks and surface flaws, laminations, excessive rust
and other defects. The ends shall be cut square and
cleanly. A tube shall not deviate from a straight line by
more than 1/600 of its length measured at the center of
the tube length.

9.3.3 Aluminum Tubing

9.3.3.1

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 250
 Although the aluminum tubing is dimensionally
interchangeable with steel tubing, it must not be
used in the same structure; the difference in the
elastic modulus of the two materials results in
greater deflection in aluminum tubing for the
same loading conditions.

9.3.3.2

Aluminum tubing shall not be used where there

is likelihood of contact with materials harmful to
aluminum such as caustic liquids, damp lime, wet
cement and sea water.

9.3.4 Fittings

All fittings (couplers, clamps, etc.) shall be of a metal type

approved to ANSI or equivalent requirements. They shall
be examined regularly and care must be taken to ensure
that moving parts are sound and well lubricated and that
threads are not stripped.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 251
 9.3.5 Typical Scaffold Fittings

(Figures II.17 - II.22)

Base Plate: A 15 centimeter (6 inch) by 15 centimeter

(6 inch) steel plate greater than 0.64 centimeters (1/4
inch) thick providing a flat bearing surface for load
distribution from posts. It has an integral spigot and fixing
holes for use with sills.

Screwjacks: Used for compensating variations in ground

levels.

o
Standard Coupler: Also known as a Right Angle or 90
Coupler. A load bearing coupler used for connecting two
tubes together at right angles.

Adjustable Coupler: Used for connecting two tubes

together at any angle through 360o. Not to be used
where a load bearing standard coupler is required.

End-to-End Coupler: Also known as a Sleeve Coupler.

Used for connecting two tubes end-to-end.

Reveal Pin: Inserted into the end of a tube and adjusted

to form a rigid horizontal or vertical member between
two opposing surfaces. It forms a solid anchorage to
which a scaffold can be tied.

9.3.6 Planks

9.3.6.1

Planks shall be of rough timber and graded as

scaffold planks without defects (2" x 9"), 5
centimeters (2 inches) thick by 23 centimeters (9
inches) wide, and shall conform to the following
specifications:

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 252
 1 All planking shall be Scaffold Grade to ANSI
requirements.

2 On the face of the plank, the ends shall not be

split up more than 30.5 centimeters (1 foot),
without fixed banding or the end bolted
through.

3 On the face of the plank, not more than one

third the width in any one place shall be knot
wood.

4 On the edge of the plank, not more than half

the depth shall be knot wood.

5 On the edge of the plank, the grain shall not

cross from face-to-face within a distance of
less than 30.5 centimeters (1 foot).

6 From end-to-end, the plank must not be

twisted by more than 1.3 centimeters (1/2
inch).

7 Scaffold planks shall meet the loading

requirements of Table II.2.

9.3.6.2

Planks shall not be painted or treated in any way

that would conceal defects.

9.3.6.3

Planks which are split, decayed or warped shall

not be used, but the parts affected may be cut off
to produce shorter planks with the ends banded
or bolted through.

9.3.6.4

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 253
 Planks should be stacked on a suitable
foundation. Where the height of a stack exceeds
20 planks, measures should be taken to tie or
bond succeeding layers.

9.3.6.5

Planks should not be stood on end unattended.

9.3.6.6

Scaffold planks shall not be used for shuttering

for concrete, shoring for trenches, or as sills for
scaffolding. Planks shall be inspected for defects,
including decay, prior to each use.

9.3.6.7

The design working load of each platform unit

(i.e., plank) shall be capable of supporting
without failure one or more 91 kg (200 lb) person
with 22.7 kg (50 lb.) of equipment.

9.3.6.8

Platform units rated for one person capacity shall

be designed and constructed to carry 113.6 kg
(250 lb.) at the center of the span.

9.3.6.9

Platform units rated for two persons shall be

designed and constructed to carry a working load
of 227 kg (500 lb.) : 113.6 kg (250 lb.) placed at
0.46 meters (18 inches) to the left and right of
the center of the span.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 254
 9.3.6.10

Platform units rated for three persons shall

designed and constructed to carry a working load
of 341 kg (750 lb.) : 113.6 kg (250 lb.) placed at
0.46 meters (18 inches) to the left and right of
the center of the span, and at the center of the
span.

9.3.6.11

The design loads in sections 9.3.6.7 to 9.3.6.10

are not to be added to uniformly distributed
loads for light, medium and heavy duty scaffold
(i.e., 25, 50 and 75 lb./ft2 respectively), but are
shown as alternates.

9.3.6.12

Each platform, where applicable, shall be

designed and constructed to carry a uniformly
distributed load as an alternate to the person
loading of 9.3.6.7 to 9.3.6.10. Uniformly
distributed loads and person loading are not
cumulative and the most restrictive loading shall
be used for platform design.

9.3.6.13

Light, medium and heavy duty uniformly

distributed load requirements shall be 25, 50 and
75 pounds per square foot respectively. Greater
uniformly distributed loads shall be specially
designed.

TABLE II.2: WOOD SCAFFOLD PLANK LOADING CHART

Permissible Span (ft)

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 255
 Douglas Fir or Spruce

Southern Pine Rough Sawn

2 in x 10 in 1-7/8 in x 9-7/8
in

Nominal or or

Loading Condition 1-1/2 in x 9-1/4 in 2 in x 9 in

Actual

One worker or 10 ft 8 ft
medium-duty

Two workers or 8 ft 7 ft
heavy-duty

Three workers 5 ft 5 ft

REFERENCE: ANSI A10.8-1988

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 256
 FIGURE II.17: STANDARD COUPLER FIGURE II.18: ADJUSTABLE
COUPLER
(Bearers, Runners) (Braces Only)

FIGURE II.19: TYPICAL END TO END COUPLER FIGURE II.20: SCREWJACK

FIGURE II.21 TYPICAL REVEAL PIN FIGURE II.22 TYPICAL BASE

PLATE

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 257
 9.4 Requirements Common to All Scaffolding
9.4.1 Foundations

9.4.1.1

A sound base is essential; therefore, the ground

or floor on which a scaffold is going to stand must
be carefully examined. Sand or made-up ground
may need compacting to ensure there are no
cavities. Such bases as floors, roofs, etc. may
need shoring from underneath.

Scaffolds, including components, shall be capable

of supporting without failure at least 4 times the
maximum intended load.

9.4.1.2

Timber sills at least 23 centimeters (9 inches)

wide by 3.8 centimeters (1-1/2 inches) thick (not
scaffold planks) will be required to spread the
load on sand, made up ground, asphalt
pavement, wooden floors, and slippery surfaces.
A sill shall extend under at least two posts.

9.4.1.3

Where scaffolding is erected on a solid bearing

such as rock or concrete, small timber pads may
be used in place of sills and nailed to prevent the
base plates sliding off.

9.4.1.4

Concrete blocks, barrels, and other loose or

unsuitable material shall not be used for the
construction or support of scaffolding.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 258
 9.4.1.5

If used to compensate for variations in ground

level, the screwjack shall not be adjusted to more
than two-thirds of the total length of the thread.
The base plate shall be of a type approved for
supporting scaffolding posts. (See
manufacturer's specifications.)

9.4.2 Posts

9.4.2.1

Posts shall be pitched on 15 centimeters (6

inches) by 15 centimeters (6 inch) steel base
plates and at least 0.64 centimeter (1/4 inch)
thick. Joints in posts should be staggered, i.e.,
joints in adjacent posts should not occur in the
same lift. All posts shall be vertical.

9.4.2.2

The inner row of posts shall be placed as close as

possible to the face of the building or structure.
To avoid projections, the posts may be up to 41
centimeters (16 inches) away from the wall or
structure as necessary, provided that, where
there is room to do so, the gap between the wall
or structure and the inner posts shall be closed
with planks on extended board bearers. The
outer row of posts shall be positioned from the
inner row of posts depending on the load
requirements of the scaffold, and the working
platform shall be fully decked out.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 259
 9.4.3 Runners

9.4.3.1

Runners shall be securely fixed to posts with

standard couplers and shall be horizontal. Joints
in runners should be staggered, i.e., joints in
adjacent runners should not occur in the same
bay. Runners should be secured end-to-end by
sleeve couplers, not by joint pins.

9.4.3.2

Runners shall be vertically spaced no more than

2.0 meters (6 feet, 6 inches) to give adequate
headroom along the platforms.

9.4.4 Bearers

Bearers should be installed between posts and securely

fixed to the posts bearing on the runner coupler and
secured with standard couplers. When coupled directly
to the runners, the coupler must be kept as close to the
posts as possible. These bearers must remain in position
as they are a structural part of the scaffold.

9.4.5 Board Bearers

Board bearers shall be installed between bearers to

accommodate differences in plank lengths.

Board bearers shall be secured to the runners between

bearers where necessary to support platform units
(planks). These may be removed when no longer
required to support platform units.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 260
 9.4.6 Bracing

9.4.6.1

Cross bracing shall be installed across the width

of the scaffold at least every third set of posts
horizontally and every fourth runner vertically.
Such bracing shall extend diagonally from the
inner and outer runners upward to the next
outer and inner runners. These braces should be
fixed to the runners with standard couplers as
close to the posts as possible. Where such a
fixing is impracticable, adjustable couplers may
be used to fix the braces to the posts. (See
Figures II.23 and II.24.)

9.4.6.2

Longitudinal diagonal bracing shall be installed at

approximately 45-degree angle from near the
base of the first outer post upward to the
extreme top of the scaffold. Where possible,
such bracing shall be duplicated at every fifth
post. On short but high runs, diagonal bracing
shall be installed at an angle of 45 degrees from
the base of the first outer post to the last outer
post and shall alternate directions to the top of
the scaffold. When bracing cannot be attached
to the posts, this bracing may be attached to the
runners, as close as possible to the posts. Only
standard couplers or adjustable couplers may be
used. Joints in braces shall be made with end-to-
end or parallel couplers.

9.4.6.3

Temporary rakers (inclined load-bearing tube

supports) brace the scaffold against the ground

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 261
 when setting out. These rakers are replaced by
permanent braces when the scaffold has been
plumbed, leveled and tied. Rakers must be
secured with proper couplers at the scaffold and
coupled to a ground stake.

9.4.7 Ties

9.4.7.1

It is essential that all scaffolds, with the exception

of certain tower and mobile scaffolds (See 9.7
and 9.8), be securely tied to the building or
structure throughout their length and height to
prevent movement of the scaffold either towards
or away from the building or structure. This
should be done by connecting a tie tube to both
runners or posts and coupling this to a two-way
tie or column box tie assembly. (See Figures II.25
and II.26.)

9.4.7.2

Where the foregoing is impracticable, tubes may

be securely wedged between opposing surfaces
on the building or structure by the use of reveal
pins and coupled to the tie tubes (Figure II.27).
Where reveal ties are used, they shall not exceed
50% of the total number of ties. Two-way ties or
column box ties shall be evenly distributed over
the scaffold area. To ensure the security of
reveal ties, it is necessary to check frequently for
tightness.

9.4.7.3

Ties shall occur at the top of the scaffold and at

least every 7.9 meters (26 feet) vertically and 9.1
meters (30 feet) horizontally and at each end of

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 262
 the scaffold. All tie assembly connections shall be
made with standard couplers.

9.4.8 Platform Units

9.4.8.1

All platform units (i.e., planks, fabricated decks,

etc.) shall be closed planked with, whenever
practicable, each plank resting on at least three
supports. Planks shall extend over their end
supports by not less than 15 centimeters (6
inches) and not more than 30.5 centimeters (12
inches).

9.4.8.2

Supports for scaffold planks shall be spaced with

due regard to the nature of the platform and the
load it will bear. (See Table II.2.)

9.4.8.3

Except on platform units adjacent to the surface

of a cylindrical or spherical structure, planks shall
be laid flush.

9.4.8.4

Planks shall be secured in position to prevent

displacement by high winds.

9.4.8.5

Adequate space for men to pass in safety shall be

provided and maintained wherever materials are
placed on platform units or if any higher platform
is erected thereon.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 263
 9.4.8.6

Platform units shall be kept free of unnecessary

obstructions, materials, and projecting nails.

9.4.8.7

Platform units which have become slippery with

oil or any other substance shall be cleaned, or
otherwise removed and replaced.

9.4.8.8

Slopes in platform units shall not exceed 1

vertical to 4 horizontal and stepping cleats at 0.3
meter (1 foot) intervals shall be provided.

9.4.8.9

All platform units shall be closed planked for the

full width of the scaffold structure.

9.4.9 Guardrail Systems and Toeboards

9.4.9.1

Guardrail systems (consisting of toprails and

midrails) and toeboards shall be installed at all
open sides and ends of all scaffolds and supports
on no more than 3-meter (10-foot) centers from
which men or materials could fall a distance of
more than 1.8 meters (6 feet). Toprails shall be
no less than 0.91 meter (36 inches) and no more
than 1.14 meters (45 inches) above the working
surface; midrails shall be installed equidistant
between the working surface and the toprail.
Toeboards shall not be less than 10 centimeters
(4 inches) in height by 2.5 centimeters (1 inch)
thick. Guardrail systems and toeboards shall be

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 264
 securely fixed to the inside of posts to withstand
a lateral thrust of 200 pounds.

9.4.9.2

Landings: Safe landings shall be provided at the

top of all ladders. Rings shall be eliminated
above the landing level, and side rails shall
extend 36 to 42 inches above the landing for
mounting and dismounting. Where multiple
ladders are required, solidly decked platforms
shall be provided. Guardrails, intermediate rails
and toeboards shall be erected on the outside
edges and exposed sides of the platform.

9.4.10 Access

Access to a working platform is best achieved by

providing a separate ladder tower or a cantilevered
access platform so as not to obstruct the working
platform and to minimize the risk of persons falling
through gaps in the guardrail system or platform units.
Access must be provided to working platforms.

9.4.11 Scaffold Ladders

Scaffold ladders provide the means of access and egress

for scaffolds. They can generally be classified as follows:

9.4.11.1 Portable Straight and Extension Ladders

(Figure II.24)

A straight ladder is a portable ladder that only

consists of one section which determines its
overall length. It cannot support itself or be
adjusted in length.

An extension ladder is a portable ladder that

cannot support itself but can be adjusted in

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 265
 length. It consists of two or more sections which
are arranged to permit length adjustment. Its
overall length is the sum of the length of all its
sections measured along the side rails.

Portable straight and extension ladders shall

have a firm base and be positioned with a slope
of 1:4.

9.4.11.2 Vertical Ladder

A vertical ladder is a type of fixed ladder which is

permanently attached to the horizontal or
vertical components of a scaffolding.

The main criteria to consider in the use of a

vertical ladder is clearance. The following
clearance guidelines shall be used.

· General:

Safe clearances shall be maintained to

prevent workers from bumping into, or
snagging onto, projecting objects while
ascending or descending the ladder.

· Climbing Side:

Ladders shall have a minimum clear

perpendicular distance of 30 inches from the
rungs to the nearest projecting object on the
climbing side. When unavoidable
obstructions are encountered, the minimum
clearance distance may be reduced to 24
inches if deflector plates are provided.

· Back Side Of Ladder:

The perpendicular distance from the face of

the rung on the climbing side to the nearest

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 266
 fixed object on the back side of the ladder
shall not be less than 10 inches. When
unavoidable, horizontal obstructions (e.g.
beams, pipes, etc.) are encountered, the
vertical toe clearances specified in the
following sections, shall apply.

· Side Clearance:

The minimum clear distance to the nearest

fixed object shall be 15 inches on each side of
the centerline of single rung ladders.

· Vertical Clearance:

The minimum vertical toe clearance from

horizontal obstructions shall be 1 1/2 inches
below and 4 1/2 inches above the top edge of
the rung.

· Multiple Ladders:

When two or more separate ladders are used

with a landing platform, the side-step distance
shall be a minimum of 15 inches from the
centerline of the upper ladder to the near side
of the lower ladder.

9.4.12 Workmanship

9.4.12.1

Scaffolding shall be erected, altered, and

dismantled by experienced men working under
the direction of a competent supervisor.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 267
 9.4.12.2

Posts shall be set accurately in place and checked

vertically by using a spirit level or by using
vertical lines on the building or structure.

9.4.12.3

Scaffolding couplers should be tightened with

proper scaffolding spanners. The use of an
ordinary spanner or tool giving greater leverage
could damage the screw threads and render the
coupler unserviceable.

9.4.12.4

Scaffolding materials shall not be thrown or

dropped from heights.

9.4.13 Inspections

All scaffolds shall be inspected regularly by a competent

Supervisor and after adjustments, modifications, adverse
weather conditions, etc. Erected scaffolds and platforms
should also be inspected continuously, by those using the
scaffold, to insure that the scaffold has not been altered
and is in a safe working condition.

9.5 Fabricated Tubular Frame and System Scaffolding

Fabricated tubular frame and system scaffolding are composed
wholly or partly of prefabricated sections. There are many types
of fabricated tubular frame and system scaffolding available
which vary in design and methods of erection; however, the
same basic principles set out in 9.4 apply and the following
matters warrant particular attention. All scaffolds must be
erected as per manufacturer's direction and limitations. A
scaffold plan needs to be submitted to Loss Prevention
Department for review. (See Figures II.28 to II.31)

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 268
 9.5.1

To be erected, altered and dismantled by experienced

men, under the direction of a competent Supervisor.

9.5.2

Periodic inspections shall be made of all parts and

accessories. Broken, bent, altered, excessively rusted or
otherwise structurally damaged frames or accessories
shall not be used.

9.5.3

All fabricated tubular frame and system scaffolding shall

be constructed and erected to support four times the
maximum intended loads.

9.5.4

Scaffold posts shall be pitched on steel base plates and on

timber sills or pads as necessary. Screwjacks shall be used
to compensate for variations in ground level.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 269
 9.5.5

Scaffolds shall be properly braced by cross braces and

longitudinal diagonal braces for securing vertical
members together. The cross braces shall be of such
length as will automatically square and align vertical
members so that the erected scaffold is always plumb,
square, and rigid. All brace connections shall be made
secure.

9.5.6

The frames or posts shall be placed one on top of the

other with coupling or stacking pins to ensure proper
vertical alignment of the legs.

9.5.7

The frames and posts shall be locked together vertically

by pins or other equivalent suitable means.

9.5.8

Fabricated tubular frame and system scaffolding over 38

meters (125 feet) in height shall be specially designed by a
Professional Engineer. In Saudi Aramco, scaffold heights
are limited to a maximum height of 12.2 meters (40 feet),
unless a scaffold plan has been reviewed by the Area Loss
Prevention Division representative prior to construction.
Scaffolds above 12.2 meters (40 feet) should be
constructed using scaffold contractors; however no
scaffolds shall exceed 38.1 meters (125 feet) unless the
design has been reviewed by an Area Loss Prevention
Division representative, Consulting Services Department
and approved by a qualified engineer. (See also GI 8.001,
section 6.1.1.)

9.6 Tube and Coupler Scaffolds

(Tube and Coupler Construction - Figure II.23)

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 270
 9.6.1 Independent Tied Scaffold

An independent tied scaffold (also commonly known as a

double pole scaffold) consists of a double row of posts
connected together longitudinally with runners and with
bearers at right angles to the runners. Braces and ties are
essential for stability. Independent tied scaffold is the
most common form of tube and coupler scaffolding and is
divided into three groups.

In Saudi Aramco the height limitation of the tube and

coupler scaffold shall not exceed 12.2 meters (40 feet)
unless a scaffold plan proposing to use such a scaffold at a
greater height has been reviewed by the Loss Prevention
Department per the provisions of Section 9.5.8.

1 Light Duty: for painting, cleaning, etc.

2 Medium Duty: when materials are deposited on the
platforms.
3 Heavy Duty: where the deposited material is of a
more substantial nature.

9.6.2 Light Duty Tube and Coupler Scaffolds

(For general requirements, see 9.4 and 9.5)

9.6.2.1 Design, Loading and Dimensions

A light duty tube and coupler scaffold can have

up to three working platforms in use at any one
time, and the maximum distributed load on the
platform shall be 1.2 kPa (25 lb./sq. ft) with posts
3.05 meters (10 feet) apart longitudinally and
1.83 meters (6 feet) transversely.
TABLE II.3: TUBE AND COUPLER SCAFFOLDS--LIGHT DUTY

Uniformly distributed load Not to exceed 25 p.s.f.

Post Spacing (longitudinal) 10 ft. 0 in.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 271
 Post Spacing (transverse) 6 ft. 0 in.

Working Levels Additional Maximum Height

Planked Levels

1 8 125 ft.
2 4 125 ft.
3 0 91 ft. 0 in.

Reference: CFR 1910.28

9.6.2.2 Platform

The platform between posts should be decked

out with 23 centimeters (9 inches) wide by 5.1
centimeters (2 inches) thick planks. Bearers may
be cantilevered for use as brackets to carry not
more than two planks between the building and
inner post.

9.6.2.3 Limitations

Light duty tube and coupler scaffolds erected in

accordance with these directions may be used
up to a maximum height of 38.1 meters (125
feet) and limited to a uniformly distributed load
of 25 lb./ft2. Light duty tube and coupler
scaffolds departing from these directions shall be
specially designed or designed to a higher rating
such as medium or heavy duty.

9.6.3. Medium Duty Tube and Coupler Scaffold

(For general requirements, see 9.4)

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 272
 9.6.3.1 Design, Loading, and Dimensions

A medium duty tube and coupler scaffold may

have up to two working platforms in use at any
one time. The maximum distributed load on
each platform shall not exceed 2.39 kPa (50
lb./sq. ft) with posts not more than 2.4 meters (8
feet) apart longitudinally and 1.83 meters (6 feet)
transversely.
TABLE II.4: TUBE AND COUPLER SCAFFOLDS--MEDIUM DUTY

Uniformly distributed load Not to exceed 50 p.s.f.

Post Spacing (longitudinal) 8 ft. 0 in.
Post Spacing (transverse) 6 ft. 0 in.

Working Levels Additional Maximum Height

Planked Levels

1 6 125 ft
2 0 78 ft. 0 in.

Reference: CFR 1910.28

9.6.3.2 Platform

The platform between posts should be decked

out with 23 centimeters (9 inches) wide by 5.1
centimeters (2 inches) thick planks. Bearers may
be cantilevered for use as brackets to carry not
more than two planks between the building and
inner post.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 273
 9.6.3.3 Limitations

Medium duty tube and coupler scaffolds erected

in accordance with these directions may be used
up to a maximum height of 38.1 meters (125
feet) and limited to a uniformly distributed load
of 50 lb./ft2. Medium duty tube and coupler
scaffolds departing from these directions shall be
specially designed or designed to a higher rating
such as heavy duty.

9.6.3.4 Bearers

Bearers on medium duty tube and coupler

scaffolds shall be 6.35 centimeters (2.5 inches)
outside diameter steel tube and of nominal wall
thickness of 0.4 centimeter (5/32 inch).

9.6.4 Heavy Duty Tube and Coupler Scaffolds

(For general requirements, see 9.5)

9.6.4.1 Design, Loading and Dimensions

A heavy duty tube and coupler scaffold has one

working platform with a maximum distributed
load of 3.6 kPa (75 lb./sq ft) on the platform. The
posts shall be no more than 2.0 meters (6 feet, 6
inches) apart longitudinally and 1.8 meters (6
feet transversely).

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 274
TABLE II.5: TUBE AND COUPLER SCAFFOLDS--HEAVY DUTY

Uniformly distributed load Not to exceed 75 p.s.f.

Post Spacing (longitudinal) 6 ft. 6 in.
Post Spacing (transverse) 6 ft. 0 in.

Working Levels Additional Planked Maximum Height

Levels

1 6 125 ft.

Reference: CFR 1910.28

9.6.4.2 Platform

The platform between the posts shall be decked

out with 23 centimeters (9 inches) wide by 5.1
centimeters (2 inches) thick planks.

9.6.4.3 Limitations

Heavy duty tube and coupler scaffolds erected in

accordance with these directions may be used up
to a maximum height of 38.1 meters (125 feet).
Heavy duty tube and coupler scaffolds departing
from these directions shall be specially designed.

9.6.4.4 Bearers

Bearers on heavy duty tube and coupler scaffolds

shall be 6.35 centimeters (2.5 inches) outside
diameter steel tube and be of nominal wall
thickness 0.4 centimeter (5/32 inch).

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 275
 9.7 Free-Standing Tower Scaffolds
A free-standing tower scaffold consists of four or more posts
connected together longitudinally with runners and bearers at
right angles to the runners, forming a square or rectangular
tower (see Figure II.32). Alternatively, a free-standing tower
scaffold may be constructed of a fabricated tubular frame or
system scaffolding (see 9.5). A free-standing tower scaffold has
a single working platform and is a common form of access
scaffolding for painters and others who do work of a light nature
and of short duration.

9.7.1 General Requirements

For general requirements, see 9.4 and where a fabricated

tubular frame or system scaffolding is to be used, see 9.5.

9.7.2 Design, Loading and Dimensions

A free-standing tower scaffold shall have only one

working platform and the maximum distributed load shall
not exceed the load rating which is determined by the
platform unit type and the scaffold duty.

The height from the base to working platform of a free-

standing tower scaffold shall not exceed four times the
minimum base dimension. In no case shall the minimum
base dimension be less than 1.2 meters (4 feet).

9.7.3 Runners and Bearers

The vertical spacing of runners and bearers shall be 2.0

meters (6 feet, 6 inches). The lowest runners and
bearers shall be as near to the base as possible. Runners
and bearers shall be secured to the posts with standard
couplers.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 276
 9.7.4 Bracing

Sway bracing is necessary on all four elevations to the full

height of the scaffold. Plan bracing is also required at the
base, at the top, and at every third lift to prevent racking.

9.7.5 Ties

Free-standing tower scaffolds more than 9.8 meters (32

feet) in height shall be adequately tied to a building or
structure. Where tying to a building or structure is
impracticable, one of the following methods of ensuring
stability shall be used (see Figures II.33 to II.35):

1 Guy wires at a slope of approximately 45o

connected to the working platform level of the
tower.
2 Bottom corners of the tower securely anchored.
3 Outriggers extending to the ground.

The strength of the guy wires or of the anchorage used

shall be calculated, having due regard to the horizontal
wind forces and other known forces which may be
applied to the tower. These calculations shall be
reviewed by Loss Prevention Department.

9.7.6 Platform

The single working platform of a free-standing tower

scaffold shall not project beyond the base area and the
platform unit(s) shall be securely fixed in position.

9.7.7 Access

Where the means of access to the working platform is

outside the tower structure, due consideration must be
given to the effect of such means of access on the
stability of the scaffold. Where a sloping ladder would

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 277
 cause instability, a securely fixed vertical ladder may be
used.

9.7.8 Limitations

Free-standing tower scaffolds erected and used in

accordance with these directions and with one working
platform may be used up to a maximum height of 12
meters (40 feet) to the work platform. Free-standing
tower scaffolds departing from these directions shall be
specially designed.

9.8 Mobile Tower Scaffolds

(Figure II.31)

The requirements for free-standing tower scaffolds in 9.7 also

apply to mobile tower scaffolds with the exception that wheels
are used in place of base plates and sills.

9.8.1 Foundations

Wheels or casters, not less than 12.7 centimeters (5

inches) in diameter, and fitted with brakes, which cannot
be released accidentally, shall be securely fixed to the
bases of the posts by lock pins or dowels.

A mobile tower scaffold shall only be used and moved on

surfaces sufficiently firm and level to ensure stability.
Where the scaffold is to be used on a suspended floor, it
shall be designed to apply loads no greater than the
bearing capacity of the floor.

Temporary foundations or track laid on soft or uneven

ground to facilitate the erection and movement of the
tower shall be constructed and anchored so that its
bearing capacity is not exceeded due to imposed loading
from the tower. The track shall be level and properly
secured.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 278
 9.8.2 Operation

A mobile tower scaffold shall be moved only by pushing

or pulling at the base. Force must not be applied at a
height greater than 1.4 meters (4 feet, 6 inches) above
the base. No men, equipment or materials shall be on
the working platform or elsewhere on the structure while
it is in motion. Wheel brakes shall be applied at all times
when men are on the stationary mobile tower scaffold.

9.8.3 Limitations

Mobile tower scaffolds, erected and used in accordance

with these directions, supported on four wheels and with
one working platform, may be used up to a maximum
height of 12 meters (40 feet). Mobile tower scaffolds
departing from these directions shall be specially
designed and properly secured (See 9.7.5).

9.9 Scaffolds for Tanks and Vessels

Tube and coupler scaffolds for tanks and vessels shall be erected
in accordance with 9.6. Secure tying to the structure is essential
for stability.

9.9.1 Bracket Scaffolds

9.9.1.1

Brackets and bracket straps shall be constructed,

fixed and erected in accordance with the
manufacturer's instructions.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 279
 9.9.1.2

It is essential that the brackets, straps and welds

are of sufficient strength to support the weight of
the scaffold, men, tools and materials.

9.9.1.3

The bracket straps shall be welded to the wall of

the tank by a certified welder. The weld shall be
a full 5 millimeters (3/16 inch) fillet. Prior to
welding on any tank, approval is required from
Saudi Aramco Consulting Services Department.

9.9.1.4

The weld shall be made with the same type of

electrode as used for the main tank weld joints.
Before the bracket is attached to the strap, the
weld shall be inspected by a competent welding
inspector or welding supervisor who will approve
and accept the weld.

9.9.1.5

Brackets shall be inspected prior to each use and

damaged or defective brackets shall be removed
from service. Brackets shall be vertical and
horizontal spacing shall not exceed 2.5 meters (8
feet) on centers.

9.9.1.6

A rigid guardrail system and toeboards shall be

securely fixed to the uprights of the brackets (see
Section 9.4.9). Alternatively, 3/8 inch diameter
wire ropes may be used in place of toprails and
midrails providing that they are securely fixed
and kept taut by the use of turn buckles.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 280
 9.9.1.7

Whenever men are working, the platform shall

be fully decked.

9.9.1.8

Excessive storage or accumulation of materials or

platform units (planks) shall not be permitted.

9.9.1.9

The scaffold shall be designed to support a

minimum load of 1.2 kPa (25 lb./sq. ft). No more
than two persons shall occupy any given 2.5
meters (8 feet) of bracket scaffold at any one
time. Tools and materials shall not exceed 34 kg
(75 lb.) in addition to person(s) occupying the
area.

9.10 Special Scaffolds

Scaffolds to suit special applications and those required for
unusual heights or for use in abnormal circumstances shall be of
a special design, which has been reviewed by the Loss
Prevention Department as per the provisions of section 9.5.8.

Vehicle-mounted elevating and rotating aerial devices shall

comply with ANSI A92.2-1990.

9.11 Scaffold Terminology

Where possible, the scaffold terminology used in this document
is based on ANSI A10.8-1988: Scaffolding - Safety
Requirements. A list of common ANSI scaffold terms is included,
and in brackets are equivalent British Standard (BS 5973: 1990
scaffold terms, where an equivalent term exists.

(1) Base Plate. A metal plate with a spigot or screwjack for

distributing the load from a post or other load bearing tube.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 281
 (2) Bearer (Transom). A horizontal tube across runners to form
the support for a platform or to connect the outer posts to
the inner posts.

(3) Brace. A tube placed diagonally with respect to the vertical

and horizontal members of a scaffold and fixed to them to
give stability.

(4) Coupler. A device for locking together component parts of

tube and coupler scaffold.

(5) Design Load. The maximum intended load; that is, the total
of all loads including the worker(s), material and the
equipment placed on the unit.

(6) Dropline. A vertical line from a fixed anchorage, which is

independent of the work platform and its rigging, and to
which the lanyard is affixed.

(7) Fabricated Tubular Frame Scaffold. A system of tubular

frames (panels) field erected with bracing members.

(8) Guardrail System. A rail system erected along open sides

and ends of platforms. The rail system consists of a toprail
and midrail and their supports.

(9) Lanyard. A flexible line to secure the wearer of a body belt

or harness to a dropline or a fixed anchor.

(10) Load Ratings. Maximum loading for the

following categories:

(a) Heavy Duty: Scaffolding constructed to carry a

working load of 75 lb./ft2 such as for masonry work,
with storage of materials on the platform.
(b) Medium Duty: Scaffolding constructed to carry a
working load of 50 lb./ft2 such as for bricklayers
with the weight of materials in addition to workers.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 282
 (c) Light Duty: Scaffolding constructed to carry a
working load of 25 lb./ft2 and is intended for
workers only, with no material storage other than
the weight of tools.
(d) Special Duty: Scaffold designed and constructed to
carry specific types of objects.

(11) Mobile Scaffold. A scaffold assembly supported

by casters and moved along manually.

(12) Midrail. A horizontal rail approximately midway

between the toprail and platform of a guardrail system.

(13) Plank. A wood board or fabricated component

that is a flooring member.

(14) Platform. An elevated work surface composed

of one or more platform units.

(15) Platform Unit. Individual wood planks,

fabricated planks, fabricated decks, and fabricated
platforms.

(16) Post (Standard). Vertical scaffold tube that

bears the weight of the structure.

(17) Putlog (Truss). A fabricated tube upon which

the platform rests, the putlog has a flattened end, to rest in
or on part of the brickwork.

(18) Rated Load. The manufacturer's recommended

maximum load.

(19) Runner (Ledger). A horizontal scaffold tube

that extends from post to post, that supports putlogs or
bearers and that forms a tie between the posts.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 283
 (20) Scaffold. A temporary elevated or suspended
work unit and its supporting structure used for supporting
worker(s) or materials, or both.

(21) Scaffold Access. A separate, attachable or built-

in means of access to and from a scaffold or work unit.

(22) Scaffold Deck 'Fabricated'. A work unit

equipped with end hooks that engage the scaffold bearer.

(23) Sill (Sole Plate). A timber, concrete or metal

spreader used to distribute the load from a post or base
plate to the ground.

(24) Tie. A device used between scaffold

components and the building or structure to enhance lateral
stability.

(25) Toeboard. A barrier secured along the sides

and the ends of a platform unit to guard against the falling
of material, tools and other loose objects.

(26) Toprail. The uppermost horizontal rail of a

guardrail system.

(27) Tube and Coupler Scaffold. A scaffold system

consisting of tubing that serves as posts, bearers, braces,
ties and runners; a base supporting the posts; and special
couplers that serve to connect the uprights and join the
various members.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 284
FIGURE II.23: A TYPICAL INDEPENDENT TIED SCAFFOLD CONSTRUCTED USING TUBE AND COUPLER SCAFFOLDING

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 285
FIGURE II.24: A TYPICAL TUBE AND COUPLER SCAFFOLD

February 1993 - Working Places, Ladders, and Scaffolding Page 286

FIGURE II.25: PLAN VIEW OF TWO-WAY TIE

FIGURE II.26: PLAN VIEW OF COLUMN BOX TIE

FIGURE II.27: PLAN VIEW OF REVEAL TIE

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 287
February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 288
FIGURE II.28: A TYPICAL SYSTEM SCAFFOLD

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 289
FIGURE II.29: A TYPICAL SYSTEM SCAFFOLD BEING ASSEMBLED

FIGURE II.30: A TYPICAL SYSTEM SCAFFOLD BASE IN THE PROCESS OF BEING

ASSEMBLED AND LEVELED

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 290
FIGURE II.31: A TYPICAL FABRICATED TUBULAR FRAME MANUALLY PROPELLED
MOBILE SCAFFOLD

Working Platform Guard Rail System Spring

Loaded Access Gate

End Frame Toeboard

Locking Pins Coupler

Cross Bracing Access Ladder

Horizontal Diagonal Brace Caster Fastening Pins Locking

Casters

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 291
FIGURE II.32: A TYPICAL TUBE AND COUPLER MOBILE ACCESS TOWER

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 292
FIGURE II.33: CROSS TUBE ANCHOR

FIGURE II.34: OUTRIGGERS IN USE FIGURE II.35: DRIVEN

TUBE ANCHOR

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 293
10.0 HAND TOOLS AND POWER TOOLS
Hand tools are those tools for which the hand provides the motive force,
e.g., picks, shovels, axes, crowbars, wrenches, saws, chisels, hammers,
screwdrivers, etc. It is the contractor's duty to ensure that his workmen
are properly instructed in the selection and use of the correct tool for the
job. Tools constructed of good quality materials should always be used.
Poor quality tools increase the risk of accidents and also reduce the
efficiency of work.

Power tools, however, allow many jobs to be carried out more efficiently
and with greater speed and accuracy. The correct use of power tools can
only be achieved by the proper training of workmen, by proper
maintenance, and by adequate site supervision. Many accidents have
occurred because unskilled and untrained labor have been allowed to
operate power tools in an incorrect manner.

INSTRUCTIONS AND STANDARDS

Saudi Aramco Instructions And Standards:

Schedule 'D':

Saudi Aramco Safety, Health and Environmental

Requirements - Cartridge Operated Tools

United States Code of Federal Regulations 29, Part 1910, Subpart "0",
Machinery And Machine Guarding

American National Standards Institute:

ANSI A10.3-1985

Safety Requirements For Powder Actuated Fastening Systems

ANSI A10.9-1983

Safety Requirements For Concrete Construction and Masonry

Work

February 1993 - Construction Safety Manual: Hand Tools And Power Tools Page 294
ANSI B7.1-1988

Safety Code For The Use, Care, And Protection Of Abrasive

Wheels

ANSI B15.1-1984

Safety Code For Mechanical Power Transmission Apparatus

NFPA - 70-90

National Electrical Code (NEC)

10.1 Hand Tools, General

10.1.1 Quality

The contractor shall ensure that the finest quality tools

shall be provided for all jobs where hand tools are used.

10.1.2 Cleanliness

The contractor shall ensure that hand tools are regularly

cleaned and, where necessary, lightly oiled as a protection
against corrosion.

10.1.3 Repair and Storage

All hand tools shall be regularly inspected before and after

use, and before storage. If wear or damage is observed,
the tool should be withdrawn from use for repair or
disposal. The contractor shall ensure that the storekeeper
maintains a record of all tools issued, repaired, and
withdrawn from use. Proper racks and boxes shall be
provided for the storage of hand tools.

February 1993 - 10.0 Hand Tools And Power Tools Page 295
 10.1.4 Selection

The majority of accidents are caused by using an incorrect

tool for the job. It is essential that the correct type, size,
and weight of tool should be decided upon before any
work is carried out.

10.1.5 Electrical Risks

All uninsulated metal tools are conductors of electricity.

Where work takes place on or near electrical operations,
only properly insulated and non-conductive tools should
be used. Insulation should be checked at regular intervals
by a competent electrician.

10.2 Individual Hand Tools, Precautions

10.2.1 Screwdrivers

It is essential that a screwdriver has the correct size of tip

to fit the slot of the screw. If the screwdriver fits the
screw correctly, the screw will be drawn into the correct
position without unnecessary force being applied. Over-
tightening of screws can lead to possible hand injury if the
screwdriver slips.

Screwdriver shanks are not designed to withstand the

twisting strain applied by a pair of pliers or more grips in
order to obtain additional leverage. On no account
should screwdriver handles be subjected to blows from a
hammer or similar instrument.

Screwdrivers should never be carried in the pockets of

coveralls or other clothing. A screwdriver can produce a
serious wound.

February 1993 - 10.0 Hand Tools And Power Tools Page 296
 10.2.2 Hammer

It is essential that the right kind of hammer be selected

for the job. Hammer handles should be made from
smooth timber or be made of an integral head and shaft
of steel. Hammer heads should be secured to wooden
handles with proper wedges.

10.2.3 Chisels

Cutting edges should be kept sharp at all times, and the

original shape and angle should be maintained. Re-
sharpened cold chisels should be suitably hardened and
tempered to maintain them in a safe working condition.
The chisel heads will mushroom in use. As soon as
mushrooming is observed, the head should be reground
with a slight taper around the edge to prevent chipping
and reduce the tendency to re-mushroom. Eye protection
should be worn at all times when a cold chisel is used.

On jobs where it is necessary to use a sledge hammer for

striking the chisel, the chisel should be held by a second
person using a pair of tongs.

Wood chisels should also be maintained in a sharp

condition so that minimum pressure is exerted when
making a cut. If the chisel is to be struck, only a wooden
or soft mallet should be used.

February 1993 - 10.0 Hand Tools And Power Tools Page 297
 10.2.4 Picks and Shovels

Picks and shovels shall be maintained in a serviceable

condition at all times. Shovel blades should not be
allowed to become blunt, turned, split, or jagged. Pick
head points should be kept sharp and heat-treated so that
the metal wears down in use and does not splinter or chip
off. Shafts of picks and shovels should be kept free from
cracks and splinters.

10.2.5 Spanners and Wrenches

Only spanners and adjustable wrenches of the right size

should be used. When possible, use box-end rather than
adjustable wrenches. The jaw should first be checked for
any sign of opening out or splitting. Spanner and wrench
lengths are graded to provide sufficient leverage on the
nuts for which they are designed. Improvised extension
to these tools is an unsafe practice and may cause the
bolt tread to strip or cause shearing of the bolt. On no
account should ordinary wrenches be struck by a hammer
when tightening nuts. For heavy work of this nature, a
properly designed slugging wrench should be used.

10.2.6 Pipe Wrenches

Pipe wrenches must be large enough for the job, the jaw
teeth must be kept clean and sharp, and the knurl, pin,
and spring should be kept free from damage. Pipe
wrenches should never be struck with a hammer, nor
should they be used as a hammer.

10.2.7 Pliers

Pliers should only be used when there are no other tools

for the job. They are meant only for gripping around
objects and should not be used as a wrench.

February 1993 - 10.0 Hand Tools And Power Tools Page 298
 Care should be taken when cutting soft metal with pliers
to ensure the scrap portion does not fly off and cause
injury. If wire is cut under tension, then long handled
pliers should be used. Where pliers are used for electrical
work, they must be fitted with insulated handles. All
pliers should be kept free from dirt and grit, and the
movable parts should be lightly lubricated.

10.2.8 Jacks

Jacks should be marked with rated capacity and must be

heavy enough and strong enough to raise and maintain
the load. They should be placed on a firm and solid
support, and the load should be positioned on the center
line of the jack.

Once a load has been raised, it must be shored or

blocked. The jack should never be relied upon to hold the
raised load in position by itself. Extreme care should be
taken when working under or near a raised load.

10.2.9 Hacksaws

The correct type of blade should be selected to suit the

material to be cut. The blade should be set in a hacksaw
frame so that the teeth are pointing in the forward
direction, and sufficient tension should be applied to
ensure blade is maintained rigid.

10.2.10 Hand saws

Many kinds of woodworking hand saws are available, and

care should be taken to select the correct saw. All hand
saws shall be regularly examined to ensure that the saw
teeth are properly set so as to avoid binding in the timber
which can cause the blade to buckle. The teeth should be
kept sharp, clean, and lightly oiled. When the saw is not
in use, the blade should be protected by a slotted piece of
timber or a sheath.

February 1993 - 10.0 Hand Tools And Power Tools Page 299
 Two-man saws should be operated by pulling only. The
cut should be kept straight to avoid the blade buckling.
The cut should be wedged open to prevent the timber
from pinching the blade.

10.3 Power Tools, General

10.3.1 Quality

The contractor shall ensure that all portable power tools

do not exceed 125 volts rating, are manufactured of
sound materials, and are free from defects and properly
grounded.

10.3.2 Repair and Storage

All portable power tools shall be stored in clean, dry

conditions. The contractor shall provide a schedule of
systematic inspection and maintenance for all power
tools. All tools shall be returned to the storekeeper at the
completion of each individual job. Power tools must not
be left lying around the job site where they could be
damaged.

Rotating tools should be switched off and held until

rotation has completely stopped before they are set
down. Tools must be disconnected before changing bits,
blades, cutters, or wheels.

Power for tools can be supplied by compressed air,

explosive cartridge, or electricity. All portable power
tools must be equipped with properly functioning "dead
man" switches.

February 1993 - 10.0 Hand Tools And Power Tools Page 300
10.4 Pneumatic Tools
10.4.1 General

10.4.1.1

An air compressor shall always be under the

supervision of a competent person. It should
always be sited in such a place so as to have
adequate ventilation. Compressors shall not be
permitted to operate in confined spaces without
the provision of adequate exhaust ventilation.

10.4.1.2

All compressed air hoses shall be of the correct

size to fit the tool being used. Any joint in the
hoses shall be made with a proper coupler and
secured by safety wire. The hose length shall be
kept as short as possible and placed so as not to
be subjected to damage.

10.4.1.3

Pneumatic tools require clean air to operate

efficiently. In every line feeding a power tool,
there shall be an adequate filter and lubricator.

10.4.1.4

During operation all air tools should be held

firmly to prevent them spinning and jumping.
This pressure should be maintained during the
stopping process to prevent injury to the
operator's feet and hands.

February 1993 - 10.0 Hand Tools And Power Tools Page 301
 10.4.2 Individual Tools, Precautions

10.4.2.1 Jack Hammer and Concrete Breakers

The tool bit retaining spring shall always be securely

in position to prevent the bit from dropping out.
The bit must be kept sharp.

Ear, eye and foot protection shall be required when

working with this type of equipment. See I.9 for
other personal protective equipment
requirements.

10.4.2.2 Rock Drill

It is extremely important that the operator

maintains a firm grip with both hands and stands
in a balanced position. Any other method of
using the tool can cause serious bodily injury.

10.4.2.3 Grinding Machine

This tool is probably the most misused of all the

power tools. Care should always be taken to
ensure that the grinding wheel is free from
defect before mounting. Any defect may cause
the wheel to disintegrate as it gains momentum.

Only persons who have been instructed in the

proper selection and fitting of grinding wheels
should be allowed to install wheels on tools.

The proper size and type of wheel should be

fitted to the tool so that the maximum
permissible running speed of the spindle does
not exceed the maximum periphery speed
displayed on the grinding wheel. No grinding
machine shall be used unless the maximum
speed is clearly marked on the case. All wheels

February 1993 - 10.0 Hand Tools And Power Tools Page 302
 shall be fitted with adequate guards in
conformance with ANSI B7-1-1988. (See Figure
II.36.)

Floor stand and bench mounted abrasive wheels,

used for external grinding, shall be provided with
safety guards (protection hoods). The maximum
angular exposure of the grinding wheel periphery
and sides shall be not more than 90o, except that
when work requires contact with the wheel
below the horizontal plane of the spindle, the
angular exposure shall not exceed 125 o. In
either case, the exposure shall begin not more
than 65o above the horizontal plane of the
spindle. Safety guards shall be strong enough to
withstand the effect of a bursting wheel. (See
Figures II.37 and II.38.)

Floor and bench-mounted grinders shall be

provided with work rests which are rigidly
supported and readily adjustable. Such work
rests shall be kept at a distance not to exceed
one-eighth inch from the surface of the wheel.
(See Figure II.37.)

Cut type wheels used for external grinding shall

be protected by either a revolving cup guard or a
band type guard in accordance with the
provisions of the American National Standards
Institute, B7.1-1988 Safety Code for the Use,
Care, and Protection of Abrasive Wheels. All
other portable abrasive wheels used for external
grinding, shall be provided with safety guards
(protection hoods) meeting the requirements of
this paragraph, except as follows:

February 1993 - 10.0 Hand Tools And Power Tools Page 303
 · When the work location makes it possible, a
wheel equipped with safety flanges shall be
used.

· When wheels 2 inches or less in diameter

which are securely mounted on the end of a
steel mandrel are used.

Portable abrasive wheels used for internal

grinding shall be provided with safety flanges
(protection flanges) except as follows:

· If the wheels are entirely within the work

being ground while in use.

· When wheels 2 inches or less in diameter

which are securely mounted on the end of a
steel mandrel are used.

When safety guards are required, they shall be so

mounted as to maintain proper alignment with
the wheel, and the guard and its fastenings shall
be of sufficient strength to retain fragments of
the wheel in case of accidental breakage. The
maximum angular exposure of the grinding wheel
periphery and sides shall not exceed 180o.

When safety flanges are required, they shall be

used only with wheels designed to fit the flanges.
Only safety flanges of a type and design and
properly assembled so as to ensure that the
pieces of the wheel will be retained in case of
accidental breakage, shall be used.

All abrasive wheels shall be closely inspected and

ring-tested before mounting to ensure that they
are free from cracks or defects. (See Figure
II.39.)

February 1993 - 10.0 Hand Tools And Power Tools Page 304
 Grinding wheels shall fit freely on the spindle and
shall not be forced on. The spindle nut shall be
tightened only enough to hold the wheel in place.
(See Figure II.40.)

All employees using abrasive wheels shall be

protected by eye protection equipment.

Materials that require grinding shall be placed on

the tool rest with moderate head-on pressure
applied. Materials should not be forced or
jammed into the wheel. Grinding the materials
on the sides of the wheel is an unsafe practice
which can damage the wheel. A grooved or
damaged wheel must be replaced.

February 1993 - 10.0 Hand Tools And Power Tools Page 305
FIGURE II.36: ABRASIVE/GRINDING WHEEL

1 Dimensions

2 Nature of the Abrasive

3 Abrasive Grain Size

4 Grade

5 Structure

6 Bond

7 Maximum Speed

8 Color Stripe = Speed

February 1993 - 10.0 Hand Tools And Power Tools Page 306
FIGURE II.37: GRINDER GUARDS

1. Work rests shall be kept adjusted to the wheel with a

maximum gap of 1/8 inch.

2. Tongue guards shall be kept adjusted closely to

the wheel with a maximum opening of 1/4 inch.

3. The maximum angular exposure of the grinding wheel

periphery should not exceed 90 o. This exposure shall begin
at a point not more than 65o above the horizontal plane.

4. Whenever the nature of the work requires contact with the

wheel below the horizontal plane, the exposure shall not
exceed 125o.

February 1993 - 10.0 Hand Tools And Power Tools Page 307
FIGURE II.38: BENCH GRINDER - MACHINE GUARDING

February 1993 - 10.0 Hand Tools And Power Tools Page 308
10.5 Cartridge Operated Tools
10.5.1 General

Cartridge operated tools have a great advantage in that

they can be used in almost any situation without the
inconvenience of trailing leads or hoses. However, it is
essential that these tools be operated only by properly
trained personnel who are over 18 years of age. The
contractor shall ensure that each man required to operate
such a tool will undergo a thorough training period and be
certified by the tool vendor. Use of cartridge operated
tools will be in accordance with Saudi Aramco GI 2.100,
ANSI A10.3-1985 and the manufacturer's specifications
and shall be subject to review and concurrence by the
Loss Prevention Department.

10.5.2 Storage

Safe and secure storage for cartridges and tools must be

provided on the job site. Storage must be fire proof, dry,
must be capable of being locked and should be sited in a
clear, but easily accessible location where constant
supervision can be maintained.

Cartridges and tools must not be stored together. A

storage unit providing positive physical separation of
cartridges and tools (i.e., a wall or partition) is required.

Warning to be posted where cartridges are stored:

"DANGER - NO SMOKING Cartridge Storage".

Ventilation must be provided in the store. Cartons of

cartridges must not be stacked against the wall and
ventilation spaces must be left around the cartons. Only
one carton of each strength cartridge shall be open at any
one time. All empty cartons, and intermediate packing,
must be removed at once.

February 1993 - 10.0 Hand Tools And Power Tools Page 309
 Tools must be stored in their carrying cases. No loose
cartridges must be in the carrying cases; all cartridges
must be in their color coded boxes.

Only authorized personnel must be allowed access to the

store.

10.5.3 Selection and Training of Personnel

No person may operate, clean, maintain, or repair any

cartridge tool without possessing a certificate of
competency, issued by an accredited tool vendor or
manufacturer's representative, which identifies the
particular model that the person is qualified to handle.

Personnel for training must be selected with the following

points in mind:

1 Must be over 18 years of age.

2 Must be physically fit and have full use of both hands
and both eyes.
3 Should ideally be a tradesman, e.g. plumber, mason,
electrician, joiner/carpenter, etc.
4 Storemen may also need to be trained if they are
required to clean and maintain the tools.

Training, both theoretical and practical, must be given by

a competent instructor.

The training must follow the manufacturer's instructions

as contained in the handbook of each particular model.

10.5.4 Personal Protective Equipment

Eye Protection shall be worn by the operator and his

assistant whenever using the tools. Goggles must be of a
satisfactory standard designed to withstand high speed
impacts and/or, penetrations.

February 1993 - 10.0 Hand Tools And Power Tools Page 310
 Ear muffs will be available for use at any time and shall be
used in confined spaces.

Safety belts may be required in certain situations where

the recoil from the tool could cause an operator to loose
his balance.

February 1993 - 10.0 Hand Tools And Power Tools Page 311
 10.5.5 Issue and Returns

Contractors will ensure that a full register of the serial

numbers of each tool is made and kept up to date.

A log inventory system of issuing and returning cartridges

and tools against signatures must be initiated and
maintained. See Figure II.47: Cartridge/Tool Issuance
Control.

Only personnel in possession of a user certificate will be

allowed to withdraw tools or cartridges from the store.

Only the minimum number of cartridges required for that

particular shift's operation should be issued at any one
time.

Cartridges and tools must not be left on the job site at

lunch break or at end of shift but must be returned to the
store for safekeeping.

Any loss, either of tools or cartridges, must be reported,

at once, to Saudi Aramco project proponent.

10.5.6 Work Permits

Work Permits will not normally be required for use on job

sites.

Where tools will be used in restricted areas (as defined in

GI 2.100 Work Permits), a Hot Work Permit must be
obtained before work commences.

10.5.7 Use

No person may operate, clean, maintain or repair any

cartridge tool without possessing a certificate of
competency which identifies the particular model that
person is qualified to handle.

February 1993 - 10.0 Hand Tools And Power Tools Page 312
 The manufacturer's operating instructions must be
followed at all times.

Cartridges are manufactured in different calibers and

strengths. There are three sizes: .25 short, .27 short, and .
27 long; and, four strengths, as follows:

POWER NUMBER COLOR LETTER

LEVEL CODE CODE
Low 3 Green L
Low/Mediu 4 Yellow LM
m
Medium/Hig 5 Red MH
h
Extra High 6 Purple/Black EX

It is, therefore, imperative that the correct size and

strength of cartridge required for the tool, the fixing, and
the material to be fixed onto be properly determined. A
wrongly sized cartridge will cause a stoppage or misfire.

Using a cartridge which is too powerful could cause a

ricochet or a spalling or fracture of the material.

February 1993 - 10.0 Hand Tools And Power Tools Page 313
 The following General Safety and Operating Rules are
common to all types of tools:

1 As soon as the tool is removed from its carrying case,

check to make sure that a cartridge is NOT LOADED.

2 Inspect the tool before use each day to ensure that it

is complete, in good condition (e.g., clean), and that
the safety devices are in proper working condition.

3 Any tool that is not in proper working order or that

develops a defect during use, shall be immediately
withdrawn from service and not used until properly
repaired.

4 Tools shall not be loaded with a cartridge until just

prior to the intended firing time. When loading a
tool, point it away from you and anyone else. Never
walk around with a loaded tool; load it where you are
working. Never leave the tool loaded when not in
use. Loaded tools shall not be left unattended.

5 Never try to operate the tool without the end of the

barrel hard against the fixing surface.

6 All tools shall be used with the correct shield, guard,

or attachment recommended by the manufacturer.

7 Fasteners shall not be driven into very hard or brittle

materials including, but not limited to, cast iron,
glazed tile, surface hardened steel, glass blocks,
hollow tile, terra cotta, marble, granite, slate, etc.

8 Driving into soft or easily penetrable materials shall

be avoided unless materials are backed by another
material that will prevent the pin from passing
completely through and creating a flying missile
hazard on the other side. Careful inspection of all

February 1993 - 10.0 Hand Tools And Power Tools Page 314
 materials should be made before deciding on the use
of a cartridge tool.

9 No pins shall be driven into a spalled area caused by

an unsatisfactory shot, or into any existing hole in the
material. Care should be taken to ensure that the
new fixing is at least two inches away from any
previous hole, and a similar distance from any
welded joint.

10 Pins must not be fired into corner bricks, mortar

joints, and must be at least four (4) inches (100 mm)
away from the edge of concrete or brick work and
one-half inch (12 mm) from the edge of steel.

11 Ensure that the correct strength cartridge is used for

the pin, fixing and material involved. For the first, or
test firing use the weakest cartridge. Too strong a
cartridge may result in over penetration, or the
fastener may rebound or ricochet.

12 The tool must be held at right angles to the job when

firing.

13 In the event of a misfire, the tool should be re-

triggered without moving the tool from the work
face. If the shot again fails, then the tool must be
held firmly in the firing position for at least 30
seconds to allow for a possible "Hang Fire" in the
cartridge. The removal of the misfired cartridge must
be as per the manufacturer's instructions. Do not
use nails, knives, etc., to pry the cartridge loose.

14 Recoil from firing can throw an operator off balance,

especially when working from ladders or scaffolds.
Care must be taken to ensure that the operator has a
secure and safe work area. Safety belts should be
used if necessary.

February 1993 - 10.0 Hand Tools And Power Tools Page 315
 15 Do not leave cartridges loose on the job site or in the
carrying case or carry them in your pockets.
Cartridges are of the 'Rim Fire' type and could
explode accidentally if in receipt of a knock from a
pin, fixing, or even a bunch of keys.

16 Before returning the tool to the stores, ensure that it

is clean and complete and that all cartridges are in
their correct color coded box.

10.5.8 Maintenance and Repair

Before any repair/maintenance work is carried out, check

to make sure that the tool is NOT LOADED with a
cartridge.

No person may operate, clean, maintain or repair any

cartridge tool without possessing a certificate of
competency which identifies the particular model that the
person is qualified to handle.

Tools must be dismantled, as far as the manufacturer's

instructions indicate, at least once every week and
checked for defects and excessive wear before being
cleaned and oiled. If any defect is found, the tool must be
made serviceable before being issued for use.

February 1993 - 10.0 Hand Tools And Power Tools Page 316
 Only manufacturer's authorized spare parts are to be used
for repair/replacement.

NO CARTRIDGES must be allowed in the

repair/maintenance area. Test firing of repaired tools
must be done in a safe location away from work and store
or office areas.

10.6 Electrically Operated Tools

10.6.1 General

10.6.1.1

All electrically operated hand tools shall be rated

and used at a voltage not exceeding 125V to
ground.

10.6.1.2

Before any electrical tool is used, a careful check

shall be made by the supervisor to ensure that
the supply voltage is within the range marked on
the information plate on the tool. Ground Fault
Circuit Interrupters (GFCIs) are required for all
120 volt, single phase, 15 and 20 ampere
receptacle outlets on construction sites which are
not a part of the permanent wiring system.

10.6.1.3

All electrical power hand tools shall be of the

double insulated type or properly grounded.

External metal parts of double insulated tools

(drill chucks, saw blades, etc.) are insulated from
the electrified parts inside the tool and, under
normal conditions, contact with electrified parts
of the tool does not take place. However, under

February 1993 - 10.0 Hand Tools And Power Tools Page 317
 wet conditions, rain, condensation, high
humidity, damp locations, etc., the hazards are as
great as with faulty grounded tools. All electrical
tools are hazardous when used damp or wet, but
with double insulated tools the moisture coupled
with metal dust, carbon dust, etc. can form a
conductive path from inside the tool to the
surface through the ventilation holes or cracks.
Since there is no ground wire to carry this current
away, the user can receive an electric shock.
Double insulated tools, like all electric tools, must
be kept dry and should not be used without a
ground fault circuit interrupter.

10.6.1.4

All tools shall be used with extension cords which

are as short as possible. All extension cords shall
be fitted with grounding pin and blades to fit the
socket outlet on the distribution board.
Extension cords shall be of the three-wire
conductor type. Plugs and sockets must meet
the National Electrical Code requirement with
respect to grounding and polarity.

Overcurrent protection shall be provided to

extension cords in accordance with the
requirements of the National Electrical Code
Article 240. Factors to be considered for
adequate overcurrent protection are: type of
conductors, size, and length of run.

Example: Consider electrical equipment being

used on a construction site that may require 15
or 18 ampere (amp.) capacity. Construction
plans call for three No. 12 AWG (wire size)
copper conductors which run to a 20 amp.
receptacle (120 v) 40 feet from the electrical

February 1993 - 10.0 Hand Tools And Power Tools Page 318
 panel box. This circuit is protected by a 20 amp.
circuit breaker. Is this a problem? Yes - There
may be three problems: (1) the size of the
conductors, (2) the length of cable run and, (3)
the circuit breaker size.

In order to prevent an employee from receiving

an electric shock, the breaker size and receptacle
should be reduced to 15 amp. or the conductors
changed to a No. 10 AWG so that the breaker can
function at 20 amp. when required. Leaving the
circuit the way it is would allow considerable
electrical leakage without tripping the circuit
breaker. Also conductor insulation would be
subject to heat damage causing electrical leakage
and fire. Heavy duty construction type extension
cords are required for 20 ampere circuits, No. 14
AWG or larger size for 100 feet of run length.
(See Figure II.41.)

10.6.1.5

Where it is necessary to make electrical splices,

these shall be made with proper connector
blocks or by plug and socket connectors. Taped
joints shall not be permitted.

10.6.2 Maintenance and Storage

A proper inspection and maintenance routine shall be

established by the contractor for all electrical tools. The
inspection and maintenance of all tools shall be carried
out at least once in every working week by a competent
electrician.

All tools shall be stored in a clean, dry place, and a record

of issue and receipt shall be maintained by the
storekeeper.

February 1993 - 10.0 Hand Tools And Power Tools Page 319
 10.6.3 Personal Protective Equipment

The contractor shall ensure that all operators are

provided with eye, head, and ear protection. If there is
any likelihood of harmful dust being emitted, dust
respirators should be used.

10.6.4 Individual Tools, Precautions

10.6.4.1 Grinders

All grinders shall be equipped with a protective

guard which allows only the working part of the
wheel to be exposed. This guard must not be
removed.

Grinders shall be clearly marked with their

maximum running speed. The maximum running
speed of the spindle must not exceed the
maximum periphery speed marked on the
grinding wheel. Wheels should be checked for
defects before mounting. All defective wheels
must be destroyed. (See Figure II.40.)

10.6.4.2 Drills

Care should be taken not to drill too large a hole at

one time. Drilling of large holes should be done
in stages by using small bore drills and gradually
increasing the size as necessary. If this is not
done, the drill may bind on breakthrough, and
the torque set up could twist the tool against
the user's wrist.

10.6.4.3 Saws

Hand operated circular saws shall be fitted with

spring loaded guards which allow only the

February 1993 - 10.0 Hand Tools And Power Tools Page 320
 working part of the blade to be exposed. (See
Figure II.42.)

Portable table saws shall be provided with

adjustable guards, anti-kick-back devices, and
push-type start/stop buttons within easy reach
of the operator. (See Figures II.43 and II.44.)
Fixed table saws shall be hard wired to an
emergency electrical disconnect switch that has
the capability of locking out in addition to having
start/stop buttons at the operator's location,
etc. Portable table saws must be unplugged for
repair, maintenance, or when not in use.

Where a provision is made for a table saw riving

knife to be fitted, it shall be kept clean and
properly adjusted to the work at all times. Push
sticks must be provided and used when
necessary on all bench saws.

The work area shall be cleaned to prevent excessive

build-up of sawdust and scrap wood.

Operators shall wear eye and hearing protection.

10.6.4.4 Radial Saws

(Figure II.45)

Radial saws must be provided with:

· An upper hood to enclose the top portion

of the blade down to a point that includes
the end of the saw arbor. The sides of the
lower, exposed portion of the blade must
be guarded to the full diameter of the
blade by a device that automatically
adjusts to the thickness of the stock being
cut.

February 1993 - 10.0 Hand Tools And Power Tools Page 321
 · Anti-kickback dogs (on both sides of saw)
designed to provide adequate holding
power for all thicknesses of ripping stock.

· An adjustable stop limiting the forward

travel of the blade beyond the distance
necessary to complete the cut in
repetitive operations.

· A saw housing which automatically

returns to the starting position.

· A marking on the hood showing the

direction of the saw rotation. In addition,
a permanent label must be affixed to the
rear of the guard, reading: "DANGER. DO
NOT RIP OR PLOUGH FROM THIS END."

· Start/stop buttons at the operator's

position. Additionally, in the case of fixed
saws, each saw must be wired to an
emergency electrical disconnect isolation
switch capable of locking out the saw.

February 1993 - 10.0 Hand Tools And Power Tools Page 322
FIGURE II.39: "RING TEST"

February 1993 - 10.0 Hand Tools And Power Tools Page 323
FIGURE II.40: CORRECTLY MOUNTED GRINDING WHEEL

February 1993 - 10.0 Hand Tools And Power Tools Page 324
FIGURE II.41: WIRE CONVERSION CHART

* Middle Ring American * Outer Ring Allowance

Wire Gauge Ampacities Of
Insulated Conductors
Rate 0-2000 Volts, 60o
To 90o ("THWN" 75oC
Cable Temperature
Ratings)

* Inter Ring Metric or MM2

Note: Ambient Temperature Corrections Factors Must Be

Applied As Per SAES-P-104

February 1993 - 10.0 Hand Tools And Power Tools Page 325
 CMills = MM2 Example 500 mcm AWS 500000 = 250MM2 (Reference
N.E.C. Table 310-60)
19735 19735

February 1993 - 10.0 Hand Tools And Power Tools Page 326
FIGURE II.42: SELF ADJUSTING GUARD

February 1993 - 10.0 Hand Tools And Power Tools Page 327
 As the blade moves up through the
stock,
the guard rises up to the stock surface.

February 1993 - 10.0 Hand Tools And Power Tools Page 328
FIGURE II.43: TABLE SAWS

· Table saws must be provided with a hood that covers the saw at
all times.
· Table saws used for ripping must be equipped with an anti-
kickback device and spreader.
· The exposed part of the saw underneath the table must be
guarded.
· Table must be secured in position.
· Guarded start/stop buttons shall be provided at the
operator's position.
· All fixed table saws shall be hard wired to an emergency
electrical disconnect switch capable of locking out the saw.

February 1993 - 10.0 Hand Tools And Power Tools Page 329
FIGURE II.44: TABLE SAWS - MACHINE GUARDING

February 1993 - 10.0 Hand Tools And Power Tools Page 330
FIGURE II.45: RADIAL SAWS

Radial Saws must be provided with:

· An upper hood to enclose the top portion of the blade down

to a point that includes the end of the saw arbor. The sides
of the lower, exposed portion of the blade must be guarded
to the full diameter of the blade by a device that
automatically adjusts to the thickness of the stock being cut.

· Anti-kickback dogs (on both sides of the saw) designed to

provide adequate holding power for all thicknesses of ripping
stock.

· An adjustable stop limiting the forward travel of the blade

beyond the distance necessary to complete the cut in
repetitive operations.

· A saw housing which automatically returns to the starting

position.

· A marking on the hood showing the direction of the saw

rotation. In addition, a permanent label must be affixed to
the rear of the guard, reading: "DANGER. DO NOT RIP OR
PLOUGH FROM THIS END."

· Guarded start/stop buttons shall be located at the operators

position.

· Saw stand shall be secured in position.

· All fixed radial saws shall be hard wired to an emergency

electrical disconnect switch capable of locking out the saw.

February 1993 - Construction Safety Manual: Hand Tools And Power Tools Page 331
FIGURE II.46: THE WOODWORKING MACHINE REGULATIONS

Circular saws are included under types specified as woodworking

machines.

Training:
· No person should be employed on a woodworking machine who has
not been trained and instructed in its operation.

Duties Of Employed Persons:

· Employees using woodworking machines must use and keep properly
adjusted guards and other safety devices and use push sticks, jigs,
holders and backstops provided.

Working Environment:
· Sufficient space to be provided around machine to allow work
without risk of injury.
· Floors to be level, in good condition, free of loose material, and not
slippery.

Guards:
· Cutters to be guarded to the greatest practicable extent.
· Guards to be of substantial construction, properly secured and
adjusted, and constantly in position while cutters are in motion.

Top Guard:
· Guard to be strong and easily adjustable.
· Adjusted to extend from top of riving knife to a point as close as
practicable to the surface of the material being cut; or to a point not
more than 12 mm above the material being cut where squared stock
is being hand held.

Bottom Guard:
· Blade below table to be guarded to the greatest extent practicable.

Push Sticks:
· Must be available for use on every hand-fed circular saw, and used to
feed material-

February 1993 - 10.0 Hand Tools And Power Tools Page 332
 a) throughout any cut of 300 mm or less
b) during the last 300 mm of any cut more than 300 mm in
length
Push sticks should also be used to remove cut material from
between the saw blade and the fence.

February 1993 - 10.0 Hand Tools And Power Tools Page 333
FIGURE II.47: CARTRIDGE/TOOL ISSUANCE CONTROL

Cartridge Quantity Received By

Dat Issue Return Return Return Tool Cert Name/ Issued By Remarks
e d ed ed ed Un- Issued No. Signatu
Used Unuse explod (Type/M re
d ed DL)

February 1993 - 10.0 Hand Tools And Power Tools Page 334
 Warning: Above items can only be issued to workers with valid training certificate Storekeeper:
Safety Officer:

February 1993 - 10.0 Hand Tools And Power Tools Page 335
11.0 PAINTS AND COATINGS
In addition to the usual hazards associated with construction activities,
workmen engaged in surface preparation and paint application can be
exposed to the dangers of fire, explosion, chemical burns, toxic fumes,
dust, and insufficient air. This section of the manual discusses these
hazards and how to minimize them.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 2.100 Work Permit System

GI 6.021 Safety Requirements For Abrasive Blast Cleaning

GI 8.003 Breathing Apparatus

Saudi Aramco Engineering Standards:

SAES-A-105 Noise

SAES-B-067 Safety Identification and Color Coding

SAES-H-102 Safety Requirements for Painting

Steel Structures Painting Council. Steel Structures Painting Manual,

Volumes 1 and 2.

United States of America Code of Federal Regulations, 29 CFR 1910.1000

Air Contaminants.

11.1 Flammability Hazards of Coating Materials

11.1.1 Flammable Materials

In paint systems, it is normally the organic solvent vapor

that is flammable. In the Saudi Aramco paint system, all
the solvents (except for the water based paints) present a
fire hazard.

February 1993 - Construction Safety Manual: Paints And CoatingsPage 336

 11.1.2 Flash Point (Definition)

The flash point is defined as the lowest temperature at

which a liquid will give off sufficient vapor to ignite when
exposed to an open flame. For most paint solvents in the
Saudi Aramco system, the flash point is less than the
normal ambient temperatures in Saudi Arabia. The
danger of fire exists virtually always when solvents are in
use.

11.1.3 Flammable (Explosive) Limits (Definition)

The lower and upper flammable (explosive) limits define

the range of vapor/air concentrations that are potentially
explosive. The lower flammable (explosive) limit (LEL) is
typically on the order of 1% to 2% by volume, a level
readily obtained in the area near opened solvent
containers and near the nozzle of a spray painting gun in
operation.

11.1.4 Fire Precautions

Solvents in paints constitute a significant fire and

explosion hazard when in the presence of ignition
sources. No painting should be carried out within 75 feet
of potential ignition sources, e.g., welding, flame-cutting,
smoking areas, or sparking tools, unless conditions
warrant greater clearance.

Ventilation equipment should be used to maintain a

maximum level of solvent concentration, typically below
10% of the LEL.

All electrical lighting and equipment shall be explosion-

proof when required in areas where solvent vapors are
likely to be present.

All electrical equipment such as switches, panel boards,

electrical motors and associated equipment must be de-

February 1993 - 11.0 Paints And Coatings Page 337

 energized before spray painting to eliminate explosion
hazards.

Solvents and solvent based paints shall not be applied to

surfaces exceeding Saudi Arabia summer ambient
temperatures.

The use and storage of flammable paints and solvents

shall be kept to restricted areas and these areas should be
suitably marked with the appropriate warning signs.
Flammable paints should be kept in a special building or in
a sun shelter.

Fire extinguishers should be located at the work area and

the area Loss Prevention representative/Fire Chief shall
agree upon their suitability.

Work areas should be kept as clean as practicably

possible.

11.2 Health Hazards Associated With Paints

Many paint ingredients are harmful to humans; most people can
withstand these materials over a short time and in small
quantities. However, some people are immediately sensitive to
some ingredients and almost everyone will be affected to some
degree if exposed for sufficient time.

There are two major groups of irritants: toxic materials and

dermatitic or skin irritating materials.

11.2.1 Toxic Materials

The most abundant toxic materials found in paints and

coatings are solvents. Other toxic materials in paints
include pigments (lead), binders (epoxies, polyesters) and
additives (organotin). Also, dust from cleaning operations
or application of the paint can generate toxic materials.
These toxic materials can enter the body through

February 1993 - 11.0 Paints And Coatings Page 338

 breathing, ingestion or skin absorption. Most solvents are
toxic to some degree depending on exposure. The degree
of toxicity can be measured by the Permissible Exposure
Limit (PEL) expressed as parts per million (ppm) or
milligrams of particulate per cubic meter (mg/M 3) of
solvent in air over an exposure of 8 hours a day five days a
week with no ill effects.

11.2.2 Dermatitic Materials

Dermatitic materials irritate the skin which, if left

untreated, can cause infections or ulceration.

Solvents have a tendency to dissolve and remove natural

oils and fats from skin. Certain binders such as epoxy
resins may also irritate the skin.

Other chemicals used in paint related work should be

handled with care (e.g. paint removers, acid and alkaline
cleaners).

11.2.3 Prevention of Health Hazards

Many solvents and coatings contain hazardous

ingredients. A copy of the appropriate Material Safety
Data Sheet (MSDS) should be obtained for all materials
used, studied carefully, and the required safety
precautions implemented.

The following precautions should minimize health

hazards:

· Identify and seal all toxic and dermatitic materials

when not in use.

· Adequately ventilate all painting areas and provide

National Institute for Occupational Safety and Health
(NIOSH), Mine Safety and Health Administration
(MSHA)-approved or equivalent respiratory

February 1993 - 11.0 Paints And Coatings Page 339

 protection where necessary. All workmen spray
painting shall wear chemical cartridge respirators or
airline hoods depending upon the hazards of the
paint.

· Minimize dust during surface preparation, and

dispose of coating residue in accordance with the
recommendations of the Environmental Engineering
Division, Process and Control Services Department.

· Wear the appropriate personnel protective

equipment for the work being carried out.

· Avoid touching any part of the body and wear

protective equipment (e.g. gloves, Tywag suits, etc.)
when handling dermatitic materials. Personnel
involved in painting shall wash thoroughly before
eating and at the end of the day.

· Use ventilation control or respirators when working

with paint removers containing toxic solvents.

11.3 Ventilation in Confined Spaces

A supply of clean air is a necessity for all operations involving the
application of coating materials, and the paint curing/drying
process. A high quality air supply is also required for life support
(refer to GI 8.003 - Breathing Apparatus).

Ventilation is a necessity when painting in confined areas

because solvents tend to be heavier than air and migrate to
lower levels. The fresh air inlet of the ventilation system should
be located near the top of the confined space, and the discharge
should be located near the bottom, positioned to eliminate dead
air spaces. Supplementary fans may be necessary to ensure good
air circulation.

Natural ventilation through open man ways, etc. is rarely

sufficient to keep local vapor concentrations to a safe level in

February 1993 - 11.0 Paints And Coatings Page 340

 terms of PELs or LELs. As a general rule, forced ventilation shall
be used, especially in small enclosures and always during spray
painting.

Ventilation requirements are proportionally greater for vessels

with a capacity smaller than 1580 m3 (10,000 BBL's or 56,000 cu
ft). The recommended ventilation requirements for various
vessel capacities are shown in Table II.6; ref. SAES-H-102.

Ventilating to 10% of the LEL considerably reduces the likelihood

of fire or explosion; however, this level will no doubt exceed the
Permissible Exposure Limits for toxic materials. Hence, supplied
air respiratory protection is required in confined spaces.

The preparation of air used for life support involves the following
factors: PEL's of nuisance and toxic dusts; fume, gas and vapor
content; air temperature. Air required for breathing apparatus
shall meet the requirements of GI 8.003, Breathing Apparatus.

TABLE II.6: VENTILATION REQUIREMENTS FOR CONFINED SPACES

February 1993 - 11.0 Paints And Coatings Page 341

 Volume of Confined Requir
Area ed Air
Mover
Capaci
ty
m3 BBL L/s cfm
16 100 472 1000
80 500 1180 2500
160 1000 2360 5000
800 5000 4720 10000
1600 10000 7080 15000
4000 + 25000 + 9440 20000

11.4 Surface Preparation

Equipment and materials that are used in surface preparation for
paints and coatings can be hazardous if used carelessly. There
are several methods for preparing surfaces and these include:

· Blast cleaning where abrasives in the form of sand, iron shot,

grit, slag, etc. are used. Other types of blast cleaning use
high pressure water or steam.

· Hand or power tool cleaning includes grinders, sanders,

rotary wire brushes, impact tools, chisels, hammers.

· Chemical cleaning using paint removers, or solvents, alkali,

acids or detergents.

11.4.1 Abrasive Blast Cleaning

This section covers blast cleaning using abrasives in the

form of sand, iron shot, grit, slag or similar materials.

Abrasive blast cleaning operators shall have pre-

placement physical examinations, including chest X-ray

February 1993 - 11.0 Paints And Coatings Page 342

 and pulmonary function tests with repeat tests at least
every two years.

The abrasive blast cleaning operator shall wear an air

supplied protective hood approved (NIOSH/MSHA or
equivalent) for the type of abrasive material being used
and any other toxic contaminants (lead, zinc, etc.) that are
present. Where blast cleaning assistants could be
exposed to silica sand dust or toxic contaminants, then
self-contained or air supplied breathing apparatus shall be
worn by the assistant. The breathing apparatus and air
quality specification shall meet the standards referenced
in GI 8.003, Breathing Apparatus. Personnel (e.g.
maintenance, workers handling abrasive supplies or clean
up crews) within the range of rebound abrasive
contaminants shall wear approved (NIOSH/MSHA or
equivalent) dust-filter respirators for the specific airborne
hazards.

A bonding system that bonds nozzle, hose, blasting

equipment and the material being cleaned shall be
provided, and this bonding system shall be grounded to
prevent a build up of static charges. Ground continuity
tests shall be conducted periodically to ensure proper
grounding.

To prevent ignition of hydrocarbons in classified areas, the

appropriate precautions listed in GI 2.100, Work Permit
System, must be followed.

February 1993 - 11.0 Paints And Coatings Page 343

 11.4.2 Hydroblast and Steam Cleaning

Hydroblast cleaning uses a high pressure ambient

temperature water jet and steam cleaning uses a high
pressure and high temperature steam jet. Extra caution
should be exercised when using such equipment. These
types of equipment are used for removing dirt or rust
scales and the personal protective equipment
requirements are shown in Table II.7.

11.4.3 Hand and Power Tool Cleaning

This section briefly covers the safety aspects of hand and

power tools used for surface preparation.

Particular attention should be paid to eye protection to

guard against flying particles, and where necessary, ear
protection should be provided to prevent long term
hearing loss per SAES-A-105, Noise.

Tools should be correctly selected for the purpose, and

also operated and maintained to the manufacturer's
instructions.

Suitable respirators should be used if contaminant levels

exceed Permissible Exposure Limits.

Extreme care should be used if tools have the ability to

create sparks.

11.4.4 Chemical Cleaning

This section is concerned with four types of chemical

cleaners (organic solvents, alkalines, acids and detergents)
used to assist in the removal of surface contaminants such
as light oils, greases and rust.

Solvents such as kerosene, mineral spirits, and turpentine

are used to dissolve and remove oil contaminants.
Hazards associated with solvents include their flammable,

February 1993 - 11.0 Paints And Coatings Page 344

 toxic and dermatitic characteristics. Safety precautions
regarding these solvents are included in sections 11.1 and
11.2.

Alkaline cleaners are composed of highly alkaline salts

with wetting agents and/or soaps. They function by
wetting, emulsifying, dispersing and solubilizing surface
contaminants, and are generally used at elevated
temperatures.

Acid cleaners are generally composed of strong acids.

They remove contaminants by chemical attack and are
primarily used to remove metal scales such as rust.

Detergent cleaners are comparable to alkaline cleaners

except they are generally used at low temperatures (60 to
100 degrees Celsius).

For all of the above chemical cleaners, personal safety

precautions must be taken to protect personnel from
materials and conditions that present fire hazards or
cause personnel to experience dermatitic or toxic effects
(such as inhalation effects, skin burns, or eye irritants).

When using chemical cleaners, appropriate eye and body

wash facilities shall be available in the immediate area to
minimize the effects of chemical burns in the event of an
accident.

Chemical cleaning agents such as solvents shall not be

used for cleaning personnel.

The following solvents shall not be used for cleaning

purposes due to the very toxic nature: benzene, gasoline,
carbon tetrachloride, and chlorinated hydrocarbons.

February 1993 - 11.0 Paints And Coatings Page 345

 11.4.5 General Safety in Surface Preparation

Instruction and training of operators about correct use of

the cleaning agents and equipment are essential.

Surfaces other than those receiving preparation should be

protected from damage due to cleaning operations.

Where operators are using equipment such as blast

cleaners or power tools, they must have safe footing.
Extra caution should be taken on scaffoldings.

Never point a cleaning gun or nozzle at anyone or any part

of your body.

Equipment such as blast guns and power tools must have

automatic controls that shut off the flow of abrasive and
propellant if for any reason the operator releases the
control switch.

Power tools should be properly grounded to prevent

electric shock.

All manufacturers recommendations on protective guards

shall be implemented.

Fire and explosion hazards always exist when using

solvents, especially in confined areas. Adequate
ventilation must be provided.

11.5 Personal Protective Equipment

Personal protective equipment is required for the majority of
operations that involve surface preparation or paint application.
The amount and type of personal protection depends on the
work being carried out and the location. Table II.7 gives a
summary of essential personal protective equipment that must
be worn by personnel carrying out specific duties. In addition, all
personnel on Saudi Aramco industrial facilities and potentially

February 1993 - 11.0 Paints And Coatings Page 346

 hazardous areas must wear safety shoes, a hard safety hat and
safety spectacles. Other protective details such as gloves, face
shields, overalls and hearing protections should be addressed to
either the area Loss Prevention or Industrial Hygiene offices.

February 1993 - 11.0 Paints And Coatings Page 347

TABLE II.7: PERSONAL PROTECTIVE EQUIPMENT TO BE WORN OR USED
DURING SURFACE PREPARATION AND PAINT APPLICATION

February 1993 - 11.0 Paints And Coatings Page 348

 TYPE OF WORK PERSONAL PERSONAL
PERFORMED PROTECTIVE PROTECTIVE
EQUIPMENT EQUIPMENT TO BE
TO BE WORN WORN (Confined
(Outside) See key space) See key
Surface preparation
Hand or power tool 3,4,5,9,10,11 3,4,9,10,11
operations
Abrasive blast
cleaning
Operator 1,9,10,11 1,8,9,10,11
Other workmen in 3,4,5,9,10,11 1,8,9,10,11
the vicinity
Hydroblast and steam 3,4,5,9,10,11 3,4,5,8,9,10,11
cleaning
Chemical cleaning 4,7,10,11 1,4,7,10,11
Paint application
(spray)
Epoxy and coal tar 2,4,6,10,11 1,6,10,11
epoxy
(SAPCS - 1,2 and 3)
Alkyd (SAPCS - 4 and 2,5,6,10,11 1,5,6,10,11
6)
Inorganic zinc 2,5,6,10,11 1,5,6,10,11
(SAPCS -1A, 11A and
17)
Chlorinated rubber 2,5,6,10,11 1,5,6,10,11
(SAPCS - 9)
Bituminous (SAPCS - 2,5,6,10,11 1,5,6,10,11
10)
Polyurethane (SAPCS 2,5,6,10,11 1,5,6,10,11
- 25)
Paint application
(brush)

February 1993 - 11.0 Paints And Coatings Page 349

 Epoxy and coal tar 4,6,10,11 2,4,6,10,11
epoxy
(SAPCS - 1,2 and 3)
Alkyd (SAPCS - 4 and 6,10,11 2,6,10,11
6)
Inorganic zinc 6,10,11 4,6,10,11
(SAPCS -1A, 11A and
17)
Chlorinated rubber 6,10,11 2,6,10,11
(SAPCS - 9)
Bituminous (SAPCS - 6,10,11 2,6,10,11
10)
Polyurethane (SAPCS 6,10,11 6,10,11
- 25)

Note: Safety belts / harnesses shall be used when these operations are
performed above ground levels (1.82 m - 6 ft or more) if a guard
rail system is not in place, and / or in confined spaces.
The workman should always refer to the MSDS for complete
details.

February 1993 - 11.0 Paints And Coatings Page 350

 Key to Table II.7:

1. OSHA-approved, respirable air fed hood and filter, SAMS No.

21-444-934
2. Respirator; chemical cartridge, SAMS No. 21-370-
800/810/820
3. Dust respirator, SAMS No. 21-370-500
4. Face shield (1), SAMS No. 21-426-121
5. Goggles, safety impact, SAMS No. 21-434-249
6. Gloves, SAMS No. 21-432-XXX
7. Gloves; rubber, SAMS No. 21-432-630
8. Ear protection, SAMS No. 21-327-110
9. Gloves (leather and fabric), SAMS No. 21-432-353
10. Helmets (hard hats), SAMS No. 21-441-055 (MSA) / SAMS No.
21-441-050 (American Optical)
11. Safety Shoes, SAMS Nos. 21-472-200 / 21-472-221 / 21-472-
300 / 21-472-350

11.6 Paint Application

There are numerous hazards associated with paint application
and this section is concerned with air and airless spraying,
together with brush and roller painting.

11.6.1 Paint Materials

The majority of paint solvents, many pigments and some

binders are toxic in addition to having potential dermatitic
hazards. Refer to the Material Safety Data Sheet (MSDS)
for information concerning the hazards associated with
their use.

In that, solvent based painting materials also present a

fire and explosion hazards, painting shall not be carried
out near an ignition source. Also, additional care should
be taken to provide adequate ventilation in confined
spaces.

February 1993 - 11.0 Paints And Coatings Page 351

 Spraying paint using air or airless systems can be very
hazardous and should only be used by trained operators.

11.6.2 General Safety In Paint Application

All personnel involved with the application of paint to

surfaces should wear the appropriate personal protective
equipment for the work being carried out at a given
location. For some paint jobs personal protective
equipment may have to exceed the requirements
specified in Table II.7 due to the nature of the work being
performed. Some examples of these jobs are above
ground and water operations, use of special paints, etc.

All pressurized equipment should be handled carefully.

Operators and their assistants should know how to
operate and de-energize the equipment in accordance to
manufacturer's recommendations.

No spray gun should be pointed at anyone or part of the

user's body.

The spray painting operation should be conducted from

the upwind side of the object being coated, wherever
practicable.

Before using airless spray equipment, all guards

recommended by the manufacturer shall be in place and
the system shall be in good order and correctly grounded
to prevent static build-up.

Prompt professional medical aid shall be available to any

person receiving paint injuries.

The area around spray painting activity should be

enclosed by hardboard fence or equivalent to protect
outside personnel from paint over spray.

February 1993 - 11.0 Paints And Coatings Page 352

11.7 Scaffolding and Ladders
Details concerning the use and hazards associated with
scaffolding and ladders are included in Section II.9 of the
Construction Safety Manual.

Only good condition, correctly erected equipment shall be used

that meets industry standards (ANSI) or equivalent. Users and
erectors of such equipment should be trained about its use and
limitations.

11.8 Tarring Operations

Tarring operations are commonly used in roof work, and hazards
associated with this type of work include body burns, fire and
toxicity. Precautions that are required for tar operations include:

· The heating of tar shall not be carried out on roof tops or in

similar potentially hazardous locations.

· Tar heating operations shall be carried out using approved

fuel gas in the correct cylinders. The heating operations shall
be at ground level and at a minimum distance of 4.5 m (15
feet) away from fuel gas cylinders, buildings or similar
structures.

· The transferring of hot tar to its required location shall be

carried out using the safest mode of transport available
(preferably pumped). Lifting of hot asphalt in buckets is not
allowed.

· The temperature of the asphalt shall be monitored with a

temperature gauge and must not exceed 450 0F at any time
during the tarring operations.

In addition to personal protective equipment (safety shoes,

safety glasses and hard hats), the following shall be provided for
all personnel directly involved in tar operations: face shields,

February 1993 - 11.0 Paints And Coatings Page 353

 leather gloves, cotton overalls, and heat resistant aprons. Also,
respiration protection may be required in confined spaces.

11.9 General Safety for Paints and Coatings

Safety precautions concerning various stages of paints and
coatings are mentioned under their respective sub-headings of
Section 11. This section is provided to highlight areas of paints
and coating operations not covered under an individual sub-
heading.

* Colors - All color coding shall conform to the requirements in

SAES-B-067: Safety Identification and Color-Coding. Colors
reserved for safety use within Saudi Aramco are red, green,
yellow and black, orange and blue. Some equipment
identified by color coding that may be required by painters
include:

Fire protection: red.

Emergency stops: red.
Danger signs: red.
Emergency safety equipment and instructions (eye wash,
showers, first aid): green.
Hazards (physical and radioactive): yellow/black.
Potable water: blue.

* Breathing Air - Before breathing air used for respiration

purposes, it must be checked to ensure it meets the quality
requirements referenced in GI 8.003. Once compressors
providing breathing air have conformed to the requirements
of GI 8.003, they shall be re-tested every quarter to ensure
that air quality remains satisfactory.

* Personal Protective Equipment - Depending on the work

being carried out and its location, appropriate personal
protective equipment must be worn that meets both the
manufacturers requirements and those of Saudi Aramco.
Personal protective equipment shall be in good condition.

February 1993 - 11.0 Paints And Coatings Page 354

 * Blast Cleaning - Abrasive blast cleaning equipment and
abrasive materials shall be suitable for the work to be carried
out; substandard products will be removed from Saudi
Aramco facilities.

* Signs and Barricades - Areas where hazardous work is being

carried out (such as abrasive blast cleaning and airless
spraying) shall be suitably barricaded to keep personnel out
of the hazardous area, or the timing of the work shall be such
that only the work crew doing the job is present at the site,
or a lookout is posted around the site. Warning signs shall be
posted in hazardous areas with suitable warnings of the
potential dangers (i.e., "No entry, sand blasting in progress").

* Paints and Solvents - The amount of paints and solvents

stored at the site shall be restricted to a day's requirements.
Bulk storage of paints and solvents shall be in a designated,
well marked safe area away from the work area and
protected from the sun's heat.

* Work Permits - The Saudi Aramco work permit system shall

always be used where necessary for all aspects of paints and
coatings (reference GI 2.100).

* Equipment - Before any equipment is used, operators and

assistants shall be trained on the equipment's use and
operation. Also, the equipment shall be in good working
order, have an automatic shut-off system and all safety
guards installed.

* Personal Health - Personnel involved with using paints,

solvents and cleaning equipment (i.e., sand blasting) shall be
in good health and have medical examinations by
professional medical staff at least every two years.

* Assistants - No one shall work alone in hazardous areas. An

assistant shall always be available or the "buddy" system
used.

February 1993 - 11.0 Paints And Coatings Page 355

12.0 CONCRETE, CONCRETE FORMS, AND SHORING
12.1 General
All equipment and materials used in concrete construction and
masonry work shall meet the applicable requirements for design,
construction, inspection, testing, maintenance, and operations.

12.2 Reinforcing Steel

Employees working more than 1.8 meters (6 feet) above any
adjacent working surfaces, placing and tying reinforcing steel in
walls, piers, columns, etc., shall be provided with proper work
platforms with a guardrail system. When work is to be
accomplished outside a work platform, a safety belt shall be
worn that is securely fixed to a dropline or anchor.

Employees shall not be permitted to work above vertically

protruding reinforcing steel unless it has been bent over or
capped.

Guying: Reinforcing steel for walls, piers, columns, and similar

vertical form work structures shall be guyed and supported to
prevent collapse and to guard against possible wind pressures.

Wire mesh rolls: Wire mesh rolls shall be secured at each end to
prevent dangerous recoiling action.

12.3 Bulk Concrete Handling

Bulk storage bins, containers, or silos shall have conical or
tapered bottoms with mechanical or pneumatic means of
starting the flow of material.

February 1993 - Construction Safety Manual: Concrete, Concrete Forms And Shoring Page 356
12.4 Concrete Placement
12.4.1 Concrete Mixers

Concrete mixers equipped with 0.75 cubic meter (1 cubic

yard) or larger loading skips shall be equipped with a
mechanical device to clear the skip of concrete.

12.4.2 Guardrails

Mixers of 0.75 cubic meter (1 cubic yard) capacity or

greater shall be equipped with protective guardrails
installed on each side of the skip.

12.4.3 Bull Floats

Handles on bull floats, used where they may contact

energized electrical conductors, shall be constructed of
non-conductive material, or insulated with a non-
conductive sheath whose electrical and mechanical
characteristics provide the equivalent protection to a
handle constructed of non-conductive material.

12.4.4 Powered Concrete Trowels

Powered and rotating-type concrete troweling machines

that are manually guided shall be equipped with a control
switch that will automatically shut off the power
whenever the operator removes his hands from the
equipment handles. The rotating blades shall be guarded
at the top and outer perimeter.

12.4.5 Concrete Buggies

Handles of buggies shall not extend beyond the wheels on

either side of the buggy. Installation of knuckle guards on
buggy handles is recommended to protect the hands.

February 1993 - 12.0 Concrete, Concrete Forms, And Shoring Page 357
 12.4.6 Pumpcrete Systems

Pumpcrete or similar systems using discharge pipes shall

be provided with pipe supports designed for 100 percent
overload. Compressed air hose in such systems shall be
provided with positive fail-safe joint connectors to
prevent separation of sections when pressurized.

12.4.7 Concrete Buckets

Concrete buckets equipped with hydraulic or

pneumatically operated gates shall have positive safety
latches or similar safety devices installed. Prevent
aggregate and loose material from accumulating on the
top and sides of the bucket.

Riding of concrete buckets for any purpose shall be

prohibited, and vibrator crews shall be kept out from
under concrete buckets suspended from cranes or cable
ways.

12.4.8 Discharging on Slope

When discharging on a slope, the wheels of ready-mix

trucks shall be blocked and the brakes set to prevent
movement.

12.4.9 Back-Up Man, Truck Spotter

Back-up man, ready-mix truck spotter shall be used to

back ready-mix trucks.

12.4.10 Pneumatic Hose

Nozzleman applying a cement, sand, and water mixture

through a pneumatic hose shall be required to wear
protective head and face equipment.

February 1993 - 12.0 Concrete, Concrete Forms, And Shoring Page 358
12.5 Vertical Shoring
12.5.1 General Requirements

When temporary storage of reinforcing rods, material, or

equipment on top of form work becomes necessary, these
areas shall be strengthened, shored to meet the intended
loads.

The sills for shoring shall be sound, rigid, and capable of

carrying the maximum intended load.

All shoring equipment shall be inspected prior to erection

to determine that it is as specified in the shoring layout.
Any equipment found to be damaged shall not be used for
shoring.

Erected shoring equipment shall be inspected

immediately prior to and immediately after the placement
of concrete. Any shoring equipment that is found to be
damaged or weakened shall be immediately reinforced or
re-shored.

Re-shoring shall be provided when necessary to safely

support slabs and beams after stripping, or where such
members are subjected to superimposed loads due to
construction work done.

12.5.2 Tubular Welded Frame Shoring

Metal tubular frames used for shoring shall not be loaded

beyond the safe working load recommended by the
manufacturer.

All locking devices on frames and braces shall be in good

working order; coupling pins shall align the frame or panel
legs; pivoted cross braces shall have their center pivot in
place; and all components shall be in a condition similar to
that of original manufacture.

February 1993 - 12.0 Concrete, Concrete Forms, And Shoring Page 359
 When checking the erected shoring frames with the
shoring layout, the spacing between towers and cross
brace spacing shall not exceed that shown on the layout,
and all locking devices shall be in the closed position.

Devices for attaching the external lateral stability bracing

shall be securely fastened to the legs of the shoring
frames.

All base plates, shore heads, extension devices, or

adjustment screws shall be in firm contact with the
footing sill and the form.

12.6 Forms and Shoring

12.6.1 General Provisions

Form work and shoring shall be designed, erected,

supported, braced, and maintained so that it will safely
support all vertical and lateral loads that may be imposed
upon it during placement of concrete.

Personnel shall not be allowed under or in close proximity

of the form work during pour operations.

Personnel not engaged in the pour operation shall stay

clear of the pour area. A clear area shall be maintained at
1-1/2 times the highest point of the form work.

Drawings or plans showing the jack layout, form work,

shoring, working decks, and scaffolding, shall be available
at the job site.

February 1993 - 12.0 Concrete, Concrete Forms, And Shoring Page 360
 Stripped forms and shoring shall be removed and
stockpiled promptly after stripping, in all areas in which
persons are required to work or pass. Protruding nails,
wire ties, and other form accessories not necessary to
subsequent work shall be pulled, cut, or other means
taken to eliminate the hazard.

Imposition of any construction loads on the partially

completed structure shall not be permitted unless such
loading has been considered in the design and approved
by the engineer-architect.

12.6.2 Vertical Slip Forms

The steel rods or pipe on which the jacks climb or by

which the forms are lifted shall be specifically designed for
the purpose. Such rods shall be adequately braced where
not encased in concrete.

Jacks and vertical supports shall be positioned in such a

manner that the vertical loads are distributed equally and
do not exceed the capacity of the jacks.

The jacks or other lifting devices shall be provided with

mechanical dogs or other automatic holding devices to
provide protection in case of failure of the power supply
of the lifting mechanism.

Lifting shall proceed steadily and uniformly and shall not

exceed the predetermined safe rate of lift or concrete
cure.

Lateral and diagonal bracing of the forms shall be

provided to prevent excessive distortion of the structure
during the jacking operation.

During jacking operations, the form structure shall be

maintained in line and plumb.

February 1993 - 12.0 Concrete, Concrete Forms, And Shoring Page 361
 All vertical lift forms shall be provided with scaffolding or
work platforms completely encircling the area of
placement with intermittent tie breaks to ensure that
superimposed loads on the scaffold/work platforms
cannot pull down the entire scaffold works.

12.6.3 Tube and Coupler Shoring

Couplers (clamps) shall not be used if they are deformed,

broken, or have defective or missing threads on bolts, or
other defects.

The material used for the couplers (clamps) shall be of a

structural type such as drop-forged steel, malleable iron,
or structural grade aluminum. Gray cast iron shall not be
used.

When checking the erected shoring towers with the

shoring layout, the spacing between posts shall not
exceed that shown on the layout, and all interlocking of
tubular members and tightness of couplers shall be
checked.

All base plates, shore heads, extension devices, or

adjustment screws shall be in firm contact with the
footing sill and the form material and shall be snug against
the posts.

12.6.4 Single Post Shores

For stability, single post shores shall be horizontally

braced in both the longitudinal and transverse directions,
and diagonal bracing shall also be installed. Such bracing
shall be installed as the shores are being erected.

All base plates or shore heads of single post shores shall

be in firm contact with the footing sill and the form
materials.

February 1993 - 12.0 Concrete, Concrete Forms, And Shoring Page 362
 Whenever single post shores are used in more than one
tier, the layout shall be designed and inspected by a
structural engineer. Lay-out to be submitted to Saudi
Aramco for approval.

When form work is at an angle, or sloping, or when the

surface shored is sloping, the shoring shall be designed for
such loading.

Adjustment of single post shores to raise form work shall

not be made after concrete is in place

Fabricated single post shores shall not be used if heavily

rusted, bent, dented, re-welded, or having broken
weldments or other defects. If they contain timber, they
shall not be used if timber is split, cut, has sections
removed, is rotted, or otherwise structurally damaged.

All timber and adjusting devices to be used for adjustable

timber single post shores shall be inspected before
erection.

Timber shall not be used if it is split, cut, has sections

removed, is rotted, or is otherwise structurally damaged.

Adjusting devices shall not be used if heavily rusted, bent,

dented, re-welded, or having broken weldments or other
defects.

All nails used to secure bracing or adjustable timber single

post shores shall be driven home and the point of the nail
bent over if possible.

February 1993 - 12.0 Concrete, Concrete Forms, And Shoring Page 363
III. Mechanical Equipment And
Materials

February 1993 - Construction Safety Manual - III. Mechanical Equipment And Materials Page 364
1.0 CRANES AND LIFTING EQUIPMENT
SAUDI ARAMCO INSTRUCTIONS AND STANDARDS

ALL REFERENCED STANDARDS ARE INCORPORATED INTO THIS SECTION.

Saudi Aramco General Instructions:

GI 2.100. Work Permit System

GI 2.702. Electrical Safety for Boom or Derrick Type Hoisting

Equipment

GI 6.029. Reporting and Recording Of Motor Vehicle Accidents

GI 7.024. Marine and Offshore Cranes and Rigging

GI 7.025. Mobile Heavy Equipment Operator Testing and Certification

GI 7.026. Cranes and Heavy Equipment Accident Reporting

GI 7.027. Personnel Work Platform Operations

GI 7.028. Crane Lifts: Types and Procedures

GI 7.029. Inspection, Testing and Maintenance of Wire Rope Slings

GI 7.030. Inspection and Testing of Cranes, Elevators, Powered

Platforms, and Mobile Aerial Baskets

Refinery Instruction Manual:

1.087. Precautions to be taken for Operating Cranes near Overhead

Power Lines

1.808. Operating Cranes

Heavy Equipment Operator Licensing Information, Attachment No. III.1

Schedule 'D':

February 1993 - Construction Safety Manual: Cranes And Lifting Equipment Page 365
 Saudi Aramco Safety, Health and Environmental
Requirements - Cranes and Rigging Equipment

Saudi Aramco Crane Safety Handbook

Riggers Handbook

American Petroleum Institute:

API SPEC 2C Specification for Offshore Cranes

API SPEC 2D Operation and Maintenance of Offshore Cranes

Contractor Liaison Notice No. 5.

Procedure for Obtaining Crane and Heavy Equipment

Operator's Licenses for Expatriate Employees (See Appendix
F)

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI A10.4. Safety Requirements

ANSI 30.2. Overhead and Gantry Cranes

ANSI B30.3. Hammerhead Tower Cranes

ANSI B30.4. Portal, Tower and Pillar Cranes

ANSI B30.5. Mobile and Locomotive Cranes

ASME B30.6. Derricks

ASME B30.8. Floating Cranes and Floating Derricks

ASME B30.14. Side Boom Tractors

ANSI B30.16. Overhead Hoists

ANSI B30.22. Articulating Boom Cranes

February 1993 - 1.0 Cranes and Lifting Equpment Page 366

1.1 Competent Person
A competent person is a person who, by possession of a
recognized pertinent degree or certificate of professional
standing, or who by extensive knowledge, training and
experience has successfully demonstrated the ability to solve or
resolve problems relating to safe crane operations and
procedures (e.g. Rigger Technician, Crane and Rigging Specialist,
etc.). A competent person shall supervise all lifts.

1.2 Saudi Aramco Crane Operations (General

Requirements)
Before beginning any crane operation, the supervisor and
operator should complete the pre-operation checklist (Figure
III.1). A lift plan required as a part of this procedure must provide
the following information:

1. Crane radius
2. Boom length
3. Safe working limits of the crane (load chart)
4. Weight of the load
5. Ground and site conditions
6. Placement of the crane
7. Swing and tail clearances
8. Necessary communication to be used
9. Explanation of hand signals
10. Rigging hardware
11. Rigging sketch for critical or hazardous lifts
12. Rated capacity of rigging components
13. Sling angles
14. Strain calculations
15. Wind velocity
16. Load moment indicator
17. Other

One competent person shall be placed in charge of the lift with

the responsibility of explaining in detail, the duties of all involved

February 1993 - 1.0 Cranes and Lifting Equpment Page 367

 in the lift before the actual lift commences. The outriggers must
be fully extended prior to the lift, and the rubber tires must be
off the ground (see Figure III.2, Crane Lift Plan).

Cranes shall have a valid Crane Safety inspection sticker issued by

the Saudi Aramco Crane, Communication, and Facilities
Inspection Unit. (See GI 7.030.)

1.3 Saudi Aramco Crane Operator Qualifications

A valid SAG heavy equipment license and Saudi Aramco Crane
Operator Certificate are required for all contractor mobile crane
operators. Contact the Vehicle & Heavy Equipment Training and
Testing Unit (Tel. Nos. 875-4347/874-1857) to operate specific
mobile heavy equipment. (See GI 7.025.)

1.4 Special Crane Operating Procedures

Heavy lifts, critical lifts, and crane personnel work platform
operations require special procedures outlined in the Saudi
Aramco General Instructions. The Heavy Haul Unit,
Transportation Dept., Abqaiq should be contacted and lift
plans/work permits submitted. (See GI's 7.027, and 7.028.)

1.5 Effect of Wind Speeds on Crane Operations

When wind velocities are above 32 km/h (20 mph), the rated
load and boom lengths shall be reduced according to
manufacturer specifications. Wind forces are greater at height
by as much as 35% or more. All lifts above ground level, must
account for wind force, i.e., side loads, down drafts, etc. as
applied to the load and boom. (See TABLES III.1 and III.2.)

February 1993 - 1.0 Cranes and Lifting Equpment Page 368

1.6 Overhead Power Lines
There is an area surrounding every power line that is referred to as
the absolute limit of approach. It is strictly forbidden to move
any crane boom or load line or load into this are unless the line
has been de-energized or insulated. There are no exceptions.
The absolute limit of approach varies according to the following
table:

Line Voltage Absolute Limit Of

Approach
Up to 250,000 volts 20 feet (6 meters)
Over 250,000 25 feet (7.5 meters)

February 1993 - 1.0 Cranes and Lifting Equpment Page 369

FIGURE III.1: PRE-LIFT OPERATION CHECKLIST

· OPERATOR:

- CURRENT SAUDI ARAB GOVERNMENT CRANE OPERATORS'

LICENSE
- CURRENT SAUDI ARAMCO OPERATORS' CERTIFICATE

· OUTRIGGERS:

- FULLY EXTENDED
- LEVEL GROUND
- COMPACT SOIL
- HEAVY PAD SUPPORTS
- LOCKING PINS/LOCKS SET
- NO HYDRAULIC LEAKS
- NO DAMAGE
- GOOD CONDITION
- WHEELS OFF THE GROUND

· OPERATION:

- CURRENT CRANE SAFETY INSPECTION STICKER

- CLEAR 360o VISIBILITY
- NO SHADES/CURTAINS IN CAB
- LOAD CHARTS IN CAB
- CLEAR VISIBILITY
- WIND, ABOVE 20 m/h (32 km/h), NO GO
- DO NOT OPERATE DURING STORMS AND AT NIGHT
- LIGHTNING, NO GO
- BARRICADE CRANE CAB SWING AREA
- TAG LINES IN USE
- CLEAR OVERHEAD POWER LINES
- CLEAR AREA OF PERSONNEL 1-1/2 x BOOM LENGTHS
- NO LIFTS OVER WORKERS OR CRITICAL PROPERTY
- TRIAL LIFT, FLOAT LOAD ONE METER OFF GROUND TO CHECK
BALANCE
- CLEAR VIEW OF SIGNAL MAN (RIGGER)

February 1993 - 1.0 Cranes and Lifting Equpment Page 370

 - DO NOT PULL LOADS WITH CRANE
- LOAD RADIUS INDICATOR
- MAN LIFT WORK PERMIT
- ANTI-TWO BLOCK OPERATIONAL
- LMI (LOAD MOMENT INDICATOR) OPERATIONAL

· RIGGING:

- CHECK ALL RIGGING FOR DAMAGE

- CHECK SLING LOAD CAPACITY
- CHECK BLOCK, HOOKS, etc. FOR DAMAGE
- HOOK SAFETY LATCH IN PLACE
- RECORD WEIGHT OF LOAD
- RECORD WEIGHT OF CRANE GEAR, ADD CRANE GEAR
WEIGHT TO TOTAL WEIGHT
- LIFT PLAN APPROVED
- USE LOAD WEIGHT MEASURING DEVICE FOR UNKNOWN
LOADS

· TRAVELING:

- BLOCK SECURED
- TIRES PROPERLY INFLATED AND IN GOOD CONDITION
- BRAKE LIGHTS, SIGNALS, MIRRORS, HORN OPERATIONAL
- ROUTE PLAN CHECKED FOR FIRM GROUND, OVERHEAD AND
SIDE RESTRICTIONS
- ESCORT VEHICLES REQUIRED WITH FLASHING BEACON
LIGHTS
- SPEED TO BE MAINTAINED FOR SAFE LIMITS (SLOW AS
POSSIBLE)

· PARKING:
- BOOM AND HOOK BLOCK(S) LOWERED TO TRAVEL POSITION
- APPLY SWING BRAKE AND POSITIVE SWING LOCK
- TIE DOWN HOOK BLOCK(S)
- RETRACT STABILIZERS
- RETRACT OUTRIGGERS
- EXTEND STABILIZERS AND LATCH ONTO FLOAT PADS

February 1993 - 1.0 Cranes and Lifting Equpment Page 371

 - WEIGHT OF CHASSIS OFF THE TIRES
- LET ENGINE IDLE 3-5 MINUTES
REMOVE ALL FOREIGN MATERIAL FROM CAB(S)
- CLOSE ALL DOORS, WINDOWS, SKYLIGHTS AND COMPARTMENTS
- TURN OFF SWITCHES
- STOP ENGINE

February 1993 - 1.0 Cranes and Lifting Equpment Page 372

FIGURE III.2: LIFT PLAN FOR CRANES
1. Contractor:__________________________________________________ J.0.
No.:_____________________________________________
2. Crane Inspection Sticker valid: Yes: No: Date of
expiry:________________________________________________________________
3. Operator Saudi Aramco certified: Yes: No: 4. Description of
load:___________________________________________________
5. ·Type of crane to be used Stowed Erecte N/A (lbs/kg
______________________ d s)
·Boom length (total) Jib:    ______
_______________________ft/m _
·Jib length Extension:    ______
____________________________ _
__ft/m
Hookblock (Main): ______ _____ _____ ______
_
Aux. Boom Head: ______   ______
_
Headache Ball: ______   ______
_
Slings, Shackles, ______ ______ ______ ______
etc.: _
Others: _________________________ _______
_________
_________________________ _______
_________
Total (Gross Load
Weight): _______

February 1993- Cranes And Lifting Equipment Page 373

 6. · Weight of load · Effective weight of jib _____ lbs/kgs (see
_______lbs/kgs jib chart)
· Effective weight of jib headache ball · Weight of load block _____ lbs/kgs
______ lbs/kgs
· Weight of hoist rope below boom · Weight of spreader bar _____ lbs/kgs
tip______ lbs/kgs
· Weight of other rigging
______ lbs/kgs
Total load weight _____ lbs/kgs
7. Hoisting clearance ________ft/m. 8. Lift quadrant zone ___________________ . 9. Operating
radius ___________ft/m.
10. Crane capacity at operating radius __________ (Note: Do not make lift if total load is greater than crane
capacity shown in Item 10. Refer to GI 7.028 for appropriate derating based on type of lift.)
11. Crane capacity for jib configuration:____________ 12. Ground and site
conditions:______________________________________________
13. Wind speed:__________mph (Maximum 20 mph)
14. Work permit required: Yes No:
15. Load moment indicator: Yes: No: Type:_________________________________________
16. Sketch and supplementary information for crane lift is required to be attached to this plan. (Note: The
sketch of the crane should include the following rigging information: size of each component; safe working
load (SWL) capacity; length of slings; type of component; component diameter; weight of component
and sling angles).
Contractor:______________________ Date:__________________ Crane
Operator:_______________________ Date:__________________________
Approved:_______________________ Date:__________________ Reviewed by:_____________________
Date:_____________________________
(Competent Person) (Saudi Aramco Site Representative)
Approved:_______________________ Date:__________________
(Heavy Haul/Rig Move Unit, Transportation Dept., Abqaiq)
February 1993 - 1.0 Cranes and Lifting Equpment Page 374
Footnote: This form is to be filled out for the following lifts: 1. At all construction sites and operating plants;
2. Associated with offshore and marine sites and operations; 3. Within safety zones of power lines; 4.
Involving personnel platforms (as per GI 7.027, 7.028 and 7.030).

February 1993 - 1.0 Cranes and Lifting Equpment Page 375

TABLE III.1: WIND SPEED (MILES PER HOUR) VS. FORCE OF WIND IN POUNDS PER
SQUARE FOOT

MILES FORCE PER SQUARE

PER HOUR FOOT, POUNDS
1 .004
2 .014
3 .036
4 .064
5 .1
10 .4
15 .9
20 1.6
TABLE III.2: WIND SPEED DEFINITION

The following table lists speed, in the major units, relative to

Beaufortwind Scale Numbers, the internationally accepted reference for
wind force:

Beaufort Descriptio Knots M/Sec KM/H Miles/H

Numbers n
0 Calm 0-1 0-0.51 0-1.84 0-1.15
1 Light Air 1-3 0.51-1.53 1.84-5.52 1.15-3.45
2 Light 4-6 2.04-3.07 7.36-11.04 4.6-6.9
Breeze
3 Gentle 7-10 3.58-5.11 12.88-18.4 8.05-11.5
Breeze
4 Moderate 11-16 5.62-8.18 20.24- 12.65-18.4
Breeze 29.44
5 Fresh 17-21 8.69-10.73 31.28- 19.55-
Breeze 38.64 24.15
6 Strong 22-27 11.24- 40.48- 25.3-31.05
Breeze 13.80 49.68
7 Near Gale 28-33 14.31- 51.52- 32.2-37.95
16.87 60.72

February 1993 - 1.0 Cranes And Lifting Equipment Page 376

 8 Gale 34.40 17.38- 62.56-73.6 39.1-46
20.44
9 Strong 41-47 20.96- 75.44- 47.15-
Gale 24.02 86.48 54.05
10 Storm 48-55 24.53- 88.32- 55.2-63.25
28.11 101.2
11 Violent 56-63 28.62- 103.04- 64.4-72.45
Storm 32.20 115.92
12 Hurricane 64+ 32.71+ 117.76+ 73.6

Reference: GROVE COLES CRANE SPECIFICATION BULLETIN NO. 045

February 1993 - 1.0 Cranes and Lifting Equpment Page 377

2.0 SLINGS AND LIFTING GEAR (RIGGING)
Saudi Aramco General Instructions:

GI 7.027. Personnel Work Platform Operations

GI 7.029. Inspection, Testing and Maintenance of Wire Rope Slings

American National Standards:

ANSI B30.5. Mobile and Locomotive Cranes

ANSI B30.9. Slings

ANSI B30.10. Hooks

ANSI B30.20. Below the Hook Lifting Devices

ANSI B30.21. Manually Lever Operated Hoists

Saudi Aramco Crane Safety Handbook (See Appendix E)

Saudi Aramco Riggers Handbook

Saudi Aramco Inspection Procedures

07-AIP-0I-P Inspection of Steel Wire Rope Slings

2.1. Safe Working Load (SWL)

Slings and other rigging equipment must be constructed
according to a recognized standard.

The safe working load of rigging equipment is the maximum load

which the equipment should be subjected to; this load should
never be exceeded.

February 1993 - Construction Safety Manual: Slings And Lifting Gear Page 378
 Before use, all new equipment should be subjected to a proof
load test by the manufacturer and certified. The safe working
load and serial number shall be clearly marked on the sling and
the lifting gear, either by tagging, stamping, engraving, or
embossing. Riggers shall not use lifting gear unless the safe
working load is clearly visible (see Figures III.3 and III.6).

Slings shall not be tagged with an safe working load in the field.
Approval by the Inspection Department and subsequent review
by the Loss Prevention Department is required.

2.2. Chain Slings

2.2.1 Grades

Only alloy steel chain complying with ASTM A391 shall be

used. Other grades are subject to approval by the Saudi
Aramco Crane, Communications and Facilities Inspection
Unit [CCFIU] (see Figure III.5).

Each grade of chain should be clearly tagged by the

manufacturer, and riggers should be trained to look for
the safe working load marked on each sling. They shall be
forbidden to use any equipment unless the safe working
load is clearly visible.

All attached fittings (hooks, rings, etc.,) shall be as

prescribed by the manufacturer. Hooks, shackles, and
eyebolts shall be equal to or exceed the safe working load
of the chain.

2.2.2 Repairs

Modern chains are produced under closely controlled

factory conditions using proper heat treatment and
testing procedures. On-site welding repairs cannot
provide the necessary controlled conditions to safely
repair a damaged chain. Damaged chains must be
returned to the manufacturer for repair or destroyed. In

February 1993 - 2.0 Slings And Lifting Gear Page 379

 particular, watch for bent links, cracked welds, and
excessive wear.

2.2.3

Logger chains or chains used to secure truck loads shall

not be used for rigging.

2.3 Wire Rope Slings

2.3.1

Wire rope is the most common type of sling in use on

construction sites. It is essential that each wire rope sling
is properly constructed and used. All wire rope slings shall
be manufactured, inspected, and load tested by a
recognized manufacturer. Homemade wire rope slings
shall not be allowed at Saudi Aramco unless they meet all
standards and pass inspection by CCFIU.

2.3.2 Damaged slings shall be destroyed if there are:

2.3.2.1

* 10 random broken wires in one lay.

* 4 broken wires in one strand of a rope lay.
* One broken wire at the fitting.

2.3.2.2

* Severe localized abrasion or scraping.

2.3.2.3

* Kinking, crushing, birdcaging, or any other

damage causing distortion.

2.3.2.4

* Evidence of heat damage.

February 1993 - 2.0 Slings And Lifting Gear Page 380

 2.3.2.5

* End attachments are cracked, deformed, or

excessively worn.

2.3.2.6

* Bent or opened hooks.

2.3.2.7

* Severe corrosion.

2.3.3

Each sling shall bear a permanent manufacturer's

identification stating the safe working load (SWL) in tons
and serial number. Proof load test and documentation of
testing is required from the manufacturer (see Figures
III.3 and III.6).

2.3.4

Wire rope clips (bulldog clips or crosby clips) shall not be

used to make slings.

2.4 Synthetic Webbing Slings

These are manufactured from woven man-made fiber. Their
strength lies in the width of their bearing surface. These slings
must not be subjected to point loading, sharp edged objects, and
non-vertical lifting (see Figure III.7). Synthetic web slings shall be
marked with a stitched in label to show:

(a) Name or trademark of manufacturer

(b) Rated capacity for each type of hitch
(c) Type of material

February 1993 - 2.0 Slings And Lifting Gear Page 381

 2.4.1 Removal from Service

Slings which have been damaged or are defective in any

way shall be immediately removed from service, cut up
and destroyed.

2.4.2 Repaired Slings

The use of repaired slings is prohibited.

2.5 Synthetic and Natural Fiber Rope Slings

2.5.1

Each synthetic and natural fiber rope sling shall be

permanently marked to show:

2.5.1.1 Name or trademark of manufacturer

2.5.1.2 Manufacturer's code or stock number

2.5.1.3 Rated loads for the types of hitches used

2.5.1.4 Type of natural or synthetic material

2.5.1.5 Date of manufacture

2.5.2

All associated rigging hardware shall equal or exceed the

safe working load rating of the rope sling.

2.5.3

Slings shall be removed from service and destroyed when:

2.5.3.1

* The fibers are cut, badly abraded or seriously

worn.

February 1993 - 2.0 Slings And Lifting Gear Page 382

 2.5.3.2

* There is considerable filament or fiber

breakage (a light fuzzing is acceptable) on the
surface.

2.5.3.3

* There are particles of broken filament or

fibers inside the rope between strands.

2.5.3.4

* There is other damage visible such as: melting

or charring, kinks or hackles, knots, damaged
fittings.

February 1993 - 2.0 Slings And Lifting Gear Page 383

2.6 Care of Slings
The following points must be considered in the storage and
handling of slings:

2.6.1

Slings will undergo shock loading when a load is suddenly

lifted or when the hoisting is abruptly stopped. This can
be caused by the sudden application of the crane brake,
the jerking of the load by poor operation, or the sling
slipping on the load. A shock load can increase the
normal working load by as much as five times its value.

2.6.2

As the angle between the legs of a multiple sling

increases, the safe working load decreases. The included
angle should be no more than 90 0 and must never exceed
120o under any circumstances (see Figure III.9).

2.6.3

Before storage, chain and wire rope slings should be

cleaned, lightly lubricated, and inspected. Slings must be
stored in a location where they are not liable to suffer
mechanical damage, away from extremes of heat, cold,
and especially dampness.

2.6.4

Contractors shall maintain a job site log of slings

containing the following information: ID. number; date in
service; safe working load as stated in proof load
certificate; full details of periodic inspections (see Figure
III.13).

February 1993 - 2.0 Slings And Lifting Gear Page 384

 2.6.5

All rigging shall be inspected at least every six months per

ANSI B30.9, and a Sling Inspection Report shall be
completed and filed for review by the Crane Inspector to
comply with GI 7.029.

2.7 Hooks
2.7.1

Hooks should be fitted with a safety catch on the hook

opening, or should be moused with wire and a shackle
used or the hook should be designed so that the slings
cannot be displaced (Figure III.11).

2.7.2

Loads should be applied on the hook only in the part

designed to take them (i.e. the bend [bow] of the hook).
Point loading can result in over stressing the hook causing
it to open or break. Therefore, point loading shall not be
permitted.

2.7.3

Hooks should be regularly inspected for signs of damage.

2.7.4

The hook shall be removed from service for the following

reasons:

1. If there are visible cracks

2. If it is twisted 10o out of place
3. If there is a 15% throat opening beyond the
manufacturer's specification

A thorough examination shall be carried out each year by

a qualified inspector.

February 1993 - 2.0 Slings And Lifting Gear Page 385

2.8 Spreader Bars
2.8.1

All spreader bars shall be manufactured, tested, and

inspected to ANSI B30.20.

2.8.2

Spreader bars shall be permanently identified with the

safe working load, manufacturer's name and serial
number.

2.8.3

Spreader bars shall be stored away from moisture, and

protected from physical damage.

2.9 Eyebolts And Safety Hoist Rings

Sometimes machinery or other equipment is delivered to
the site with eyebolts attached as lifting points. For such
situations, the design and function of each of the three
basic types of eyebolts should be known (see Figure
III.10.).

2.9.1

Standard eyebolts are the weakest and are dependable

only for vertical lifts.

2.9.2

Shouldered eyebolts can be used at slight angles, but are

unsafe at less than 45 degrees with the horizontal.

February 1993 - 2.0 Slings And Lifting Gear Page 386

 2.9.3

Safety hoist rings (swivel eyes) are bolted in place with a

calibrated torque wrench and maintain maximum
capacity at all angles.

2.10 Shackles
Shackles (clevis) are used for making connections in
rigging. They should be tested by the manufacturer and
marked with the safe working load.

The pins are separate but matched parts of the shackles,

so care must be taken to use the correct pin for each
shackle. Rebar, mild steel bolts or similar items are not
acceptable replacements for shackle pins (see Figure
III.12.).

2.11 Rigger
The job of rigger requires thorough training. The man
assigned must be well-acquainted with the capabilities of
the crane being used, hand signals, the different functions
of lifting gear, and the various methods of loading.

February 1993 - 2.0 Slings And Lifting Gear Page 387

FIGURE III.3: IDENTIFICATION TAGS

All slings shall carry permanent

manufacturer's
identification.

February 1993 - 2.0 Slings And Lifting Gear Page 388

FIGURE III.4: INSTALLING A WEDGE SOCKET ON A ROPE

FIGURE III.5: TWO-LEGGED CHAIN SLING: MAJOR COMPONENTS

FIGURE III.6: SLING FIXINGS

February 1993 - 2.0 Slings And Lifting Gear Page 389

 (Sling No. 123
SWL 8 Tons)

February 1993 - 2.0 Slings And Lifting Gear Page 390

FIGURE III.7: SYNTHETIC WEBBING SLINGS

February 1993 - 2.0 Slings And Lifting Gear Page 391

FIGURE III.8: SLING LOADING FIGURE III.9: EYEBOLTS

FIGURE III.10: CRANE HOOKS FIGURE III.11: SHACKLES

February 1993 - 2.0 Slings And Lifting Gear Page 392

FIGURE III.12: WIRE ROPE SLING INSPECTION LOG

Contractor:______________________________________ Location: __________________________

BI/JO Number: ___________________________________ Project Title: ______________________

Sling# Diameter Length SWL Date-In Date-Out- Inspector Signature

Service Service (Date)

February 1993 - 2.0 Slings And Lifting Gear Page 393

February 1993 - 2.0 Slings And Lifting Gear Page 394
3.0 MECHANICAL EQUIPMENT
The widespread use of mechanical equipment in the construction industry
improves the quality and efficiency of the work but it can lead to
situations which are potentially hazardous.

This section cannot cover all the situations which could arise, but it
outlines some of the hazards likely to be encountered from specific items
of equipment and their use.

The only safe way of using mechanical equipment is to have properly

trained operators, running equipment that is well maintained and
carrying out the work for which it was designed.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 7.025 Mobile Heavy Equipment Operator Testing and Certification

GI 7.026 Cranes and Heavy Equipment Accident Reporting Procedures

GI 7.030 Inspection, and Testing Requirements Of Elevating / Lifting

Equipment

GI 8.003 Breathing Apparatus

GI 447.002 Pressure Relief Valves - New Installation, Change in Set

Pressure, Replacement or Retirement from Service

GI 447.003 Pressure Relief Valves - Routine Test, Inspection, Quality

Assurance and Regulation

Saudi Aramco Engineering Standards:

Inspection Procedures

17-SAIP-6.01 Diesel Electric Generating Set

20-SAIP-3.01 Welding Generator

February 1993 - Construction Safety Manual: Mechanical Equipment Page 395

31-SAIP-1.01 Pumps

31-SAIP-1.02 Compressor

31-SAIP-8.05 Vibrating Roller

31-SAIP-8.10 CAT Motor Grader

31-SAIP-8.15 Road Rollers

31-SAIP-8.16 Scraper

31-SAIP-10.01 Concrete Mixers

31-SAIP-12.04 Diesel Fork Lift Truck

31-SAIP-12.05 Electric Fork Lift Truck

Schedule 'D':

Saudi Aramco Safety, Health and Environmental

Requirements - Mechanical Equipment

AMERICAN NATIONAL STANDARDS:

ANSI-A 10.4-81

Safety Requirements For Personnel Hoists

ANSI-B 15.1-84

Safety Code for Mechanical Power Transmission Apparatus

ANSI-B 30.1-86

Safety Code for Jacks

ANSI B30.5. Mobile and Locomotive Cranes

ANSI-B 56.1-88

Safety Standard for Low and High Lift Trucks

February 1993 - 3.0 Mechanical Equipment Page 396

3.1 Operators
3.1.1 Qualifications

Only trained personnel shall operate any mechanical

equipment. Operators shall be trained in the procedures
and functions relevant to a specific piece of equipment;
they must be fully aware of the capabilities and
limitations of the machine and have a knowledge of the
day-to-day maintenance that it requires.

It is recommended that contractors train and test all

equipment operators and issue them with written
authorization specifying the equipment which they are
competent to operate.

3.1.2 Licensing Requirements

Operators of mobile heavy equipment must be in

possession of a Saudi Arab Government (SAG) license for
that particular class of machinery and a Saudi Aramco
certificate issued by the Saudi Aramco Heavy Equipment
Operator Testing and Training Unit (see GI 7.025).

3.2 Machinery Guards

All moving parts of machinery must be shielded by guards. This
is particularly true with gears, pulleys, V-belt drives, fans, and
revolving shafts. All of these are present on most of the static
equipment used on or around construction sites. Other
examples of equipment which must be guarded include cooling
fans on compressors and generators, the main drive shafts on
pumps and dumpers, and the cable drum on winches and
concrete mixers.

Guards must be installed on equipment before it arrives on site

and maintained in position at all times while the equipment is
operating. Guards removed for routine maintenance or for

February 1993 - 3.0 Mechanical Equipment Page 397

 repair must be replaced before the equipment is returned to
service.

3.2.1 Multi-Piece Tire Rims and Locking Rings

As safety equipment like tire cages, restraining bars, racks

and clips during tire check-out cannot fully protect
employees working on or near the tire repair area, always
deflate the tire first before making repairs. Inflate tires
inside a strong restraining device (tire cage) by increasing
the tire pressure very slowly.

3.3 General Requirements

3.3.1

Before any mechanical equipment is used in a Saudi

Aramco restricted area, all required work permits must be
obtained.

3.3.2

All machinery should be inspected before being placed in

service and at regular intervals thereafter.

3.3.3

Maintenance schedules should be established for each

piece of equipment and strictly followed.

3.3.4

No repair, adjustment, or replacement of parts on moving

machinery is permitted. Before making any repairs, all
equipment must be stopped and deactivated so that it
cannot be unintentionally started.

February 1993 - 3.0 Mechanical Equipment Page 398

 3.3.5

At the start of each shift, the operator must check oil,

water, fuel, and hydraulic levels, that all gauges are
operating and that the machine is functioning smoothly.
Safety equipment (e.g., guards, limit switches, governors)
must be checked daily.

3.3.6

Equipment traveling or working on the highway must

have lights and reflectors. Park equipment clear of the
roadway. If this is not possible, use flashing lights, cones,
or other warning devices to alert approaching traffic.

3.3.7

When vehicles are left unattended (even overnight),

engines must be stopped, parking brakes applied and the
wheels chocked. Blades, scraper bowls, and other
hydraulic equipment must be lowered to the ground
before the operator leaves the machine. The ignition key
should be removed and/or battery cables disconnected to
avoid start-up by unauthorized personnel.

3.3.8

Unless otherwise instructed, operators must dismount

from machines while maintenance or repair work is being
carried out.

3.3.9

Cabs fitted to equipment must give 360 o visibility. Cabs

must be kept clean and clear of such items as rubbish and
loose tools. Windows must be kept clean at all times and
should be replaced if the glass becomes pitted, cracked or
broken.

February 1993 - 3.0 Mechanical Equipment Page 399

 3.3.10

Where the operator of a mobile machine cannot see the

area all around his machine, an attendant must be in a
position to direct and assist the operator.

3.3.11

All equipment must be located so that exhaust fumes will

not affect workers in the area. Gasoline-driven
equipment shall not be used inside a building or other
confined space.

3.4 Compressors
Compressors are one of the most common pieces of equipment
used in construction work. They can be used to supply air for
portable power tools or to supply air to sustain men working
with breathing apparatus in extremely hazardous atmospheres.
There is a considerable difference in the quality of the air used
for these two functions.

3.4.1

All employees on site must know the dangers of

compressed air. Never use compressed air to dust off
clothing or machinery. Horseplay with compressed air
must be strictly forbidden. When compressed air is used
in special cleaning/purging tasks, goggles and full face
shield must be worn.

3.4.2

Compressors must be properly designed, inspected,

tested and maintained. Relief valves shall be installed in
accordance with GI 447.002/3, and the air receiver must
be periodically inspected.

3.4.3

February 1993 - 3.0 Mechanical Equipment Page 400

 Before start up, a daily check should be made of the
compressor's pressure relief valve, fuel, oil and water
levels and the air reservoir should be drained of trapped
water. The operating manual for the particular type of
compressor used should be strictly followed.

3.4.4

When compressors supply air for breathing:

1.) The air intake must be located so that it does not

draw in exhaust gas.
2.) There must be a filter to remove oil mist.
3.) They must be equipped with an automatic high
temperature alarm.
4.) The air must be tested periodically to be certain it is
safe to breathe (see Administration, I.10., 1.3.)

3.5 Concrete Mixers and Batching Plants

A concrete mixer of some type will be used on almost every
construction site. The principles of good maintenance and
properly trained operators apply equally whether it is only a
small mixer for masonry work or a full batching plant with a large
capacity cement silo, sand and aggregate bins, and a power
shovel.

3.5.1

All chains, gears, and revolving shafts must be guarded.

3.5.2

Safety chains and catches must be operative, and the

lifting mechanism must be in good order.

3.5.3

February 1993 - 3.0 Mechanical Equipment Page 401

 Men must not be allowed to work under or near the
loading skip unless it is held in position by a safety chain
or catch or positively blocked.

3.5.4

The mixer drum and the area around the machine must
be thoroughly cleaned at the end of each day's operation.

3.5.5

Cement bags must not be allowed to accumulate in the

mixer area; they should be collected and disposed of at
regular intervals during the day.

3.5.6

A hooped access ladder must be firmly attached to silos

for access to the top manhole. Men must not be allowed
to work inside the silo unless they are wearing a safety
belt with a lifeline and an attendant is posted outside
ready to assist in case of emergency.

3.5.7

The approach to the sand and aggregate bins should be

barricaded, and the barricades should only be removed to
allow access for vehicles delivering material.

3.5.8

Personal protective equipment such as respirators, ear

muffs, and goggles shall be worn. Loose fitting clothes
shall not be worn around moving machinery.

3.5.9

Lockout and tag system is required in batching plants to

ensure the safety of repair and/or maintenance
personnel. This is a means to disable process/mechanical

February 1993 - 3.0 Mechanical Equipment Page 402

 electrical 'control' equipment during repairs and
maintenance. Lockout and tag system rules must be
posted in a conspicuous location throughout the plant and
workers must be thoroughly trained in the lockout/tag
procedures.

3.6 Dumpers and Dump Trucks

Dumpers and dump trucks, commonly used for construction
work, often travel on the public highway. Therefore it is
essential that they be properly maintained.

3.6.1

The latch on dumper skips must be in good working order,

and the release mechanism should function smoothly.

3.6.2

Dumpers are not designed to carry passengers. It must be

strictly forbidden for employees to ride in the skip or on
the engine cover.

3.6.3

When repairs or maintenance are being carried out on a

hydraulically operated dump truck, the dump body should
be fully lowered. If it is necessary to have it in the raised
position, it must be blocked. Do not rely on the hydraulic
ram to support the raised body for an extended period.

3.6.4

All vehicles with cabs shall be equipped with windshields

and powered wipers. Cracked or broken windshields or
windows shall be replaced. All cab glass shall be safety
glass or equivalent.

February 1993 - 3.0 Mechanical Equipment Page 403

3.7 Excavators
Excavations are carried out using very specialized equipment
which roughly falls into two categories: 1) fixed position
machines, and 2) moving machines.

The choice of equipment to be used is determined by the size of

the project, topography, volume of earth to be hauled out and
many other factors. Fixed position machines include, but are not
limited to, face shovels, backhoes, draglines and grabs. The
"fixed" excavator loosens the soil and loads from a stationary
position. They are useful to perform specific excavation tasks at
a single location. Their loss of mobility is compensated by the
fact that greater force can be applied at the excavation face.
"Moving" machines include, but are not limited to, bulldozers,
loaders, scrapers, graders and trenching machines. They remove,
transport and deposit excavated material all in one cycle of
operation. They are used in applications where large volumes of
earth need to be moved over uneven ground. In this process,
they also help to level the ground over which they operate. (Also
see General And Civil, II.2 of this manual.)

3.7.1

The excavation work permit may require that

underground pipelines or cables be located by manual
digging. The permit must be counter-signed by the Power
Distribution Department (PDD) and the area Utilities
Services Department.

February 1993 - 3.0 Mechanical Equipment Page 404

 3.7.2

Operators of excavators must possess a valid Saudi Arab

Government license for the machine and a valid Saudi
Aramco certificate issued by the Saudi Aramco Heavy
Equipment Operator Testing Unit.

3.7.3

Outriggers must be fully extended when operating a

mechanical excavator so fitted.

3.7.4

An attendant must be appointed and be available at all

times during excavation to assist and guide the operator.

3.7.5

Excavators with a swinging motion must have a clearance

of at least 0.6 meter (2 feet) from any fixed object.

3.7.6

Booms on excavators must be latched before travel.

3.7.7

Do not excavate closer than 10 feet to the nearest

pipeline or other equipment in place.

3.8 Fork Lift Trucks

Fork lift trucks are designed to operate on firm, level ground.
This type of equipment has a limited use in construction
operations. They are, however, sometimes used in materials
handling yards and for placing loads where there are firm ground
conditions. Operators of fork lift trucks must have a valid Saudi
Arab Government heavy equipment license and a valid Saudi
Aramco certificate.

February 1993 - 3.0 Mechanical Equipment Page 405

 3.8.1

It is essential that drivers be fully trained and

experienced. They must be able to manipulate loads
smoothly and efficiently.

3.8.2

A specific course of instruction should be established for

fork lift drivers. They should not be allowed to use the
vehicles on site until they have taken the course.

3.8.3

Special equipment fitted to the truck, in addition to or in

place of the forks, must be designed for the specific
machine.

3.8.4

The truck shall be equipped with overhead protection.

3.8.5

When traveling with a load on the forks, the forks should

be as low as possible to maintain stability.

3.8.6

If the load being carried obstructs the operator's forward

view, he should travel in reverse.

February 1993 - 3.0 Mechanical Equipment Page 406

 3.8.7

Operators, loaders, helpers and other workers should

never place any part of their bodies between the mast
uprights, cross members, or other moving parts of the
fork lift truck. Stay well within limits of the truck body or
cab.

3.9 Generators
A competent electrician shall be available to ensure that
electrical connections are properly made. The operator
should be responsible only for the mechanical function of
the machine.

3.9.1

All pulleys, belts, and fans must be totally enclosed or

otherwise guarded.

3.9.2

The side panels to the engine cover are designed to give

access to the machinery for maintenance or repair. They
must be closed at all times when the engine is running.

3.9.3

The machine must be properly grounded before each use.

3.9.4 Fire Prevention Guide for Portable Generators

The following is a typical check list of the major items to

look for. There may be other potential fire hazards not
listed, therefore a thorough inspection must be made.

· Repair all fuel leaks.

· Check hose and pipe connections for wear and
cracks.
· Clean up all combustible trash around the generator.

February 1993 - 3.0 Mechanical Equipment Page 407

 · Clean up all fuel spills and place clean sand around
area when required.
· Sheds constructed of combustible materials placed
around generators and wooden base frames are
prohibited.
· Exhaust piping system shall be kept away from work
areas and combustible materials.
· Generator sets shall be located at least 50 feet from
buildings or materials that may catch fire.
· Inspect all wiring for damage or improper
splices/repairs.
· Electrically ground all generator sets (system and
frame ground).
· Fire extinguishers must be readily accessible. One
CO2 extinguisher for the generator and a dry
chemical extinguisher for the engine drive is
recommended.
· Conduct daily inspections of all generator sets using
this guide.

3.10 Graders, Dozers, Scrapers, Loaders And Miniloaders

Heavy earth moving equipment only allows the operator a
limited view of the immediate area. It is, therefore, essential
that a banksman be appointed to warn the operator of hazards
that cannot be seen from the operator's position.

This equipment shall be equipped with rollover protection. A

valid Saudi Arab Government heavy equipment license and a
valid Saudi Aramco certificate issued by the Saudi Aramco Heavy
Equipment Operator Testing Unit are required for each operator
of such equipment.

3.10.1

Before moving his machine, the driver must walk around

it to see that the area is clear.

February 1993 - 3.0 Mechanical Equipment Page 408

 3.10.2

Men must not be allowed to sit or lie in the area around

the machine.

3.10.3

The engine shall not be left running when the driver is not
at the controls. Before leaving his machine, a driver must
shut off the engine and remove the ignition key.

3.10.4

Blades, scraper bowls, etc. must be lowered to the ground

before the driver leaves his unit. The wheels should be
properly chocked.

3.10.5

If there is work to be done underneath such hydraulic

equipment, the equipment must be blocked in position.

3.11 Woodworking Machinery

Only fully trained operators may be allowed to use woodworking
machinery. This machinery is inherently dangerous since the
hazardous parts, knives, blades, etc., cannot be fully enclosed.
Only that part of the blade necessary to carry out the work shall
be exposed at any one time.

3.11.1

The area around saws, planers, and routers must be

barricaded and only authorized and trained personnel
allowed within the barricaded area.

February 1993 - 3.0 Mechanical Equipment Page 409

 3.11.2

The ground around such machinery must be kept clear of

off-cuts and other tripping hazards.

3.11.3

Machinery should be securely anchored to prevent

movement during use. (See General And Civil, II of this
manual.)

February 1993 - 3.0 Mechanical Equipment Page 410

4.0 MATERIALS HANDLING
Materials handling forms a large part of construction work. How
construction materials are handled can have a considerable effect on the
efficiency of production and on the safety record of the site. Because of
the temporary nature of site work and the frequent change of the work
place, it is not possible to mechanize material handling to the same extent
as it would be in a more stable operation. However, there are many areas
in which labor intensive, inefficient, costly, and frequently dangerous,
manual material handling work can be replaced by the use of machines.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 355.001 Identifying, Ordering, Receiving, Storing, Issuing And

Disposing Of Hazardous Materials

GI 1130.013 Vehicle Loading

GI 1131.165 Use of Trailer Brakes

GI 1131.921 Use of Trailer Safety Chains

4.1 Planning
Successful mechanization of material handling requires that the
correct machines be available and properly used. The storage
and movement of the various materials must be carefully
arranged to make optimum use of the machines so that efficient
service can be provided and ensure that all vehicle, crane and
heavy equipment operators hold current Saudi Arab Government
License and Saudi Aramco Certification where required.

Planning for materials handling operations begins as the

production schedule is being drawn. Ensure that the layout of
storage areas provides for adequate access for necessary
mechanical equipment.

February 1993 - Construction Safety Manual: Materials Handling Page 411

 4.1.1

Selection of the storage area should be made with due

consideration for drainage and protection from rain and
sandstorms (see Figure III.13 Typical Construction
Materials Store Yard).

4.1.2

Open storage areas should be planned to minimize the

reversing and maneuvering of trucks especially into and
out of confined areas.

4.1.3

Access ways must be wide enough to allow for the

passage of fire trucks. Fire fighting equipment should be
located throughout the area. Contact the Fire Prevention
Group of Loss Prevention for information (see Figure III.13
Typical Construction Materials Store Yard).

4.1.4

Cribbing timber, racks, or pallets should be used to ensure

that all materials are stored off the ground.

4.1.5

Protection should be provided for materials such as

cement, insulation, and other bulk material which could
be damaged by moisture.

4.1.6

All machinery, equipment, and valves should be

maintained fully assembled and securely closed. All
machined surfaces must be covered and fully protected
from exposure to the weather.

February 1993 - 4.0 Materials Handling Page 412

 4.1.7

The quantity of material on site at any one time must be

restricted to a minimum stock. Flammable stores shall be
kept separated. Such a policy should greatly reduce
losses due to pilferage or damage (see Figure III.13 Typical
Construction Materials Store Yard).

Once these factors have been established, the staffing of

the storage areas can then be considered.

4.1.8

On larger projects, the movement of materials could

justify the employment of a loading and unloading gang,
whereas small jobs would probably need only one man
assigned to this responsibility.

4.1.9

Routinely, on most sites, there should be a man appointed

as a materials controller responsible for materials from
the planning stage through to the final unloading, storage,
and distribution stage.

4.2 Machine Transport

A wide variety of mechanical equipment is available for
transporting and distributing materials on and around a job site.
They range from simple equipment such as a dumper or a tractor
and trailer to more sophisticated equipment such as a concrete
pump or a large crane.

4.2.1 Dumpers

Dumpers are one of the most commonly used pieces of

construction equipment and have proved very useful in
transporting concrete and other small loads around site.

February 1993 - 4.0 Materials Handling Page 413

 Unfortunately they are also a common source of injuries
and damage.

Dumper drivers must be properly trained and experienced

and must hold a current Saudi Arab Government license.
The equipment is designed for the movement of material
only. Passengers must not be allowed to travel in the skip
or anywhere else on the machine. Dumpers must be
regularly maintained with particular attention to brakes,
steering, and skip release mechanism. If they are to be
used for towing, a proper towing eye with a shackle or pin
must be provided.

4.2.2 Tractors and Trailers

Tractors and trailers are useful for moving larger loads

around the site. In addition to the normal precaution of
good maintenance, it is essential that safety chains or
wire ropes be fitted between the tractor and trailer so
that if the towing connection should break or become
separated for some reason, the trailer can still be brought
to a controlled stop by the tractor. Trailer and its load
shall not exceed the towing capacity of the tractor and
shall be fitted with an independent braking system if it is
designed to carry more than 9,072 kilograms (20,000
pounds). Trailers used for carrying pipes should be fitted
with side stops, and loads must be securely tied down
before being transported.

4.2.3 Conveyor Belts and Monorails

Conveyor belts and monorails are occasionally used for

transporting concrete, sand, or aggregate on site. They
require a complete maintenance program. Because of the
many problems associated with them, thorough
consideration must be given to their use. All pulleys,
rollers, gears and pinch points shall be guarded. On/off
switches shall be clearly marked and readily accessible.

February 1993 - 4.0 Materials Handling Page 414

 4.2.4 Concrete Pumps

Concrete pumps are used for the placement of concrete

in difficult situations. They have the advantage of being
able to move large amounts of concrete very speedily to
the area where it is required. The operation of this
equipment demands specialized knowledge of concrete
technology; however, placing concrete by this method can
significantly reduce the number of dumpers employed or
the crane usage time expended on a civil engineering
contract.

4.3 Site Stores

For small or valuable materials which cannot be conveniently
stored in outside areas, it is essential that an indoor stores shed,
under the control of a responsible person, be established on site.
Because of the nature of the materials stored in such an area, the
main considerations must be security and fire prevention.

The issuing and receiving of stores must be under the control of a

responsible person. Adequate fire fighting equipment must be
readily available in the area. Materials should be stored on
shelving or with small items such as nuts and bolts, etc. in bins
suitably marked with the contents. The safe loads allowed on
racks and the maximum stack heights should be established. All
hazardous material, such as paints, fuels, chemicals, etc., should
be separated and stored in an isolated flammable storage area
(see Appendix C). Notices warning of the dangers associated
with these materials should be posted in the hazard area.

4.4 Manual Handling

There are many areas of construction work where mechanization
cannot take the place of sheer muscle, and it is in such areas that
the majority of injuries occur. The inevitable results of lifting
incorrectly are strained backs, slipped discs, sprains and strains,
and a complexity of internal injuries.

February 1993 - 4.0 Materials Handling Page 415

 It is, therefore, essential that workers be trained in the correct
methods of manual handling. Safe lifting can only be carried out
by the proper use of the right muscles. Back and abdominal
muscles are weak, while the leg and thigh muscles are strong.
The spine has a natural and comfortable shape when a man is
standing upright; however, if he bends, the spine arches and
becomes weaker. If the spine can be kept in a straight position
when lifting, the strain of the lift goes to the strong muscles of
the leg and thigh and loads can be lifted safely, with much less
physical effort. This is the basic principle of manual handling.

4.4.1

There are four significant points in a proper lift:

1. Grip: A good grip makes maximum use of the palm

of the hand, the ball of the thumb, and base of the
fingers.
2. Back: The back must be kept straight to maintain its
most natural and strongest position. This means that
the knees and ankles must be bent and the chin kept
well into the chest. The body must be positioned as
close to the load as possible so as to act as a
counterweight.
3. Feet: The feet should be apart the width of the hips
with one foot slightly in front of the other so that a
natural lead off is obtained.
4. Arms: The arms must be kept as close as possible to
the body.

4.4.2

The important factor in manual handling is that a man

should know his capabilities and ask for assistance with
loads beyond his capabilities. In dual lifting, partners
should be approximately the same height and weight so
that the load does not become unevenly distributed.

February 1993 - 4.0 Materials Handling Page 416

 4.4.3

Loads, even when properly lifted, can slip. The man lifting
must be prepared for such a possibility and wear the
proper protective equipment. Safety footwear is
mandatory to protect feet and gloves should be worn to
protect hands from laceration or splinters and to give
some protection if the fingers are trapped between the
load and the other surfaces.

February 1993 - 4.0 Materials Handling Page 417

FIGURE III.13: TYPICAL CONSTRUCTION MATERIALS STORE YARD

February 1993 - 4.0 Materials Handling Page 418

 Note: Maximum
grid of
driveway 50 ' X
150'

February 1993 - 4.0 Materials Handling Page 419

ATTACHMENT III.1: HEAVY EQUIPMENT OPERATOR LICENSING INFORMATION

GENERAL INFORMATION

All crane and other heavy equipment operators working on Saudi Aramco
projects are required to have a valid heavy equipment operator Saudi
Arab Government (SAG) license and a Saudi Aramco Heavy Equipment
Operator Certificate. This applies to Saudi Aramco employees as well as
contractor employees.

Saudi Arabs and non-Saudi citizens employed by Saudi Aramco or

contractors working on Saudi Aramco projects may obtain their SAG
license by following the established procedure.

SAUDI ARAMCO EMPLOYEES (SAUDI AND NON-SAUDI)

WITHOUT HEAVY EQUIPMENT LICENSE

Application forms for SAG Heavy Equipment License are

completed and processed at the Saudi Aramco License
Unit, Building # 510, Dhahran. (Saudi Aramco employees
in all other areas apply to local Saudi Aramco License
Unit). After completion of an eye examination and blood
test, the applicant is scheduled for an operator
competency test by the Heavy Equipment Operator
Training/Testing Unit, Dhahran (Tel. 874-1857). Upon
successful completion of the test, application forms are
returned to the Saudi Aramco License Unit for processing
through the SAG Traffic Department, Dammam, for SAG
License issue.

SAUDI ARAMCO EMPLOYEES (NON-SAUDI)

WITH HOME COUNTRY HEAVY EQUIPMENT LICENSE

Employees with valid home country licenses need only

apply through the Saudi Aramco License Unit, Building #
510, Dhahran (Saudi Aramco employees in all other areas
apply to their local Saudi Aramco License Unit). After
completion of an eye examination and blood test,

February 1993 - 4.0 Materials Handling Page 420

 application forms are forwarded by the Saudi Aramco
License Unit for processing to the SAG Traffic Department,
Dammam, for SAG License issue. A company test is not
required.

CONTRACTOR EMPLOYEES (SAUDI AND NON-SAUDI)

WITHOUT HEAVY EQUIPMENT LICENSE

Application for SAG Heavy Equipment License is made

directly to the SAG Traffic Department, Dammam.

Upon completion of the eye examination and blood test,

the contractor company representative contacts the Saudi
Aramco Heavy Equipment Operator Training/Testing Unit
(Tel. 874-1857) for scheduling of the competency test.
(Application form is to accompany contractor employee to
the test site).

After the successful completion of the competency test,

the test sheet is attached to the application form. The
application form is then taken to the SAG Traffic
Department, Dammam, for processing and license issue.

CONTRACTOR EMPLOYEES (NON-SAUDI)

WITH HOME COUNTRY HEAVY EQUIPMENT LICENSE

Contractor employee with a valid home country license

need only apply for SAG license to the SAG Traffic
Department, Dammam, for processing and license issue.
A competency test is not required for SAG license.

On receipt of the SAG license, the contractor company

representative contacts the Saudi Aramco Heavy
Equipment Operator Training and Testing Unit (Tel. 874-
1857) for scheduling of the Saudi Aramco certification
test.

February 1993 - 4.0 Materials Handling Page 421

IV. Electrical And Radiation

February 1993 - Construction Safety Manual: IV. Electrical And Radiation Page 422
1.0 ELECTRICITY
The human senses (smell, taste, hearing, etc.) do not provide a warning of
an electrical hazard. The great majority of electrical accidents result in
burns. Fire and explosion from sparks in flammable atmospheres can and
does lead to loss of life and serious damage to property. All electrical
installations, no matter what voltages are used, should always be treated
with great caution.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 2.100 Work Permit System

GI 6.012. Isolation, Lockout And Use of Hold Tags

Power Distribution Instruction:

No. 10.0. Power Distribution System Operations

No. 11.0. Hold Orders, Clearances and Permission to Test

No. 50.0. Safety Grounding

Saudi Aramco Engineering Standards:

Electrical Power Manual (SAES-P series)

SAES-B-064 Onshore And Near Shore Pipeline Safety

Operations Instructions Manual:

No. 1.111. Electrical Connections

NFPA 70: National Electrical Code

ANSI/IEEE C2-90

National Electrical Safety Code

February 1993 - Construction Safety Manual: Electricity Page 423

ANSI B30.5. Mobile and Locomotive Cranes

29 CFR 1926 Subpart N - Cranes, Derricks, Hoists, Elevators And Conveyors

US Department of Labor, Occupational Safety And Health

Administration (OSHA)

February 1993 - 1.0 Electricity Page 424

1.1 Voltage
The severity of electric shock is not entirely dependent upon the
voltage of the power source. The ratio of the voltage to
resistance determines the current that will flow through the
body and the resulting injury.

In terms of a formula this ratio is:

Current through the body = Voltage applied across the body

Resistance of the body + contact
resistance

The hazard is greater if working conditions are wet or if the

worker perspires freely. This produces a combination of wet skin
and body salt which provides low resistance to current flow.

1.2 Temporary Installations

Distribution of electricity on a construction site is different from a
permanent installation. As construction work proceeds, the type
of equipment in use changes. From excavation to completion,
there is a constant need for convenient means of connecting
equipment. This requires a variety of voltages, phases, and
current in different places at different times. Load requirements
will vary considerably. All temporary electrical systems shall
conform to the National Electrical Code.

1.2.1

The contractor is responsible for the temporary electric

supply system on a construction site and the safety
measures associated with the National Electrical Code.

1.2.2

Cables on site are subject to rough treatment. Special

care should be taken to ensure that the grounding
conductor remains intact. If the conducting wire breaks,

February 1993 - 1.0 Electricity Page 425

 the supply will not be interrupted under a ground fault
condition and the system will no longer be safe. Only UL,
FM or other recognized testing lab approved extension
cords bearing appropriate lab trademarks shall be used.
Damaged or spliced cords are not acceptable to Saudi
Aramco.

1.2.3

Special care shall be taken to ensure that the correct fuse

or breaker ratings are strictly enforced and that the
Ground-Fault Circuit Interrupters (GFCIs) are installed
properly on all circuits.

1.2.4

All installation work must be carried out by qualified,

experienced electricians. Before connecting temporary
electrical installations to existing installations, prior
approval must be obtained from the Saudi Aramco
proponent department. This is to ensure that no
overloading of electrical devices will occur and system
protection will not be compromised.

1.2.5

A competent person must be made directly responsible

for the overall safety of the installation. Its general usage,
its maintenance, and any alterations and extensions to
the system should be under his control. He must be at
the site whenever work is being done. Before any part of
a newly installed electrical system or its equipment is
energized, it must be thoroughly tested. Safety can be
ensured by regular inspection and maintenance.

February 1993 - 1.0 Electricity Page 426

1.3 Hand Tools and Lighting
1.3.1

Many injuries, fires, and explosions have resulted when

extension lights with defective cords or fittings have been
used or when bulbs have been broken, exposing the live
filament wire to an explosive atmosphere. All electrically
operated tools shall be rated and used at a voltage not
exceeding 125V. The use of 220V is prohibited.

1.3.2

Defective extension lights and electric hand tools shall be

repaired or replaced. A defective electrical tool or cord
can cause burns, falls as a result of sudden shocks, or even
fatalities.

1.3.3

Portable electric tools, extension lights and cords should

be inspected each time they are issued and returned. This
should be part of a tool store procedure. Frequent
random checks should be made where those tools, lights
and plugs are being used on site.

Portable hand lamps shall comply with the following:

(1) Metal shell, paper-lined lamp holders shall not be

used.

(2) Hand lamps shall be equipped with insulated handle.

(3) Substantial lamp guard shall be attached to the

handle or holder. Metallic lamp guards shall be
grounded. Three-wire power cords with grounding
conductor shall be used.

February 1993 - 1.0 Electricity Page 427

 1.3.4

Failure of electrical equipment, because of misuse, is a

frequent cause of shock. Workers are prone to abuse
extension cords by pulling them over sharp metal objects,
hanging them across equipment, kicking them, or letting
them be run over by industrial equipment. They often
strain the cords during use, causing the plug and fixture to
part and expose live wires.

1.3.5

Many accidents occur when lower volt equipment is

plugged into higher volt systems. Before any portable
tool or extension light is plugged in, the voltage required
for the tool or light must be the same as the power
source, and the plugs must be checked for damage.

1.3.6

The importance of grounding all portable tools and lights

cannot be emphasized too strongly. All non-current
carrying metal parts of any electrical equipment must be
properly grounded. This will reduce the electrical shock
hazard.

1.3.7

In hazardous areas, more stringent rules apply as to the

type of equipment which may be used. Explosion proof
light fittings for extension lights is one example. As with
all work carried out on Saudi Aramco installations, Work
Permits must be obtained and the type of equipment to
be used discussed and agreed upon before the permit is
issued.

February 1993 - 1.0 Electricity Page 428

 1.3.8 General Precautions:

Only qualified electricians should make repairs and carry

out maintenance checks. All extension lights must be
fitted with protective guards, so if accidentally dropped,
the lamp remains intact. Up to a 120 volt maximum rated
AC portable lighting system may be used for illuminating
inside confined spaces and vessels, provided it is
protected by an externally located ground fault circuit
interrupter and also meets the provisions of GI 520.001
Section 5.5.5.1 and 520.001-4 (Supplement 4) - "Confined
Space Entry Procedure" (Abqaiq Plants).

1.3.9

Ground fault circuit interrupters shall be used on all

electrical circuits including portable power electrical
supplies (see NFPA Handbook of the National Electric
Safety Code, Section 305-b for GFCIs) on temporary
wiring.

1.3.10

The National Electric Safety Code defines requirements

for the construction and use of portable extension and
electric cords in industrial service. This code shall be
followed by construction groups.

1.4 Work on Live Equipment

1.4.1

Whenever workmen are required to work on energized

equipment, the job must be planned thoroughly and the
workmen should proceed with caution.

Before any work on live equipment starts, there must be a

thorough knowledge of the work involved, personal

February 1993 - 1.0 Electricity Page 429

 protective equipment must be available, and all necessary
work permits must be obtained.

1.4.2

Employees must never work alone on live equipment. In

addition to the man doing the job, there must be another
electrician standing by. A foreman or supervisor should
also be in attendance while this work is being carried out,
and he must know how to isolate the equipment.

1.4.3

Before starting a job, the exact voltages should be known.

This is important as it determines the type of personal
protection required for the work and the procedures
established in the work permit. If there is any doubt
about voltages, a check must be made before the work is
started.

1.4.4

Work platforms and equipment used near energized

equipment shall be properly grounded.

February 1993 - 1.0 Electricity Page 430

 1.4.5

Work on live equipment can be as safe as work on

isolated equipment if the following are observed:

1 There must be a thorough knowledge of the

equipment and the job to be done.
2 If there is any doubt, the advice of the supervisor or
responsible person should be sought.
3 The work must be correctly planned before starting.
4 Protective equipment must be used correctly.

1.5 Overhead and Underground Cables

On any construction site, power supplies may have already been
installed below ground or overhead.

Contact should be made with the appropriate Saudi Aramco

department at the planning stage of the job to determine the
work permit requirements, route and depth of any underground
cables and the recommended safe clearances. If re-routing
existing cables is necessary, this should be done before the main
contract starts.

1.5.1 Overhead Lines

(Figure IV.1)

High voltage or overhead lines are usually uninsulated.

Therefore, any kind of metallic object coming near or in
contact with them can cause a hazardous situation. High
voltage can easily arc across a considerable distance. (See
OSHA 29 CFR 1926 Subpart N.)

1.5.2 The Contractor Should Arrange for Power Lines to be:

1 Re-routed clear of all construction work or placed

underground if possible.
2 Made "dead", grounded, and certified as such by
Saudi Aramco.

February 1993 - 1.0 Electricity Page 431

 3 Protected by barriers and timber or wire "goal-
posts", so that no part of any mobile crane, earth
moving equipment, etc. can approach the live cable.
Clearance distances should be agreed upon with
Saudi Aramco. Access below the powerlines shall be
restricted by barriers to where the "goal-posts" are
located (see Figure IV.1).

The need for caution in working with overhead lines

cannot be over-emphasized. High voltage overhead lines
have been mistaken for telephone cables.

It should never be assumed that there is enough

clearance; it should always be proved. It should never be
assumed that a cable or line is "dead"; it should always be
checked.

1.5.2.1 Spacing Between Powerlines and Pipelines

Special precautions are required during

installation, operation or maintenance of above
grade or below grade onshore pipelines. (See
SAES-B-064.)

1.5.3 Underground Cables

Normal depth of underground cables varies between 46

centimeters (18 inches) and 0.9 meter (3 feet). (Changes
in ground level, due to the work, can mean that the "as
built" depth is no longer correct). No mechanical
excavations should be started before test trenches have
been dug by hand and cable locations established. Unless
cables have been laid very deep, heavy vehicles should
not be allowed to pass over them.

Underground cables, exposed during excavation work

should be assumed to be energized and not repositioned
or moved until certified to be de-energized. Exposed

February 1993 - 1.0 Electricity Page 432

 buried cables in open trenches should be properly
supported and the area barricaded.

Accidental damage to any cable exposed during

excavation shall be immediately reported to Saudi
Aramco. The area must be barricaded until the damaged
cable has been made safe.

1.6 Overhead Power Transmission and Distribution

The standards given in this section provide minimum
requirements for safety and health during construction.

1.6.1 Initial Inspections, Tests, or Determinations

Existing conditions shall be determined before starting

work, by an inspection or a test. Such conditions shall
include, but not be limited to, energized lines and
equipment, condition of poles, and the location of circuits
and equipment, including power and communication
lines.

Electrical equipment and lines shall be considered

energized until determined to be de-energized by testing
and grounding.

Operating voltage of equipment and lines shall be

determined before working on or near energized parts.

1.6.2 De-energizing Lines and Equipment

The procedures outlined in GI 2.100 and GI 6.012 shall be

followed, and all circuits will be identified, tagged, locked,
and tested.

Equipment shall be checked for potential and protective

grounds shall be applied.

Guards or barriers shall be erected as necessary near to

adjacent energized lines.

February 1993 - 1.0 Electricity Page 433

 When more than one independent crew needs to work on
the same line or equipment at the same time, a separate
"clearance" shall be given to each crew by the Saudi
Aramco Power Dispatcher, and a prominent tag and lock
for each such independent crew shall be placed on the
line or equipment by the designated crew leader.

Upon completion of work on de-energized lines or

equipment, the crew leader shall determine that all
members in his crew are clear and that protective
grounds installed by his crew have been removed. He
shall release his clearance to Saudi Aramco.

1.6.3 Emergency Procedures and First Aid

The Contractor shall provide training or require that his

employees are knowledgeable and proficient in the
following:

1 Procedures involving emergency situations;

2 First-aid fundamentals including cardiopulmonary
resuscitation; and
3 Remote field crews shall have an employee certified
in First-Aid.

1.6.4 Night Work

When working at night, spotlights or portable lights for

emergency lighting shall be provided as needed to
perform the work safely.

1.6.5 Work Near/Over Water

When crews are engaged in work over or near water and

when danger of drowning exists, suitable protection such
as buoyant work vests shall be worn. Life rings, ropes
and at least one skiff shall be provided.

February 1993 - 1.0 Electricity Page 434

 1.6.6 Hydraulic Fluids

All hydraulic fluids used for the insulated sections of

derrick trucks, aerial lifts, and hydraulic tools which are
used on or around energized lines and equipment shall be
of the insulating type.

1.6.7 Live-Line Tools (Hot Sticks)

Only live-line tool poles having a manufacturer's

certification meeting the following requirements shall be
used:

1 100,000 volts per foot of length for 5 minutes when

the tool is made of fiberglass, or
2 75,000 volts per foot of length for 3 minutes when
the tool is made of wood; or

All live-line tools shall be visually inspected and wiped

clean before use each day. Tools with any hazardous
defect shall be removed from service.

1.6.8 Material Handling

1.6.8.1 Unloading

Prior to unloading steel, poles, cross arms, and

similar material, the load shall be thoroughly
examined to ascertain if the load has shifted,
binders or stakes have broken, or the load is
otherwise hazardous to employees.

1.6.8.2 Pole Hauling

During pole hauling operations, all loads shall be

secured to prevent displacement and a red flag
shall be displayed at the trailing end of the
longest pole.

February 1993 - 1.0 Electricity Page 435

 Precautions shall be exercised to prevent
blocking of roadways or endangering other
traffic.

When hauling poles during the hours of darkness,

illuminated warning devices shall be attached to
the trailing end of the longest pole and haul truck
brake lights shall not be obscured.

1.6.8.3 Storage

No materials or equipment shall be stored under

energized bus, energized lines, or near energized
equipment.

1.6.8.4 Framing

During framing operations, employees shall not

work under a pole or a structure suspended by a
crane, A-frame, or similar equipment unless the
pole or structure is adequately supported.

1.6.8.5 Attaching the Load

The hoist rope shall not be wrapped around the

load. This provision shall not apply to electric
construction crews when setting or removing
poles.

Non-conductive tag lines or other suitable

devices shall be used to control loads being
handled by hoisting equipment.

1.6.9 Grounding for Protection of Workers

1.6.9.1 Isolation and Voltage Testing

Equipment to be worked on when it is

deenergized shall be isolated from the system

February 1993 - 1.0 Electricity Page 436

 and tested for voltage using test equipment rated
for the system, and be grounded.

1.6.9.2 Applying and Removing Grounds

(See Figure IV.2)

Grounding cables shall be connected to ground

first, and then the equipment. Grounding cables
shall be installed and removed using hot sticks or
insulating gloves and protective apparel.

Grounding cables shall first be disconnected from

the line or equipment and then be disconnected
from ground.

Grounding cables shall be at, or as close as

practicable to, the work location.

Protective grounds shall be installed so that it is

not possible for workers to come in contact with
a grounded component and an ungrounded
component simultaneously.

1.6.9.3 Grounding Distance

If the work is to be performed at more than one

location in a line section, the line section must be
grounded and short circuited at each end of the
line section and the conductor to be worked on
shall be grounded at each work location.

1.6.9.4 Removal of Grounds for Testing Purposes

Grounds may be temporarily removed with the

permission of the Power Dispatcher. Extreme
caution shall be exercised while the
equipment/line is not grounded.

February 1993 - 1.0 Electricity Page 437

 1.6.9.5 Grounding Electrode

When grounding electrodes are utilized, such

electrodes shall exhibit low resistance to ground;
thereby, rapidly diminishing the electrical hazard
to personnel. Otherwise, insulated tools (or
other operating equipment) must be used by
personnel.

1.6.9.6 Grounding Cables And Clamps

Grounding cables and clamps shall be capable of

conducting the anticipated fault current and shall
have a minimum size of No. 2 AWG standard
copper.

1.6.10 Overhead Lines

Prior to climbing poles, ladders, scaffolds, or other

elevated structures, an inspection shall be made to
determine that the structures are capable of sustaining
the additional or unbalanced stresses to which they will
be subjected.

Where poles or structures may be unsafe for climbing,

they shall not be climbed until made safe by guying,
bracing, or other adequate means.

Before installing or removing wire or cable, strains to

which poles and structures will be subjected shall be
considered and necessary action taken to prevent failure
of supporting structures.

When setting, moving, or removing poles using cranes,

derricks, gin poles, A-frames, or other mechanized
equipment near energized lines or equipment,
precautions shall be taken to avoid contact with energized
lines or equipment.

February 1993 - 1.0 Electricity Page 438

 Unless using protective equipment suitable for the
voltage involved, employees standing on the ground shall
avoid contacting equipment or machinery working
adjacent to energized lines or equipment.

Lifting equipment shall be bonded to an effective ground

or it shall be considered energized and barricaded when
utilized near energized equipment or lines.

Pole holes shall not be left unattended or unguarded.

Even in desert areas, unguarded pole holes are a hazard.

Tag lines shall be of a non-conductive type when used

near energized lines.

1.6.10.1 Metal Tower Construction

When working in unstable material, the

excavation for pad or pile-type footings in excess
of 1.52 meters (5 feet) deep shall be either
sloped to the angle of repose as required or
shored if entry is required. Ladders shall be
provided for access to pad or pile-type footing
excavations in excess of 1.2 meters (4 feet). (See
Section II, 2.4, Excavations, Trenching, And
Shoring for depth and slope criteria.)

When working in unstable material, provision

shall be made for cleaning out auger-type
footings without requiring an employee to enter
the footing unless shoring is used to protect the
employee.

A designated employee shall be used in directing

mobile equipment adjacent to footing
excavations.

February 1993 - 1.0 Electricity Page 439

 No one shall be permitted to remain in the
footing while equipment is being spotted for
placement.

Where necessary to assure the stability of mobile

equipment, the location of use for such
equipment shall be graded and leveled.

Tower assembly shall be carried out with a

minimum exposure of employees to falling
objects when working at two or more levels on a
tower.

Guy lines shall be used as necessary to maintain

sections or parts of sections in position and to
reduce the possibility of tipping.

Members and sections being assembled shall be

adequately supported.

No one shall be permitted under a tower which is

in the process of erection or assembly, except as
may be required to guide and secure the section
being set.

When erecting towers using hoisting equipment

adjacent to energized transmission lines, the
lines shall be de-energized when practical. If the
lines are not de-energized, extraordinary caution
shall be exercised to maintain the minimum
clearance distances required.

Erection shall be set on firm level foundations

and when the cranes are so equipped, outriggers
shall be used.

February 1993 - 1.0 Electricity Page 440

 Tag lines shall be utilized to maintain control of
tower sections being raised and positioned,
except where the use of such lines would create
a greater hazard.

The loadline shall not be detached from a tower

section until the section is adequately secured.

Except during emergency restoration procedures,

erection shall be discontinued in the event of
high wind or other adverse weather conditions
which would make the work hazardous.

Equipment and rigging shall be regularly

inspected and maintained in safe operating
condition.

Adequate traffic control shall be maintained

when crossing highways and railways with
equipment.

An employee shall be utilized to determine that

required clearance is maintained in moving
equipment under or near energized lines.

1.6.10.2 Stringing/Removing De-energized Conductors

When stringing or removing de-energized

conductors, the provisions of the following
paragraphs shall be complied with.

Prior to stringing operations, a briefing shall be

held setting forth the plan of operation and
specifying the type of equipment to be used,
grounding devices and procedures to be
followed, crossover methods to be employed,
and the clearance authorization required.

February 1993 - 1.0 Electricity Page 441

 Where there is a possibility of the conductor
accidentally contacting an energized circuit or
receiving a dangerous induced voltage buildup,
to further protect the employee from the hazards
of the conductor, the conductor being installed
or removed shall be grounded.

When the existing line has been de-energized,

proper clearance authorization shall be secured
and the line grounded on both sides of the
crossover, or the line being strung or removed
shall be worked on as if energized.

When crossing over energized conductors in

excess of 600 volts, rope nets or guard structures
shall be installed unless provision is made to
isolate or insulate the workman or the energized
conductor. Where practical the automatic re-
closing feature of the circuit interrupting device
shall be made inoperative. In addition, the line
being strung shall be grounded on either side of
the crossover or and worked on as if energized.

Conductors being strung in or removed shall be

kept under positive control by the use of
adequate tension reels, guard structures, tielines,
or other means to prevent accidental contact
with energized circuits.

Guard structure members shall be sound and of

adequate dimension and strength, and
adequately supported.

Anchors, riggings, and hoists shall be of ample

capacity to prevent loss of the lines.

The manufacturer's load rating shall not be

exceeded for stringing lines, pulling lines, sock

February 1993 - 1.0 Electricity Page 442

 connections, and all load-bearing hardware and
accessories.

Pulling lines and accessories shall be inspected

regularly and replaced or repaired when
damaged or when dependability is doubtful.

Conductor grips shall not be used on wire rope

unless designed for this application.

While the conductor or pulling line is being pulled

(in motion) employees shall not be permitted
directly under overhead operations, nor shall any
employee be permitted on the crossarm.

A transmission clipping crew shall have a

minimum of two structures clipped in between
the crew and the conductor being sagged. When
working on bare conductors, clipping and tying
crews shall work between grounds at all times.
The grounds shall remain intact until the
conductors are clipped in, except on dead end
structures.

Except during emergency restoration procedures,

work from structures shall be discontinued when
adverse weather (such as high wind or ice on
structures) makes the work hazardous.

Stringing and clipping operations shall be

discontinued during electrical storms.

Reel handling equipment, including pulling and

braking machines, shall have ample capacity,
operate smoothly, and be leveled and aligned in
accordance with the manufacturer's operating
instructions.

February 1993 - 1.0 Electricity Page 443

 Reliable communications between the reel
tender and pulling rig operator shall be provided.

Each pull shall be snubbed or dead ended at both

ends before subsequent pulls.

1.6.10.3 Stringing Adjacent to Energized Lines

Prior to stringing parallel to an existing energized

transmission line, it shall be determined whether
dangerous induced voltage buildups will occur in
the system, particularly during switching and
ground fault conditions.

When stringing adjacent to energized lines, the

tension stringing method or other methods
which preclude unintentional contact between
the lines being pulled and any employee shall be
used.

All pulling and tensioning equipment shall be

isolated, insulated, or effectively grounded.

A ground shall be installed between the

tensioning reel setup and the first structure in
order to ground each bare conductor, sub-
conductor, and overhead ground conductor
during stringing operations.

During stringing operations, each bare conductor,

sub-conductor, and overhead ground conductor
shall be grounded at the first tower adjacent to
both the tensioning and pulling setup and in
increments so that no point is more than 3.218
kilometers (two miles) from a ground.

· The grounds shall be left in place until

conductor installation is completed.

February 1993 - 1.0 Electricity Page 444

 · Such grounds shall be removed at the last
phase of aerial cleanup.

· Except for moving type grounds, the grounds

shall be placed and removed with a hot stick.

· Conductors, sub-conductors, and overhead

ground conductors shall be grounded at all
dead-end or catch-off points.

A ground shall be located at each side and within

3.2 meters (10 feet) of working areas where
conductors, or overhead ground conductors are
being spliced at ground level. The two ends to be
spliced shall be bonded to each other. It is
recommended that splicing be carried out on
either an insulated platform or on a conductive
metallic grounding mat bonded to both grounds.
When a grounding mat is used, it is
recommended that the grounding mat be roped
off and an insulated walkway provided for access
to the mat. (See Power Distribution Instruction
No. 50.)

All conductors, sub-conductors, and overhead

ground conductors shall be bonded to the tower
at any isolated tower where it may be necessary
to complete work on the transmission line.

· Work on dead-end towers shall require

grounding on all de-energized lines.

· Grounds may be removed as soon as the work

is completed, provided that the line is not left
open circuited at the isolated tower at which
work is being completed.

When performing work from the structures,

clipping crews and all others working on

February 1993 - 1.0 Electricity Page 445

 conductors, sub-conductors, or overhead ground
conductors shall be protected by individual
grounds installed at every work location.

1.6.11 Underground Lines

Warning signs shall be promptly placed when covers of

manholes, hand holes, or vaults are removed.

Before an employee enters a street opening, such as a

manhole or an unvented vault, it shall be promptly
protected with a barrier, temporary cover, or other
suitable guard.

When work is to be performed in a manhole or unvented

vault, GI 2.100, Work Permit System, shall be enforced.

· No entry shall be permitted unless forced ventilation

is provided or the atmosphere is found to be safe by
testing for oxygen deficiency and the presence of
explosive gases or fumes.

· Where unsafe conditions are detected, by testing or

other means, the work shall be ventilated and
otherwise made safe before entry.

· Provisions shall be made for an adequate continuous

supply of air.

1.6.11.1 Work in Manholes

While work is being performed in manholes, an

employee shall be available in the immediate
vicinity to render emergency assistance as
required. This shall not preclude the employee in
the immediate vicinity from occasionally entering
a manhole to provide assistance, other than for
emergencies. This requirement does not
preclude a qualified employee, working alone,

February 1993 - 1.0 Electricity Page 446

 from entering for brief periods of time, a
manhole where energized cables or equipment
are in service, for the purpose of inspection,
housekeeping, taking readings, or similar work if
such work can be performed safely. However,
someone on the surface must be aware of this
type of entry and know the expected duration of
the task.

Before entering or using open flames in a

manhole excavation in an area where
combustible gases or liquids may be present,
such as near a gasoline service station, GOSP,
refinery, etc., the atmosphere of the manhole or
excavation shall be tested and found safe or
cleared of the combustible gases or liquids (See
GI 2.100).

1.6.11.2 Trenching and Excavating

During excavation or trenching, in order to

prevent the exposure of employees to the
hazards created by damage to dangerous
underground facilities, efforts shall be made to
determine the location of such facilities and work
in accordance with GI 2.100, Work Permit
System.

When underground facilities are exposed

(electric, gas, water, telephone, etc.) they shall
be protected as necessary to avoid damage.

When multiple cables exist in an excavation, the

cable to be worked on shall be identified by
electrical means unless its identity is obvious by
reason of distinctive appearance.

February 1993 - 1.0 Electricity Page 447

 Before cutting into a cable or opening a splice,
the cable shall be identified and verified by the
proponent department.

When working on buried cable or on cable in

manholes, metallic sheath continuity shall be
maintained by bonding across the opening or by
equivalent means.

1.6.12 Construction in Energized Substations

When construction work is performed in an energized

substation, authorization shall be obtained from the local
power service dispatcher and a work permit shall be
issued. (See GI 2.100)

When work is to be done in an energized substation,

safety precautions shall be detailed in the work permit
(See GI 2.100).

Extreme caution shall be exercised in the handling of

busbars, tower steel, materials, and equipment in the
vicinity of energized facilities.

1.6.12.1 Barricades and Barriers

Barricades or barriers shall be installed to

prevent accidental contact with energized lines
or equipment.

Signs indicating the hazard shall be posted near

the barricade or barrier.

1.6.12.2 Control Panels

Work on or adjacent to energized control panels

shall be performed by designated employees.

February 1993 - 1.0 Electricity Page 448

 Precaution shall be taken to prevent accidental
operation of relays or other protective devices
due to jarring, vibration, or improper wiring.

1.6.12.3 Mechanized Equipment

Use of vehicles, gin poles, cranes, and other

equipment in restricted or hazardous areas shall
at all times be controlled by designated
employees.

All mobile cranes and derricks shall be effectively

grounded when being moved or operated in
close proximity to energized lines or equipment,
or the equipment shall be considered energized.
(See OSHA 29 CFR 1926 Subpart N.)

Fenders shall not be required for low-boys used

for transporting large electrical equipment,
transformers or breakers.

1.6.12.4 Substation Fences

When a substation fence must be expanded or

removed for construction purposes, a temporary
fence affording similar protection, when the site
is unattended, shall be provided. Adequate
bonding and grounding interconnections shall be
maintained between temporary fence and
permanent fence.

All gates to all unattended substations shall be

locked, except when work is in progress.

1.7 Electric Shock

Speed is essential in dealing with any electrical accident. A copy
of "The Treatment for Electric Shock" placard in Arabic and
English should be prominently displayed so that everyone knows

February 1993 - 1.0 Electricity Page 449

 what to do in an emergency. Employees will be trained in First
Aid and cardiopulmonary resuscitation (CPR).

In brief, the sequence for dealing with an electrical accident is:

1 If at all possible, switch off the power supply. If this is not

instantly possible, release the victim from contact with the
conductor by using dry gloves, dry blanket, dry wood, dry
clothing, rubber sheets, or properly insulated equipment.
2 If breathing has stopped, begin CPR and continue as
necessary.
3 Call for first aid assistance, a doctor, and an ambulance. The
Saudi Aramco emergency number is 110.

February 1993 - 1.0 Electricity Page 450

FIGURE IV.1: TEMPORARY CROSSING FOR CONSTRUCTION EQUIPMENT

Overhead power lines are usually uninsulated

and any kind of metallic object coming near or
in contact with them can cause a hazardous
situation. High voltage can easily arc across
considerable distance. Overhead lines should
therefore be re-routed, "made dead" or
protected by timber "goal posts" and barriers.
Clearance distances should be agreed upon
with Saudi Aramco before work starts.

February 1993 - 1.0 Electricity Page 451

FIGURE IV.2 PROPER USE OF INSULATING TOOLS AND PROTECTIVE APPAREL

Note: Grounding Cables Shall Be Isolated And Removed Using Insulating

Tools And Protective Apparel

February 1993 - 1.0 Electricity Page 452

2.0 IONIZING RADIATION
Ionizing industrial radiation, such as x-rays generated by equipment or
gamma rays emitted spontaneously by radioactive materials, are widely
used in industry for non-destructive testing, e.g., testing of welds in pipes
and pressure vessels, without damaging the material. The material tested
does not retain any radioactivity when testing is completed.

For all practical purposes, the radiation produced by x-ray equipment or

emitted by radioactive sources are the same. X-rays and gamma rays
both have properties which should be understood. Even though they
penetrate the body, they cannot be perceived by any of our five senses;
they can be absorbed and scattered by matter; they travel in straight lines
at the speed of light; they ionize gases; they affect photographic
emulsions; and by far the most important, they can be harmful to the
living cells of the body.

INSTRUCTIONS AND FORMS

Saudi Aramco General Instructions:

150.003 Ionizing Radiation Protection

00-AID-08 Radiation Safety Manual

Saudi Aramco Forms:

Saudi Aramco 2654 Personal Radiation Exposure

Saudi Aramco Standard Drawings:

AB-36895 Radiation Warning Sign

2.1 Methods of Protection Against Radiation

Distance, time, and shielding are the usual methods of reducing
radiation exposure.

February 1993 - Construction Safety Manual: Ionizing Radiation Page 453

 2.1.1 Distance

Distance is an effective method of protection because

gamma and x-rays obey the inverse square law, that is,
the radiation intensity decreases with the inverse square
of the distance. Conversely, dose rates at close distances
can be extremely high, even for low activity sources. It is
essential, therefore, that unshielded sources are kept at a
sufficient distance from personnel so as not to pose a
health hazard to them.

2.1.2 Time

Time is a useful method of protection because high dose

rates can be accepted over very short periods of time.
However, the cumulative dose must remain at acceptable
limits given in GI 150.003-2.

2.1.3 Shielding

To lessen harmful radiation, materials of high density,

such as lead, depleted uranium, or tungsten, are used to
absorb emitted radiation.

In the use of x-ray equipment, precautions against

emitted radiation are necessary until the electric power is
turned off and locked out. On the other hand, radioactive
materials constantly emit radiation and cannot be
switched off. Consequently, to absorb unwanted
radiation and facilitate handling, sealed sources are
housed in shielded containers or bunkers.

2.2 Classification of Personnel and Exposure Limits

In order to control human exposure to industrial radiation, all
employees and contractors are classified as either radiation
workers or non-radiation workers according to their training and
need to use radiation sources. Classification does not guarantee

February 1993 - 2.0 Ionizing Radiation Page 454

 safety; safety procedures and adequate equipment must be used
at all times.

2.2.1 Radiation Workers

A radiation worker is an occupationally exposed person or

employee whose job involves routine use of ionizing
radiation and who has reasonable chance of being
exposed to radiation from a radioactive source.

Radiation workers are further categorized as Competent

Persons or Radiographers. Competent Persons do not
normally use radiation sources, but by training and
experience are capable of supervising both routine
operations and emergency situations involving radiation.
Radiographers are expected to safely use radiation
sources in the course of their work and must be in
possession of a valid "Saudi Aramco Permit to Use
Material/Equipment Producing Ionizing Radiation" before
they can work with a radioactive source.

Radiographers must wear two personal dosimeters when

working with radiation, a direct-reading pocket dosimeter
and an integrating permanent dosimeter (film badge or
thermoluminiscent dosimeter [TLD]).

2.2.2 Non-Radiation Workers

Non-radiation workers should not receive more than

those dose limits given in GI 150.003-2.

2.2.3 Exposure Limits

Radiation doses to workers should always be kept as low

as reasonably achievable (ALARA). Under no
circumstances shall the doses exceed those limits given in
GI 150.003-2 for occupational or non-occupational
people.

February 1993 - 2.0 Ionizing Radiation Page 455

 Special controls (see GI 150.003-2) are imposed on
persons who are, or are capable of being, pregnant. No
occupational exposure is allowed for persons less than 18
years of age.

Over exposure shall be reported to the Saudi Aramco

proponent, the Occupational Medicine Services Unit, and
the Loss Prevention Department.

2.3 Responsibilities for Safe Handling

The Radiation Protection Committee (see GI 150.003) has full
responsibility in all matters concerning the safe use, storage, and
transportation of industrial sealed sources and x-ray machines
used on Saudi Aramco property.

2.3.1 Contractor

The contractor appoints competent persons to be

responsible for the immediate supervision and the
enforcement of instructions and standards. Personnel
involved in performing non-destructive testing must be
certified and hold a valid "Permit to Use
Material/Equipment Producing Ionizing Radiation".

2.3.2 Competent Person

Each radiographer will check at the beginning of each shift

on the zeroing and recharging of dosimeters and on the
condition of the equipment. A competent person familiar
with all of Saudi Aramco radiation use requirements will
make field audits to ensure compliance with Company
instructions and standards. He must report the results of
these audits to the applicable department responsible for
the operation. Also he must be familiar with all
equipment and procedures so that the proper corrective
action can be taken in any emergency situation involving
radioactive equipment.

February 1993 - 2.0 Ionizing Radiation Page 456

 2.3.3. Radiographer

At the start of each shift, radiographers must ensure that

all equipment is in safe working order. All malfunctions
must be reported to the supervisor or Competent Person
immediately. The radiographer must also make sure that
he is wearing a valid TLD or film badge and a direct-
reading pocket dosimeter which has been charged and
zeroed. One radiation monitoring instrument must be
available for each source in use. Equipment must be
transported to the work site with safety locks in place.
Under no circumstance is equipment to be transported in
an unassembled or open condition.

Upon arrival at the job site and prior to operating with

any sealed source, the radiographer must ensure that
non-radiation workers are not subject to radiation levels
that would exceed that which is permitted. Radiation
areas must contain radiation warning signs (see Figure
IV.3) and be clearly displayed around the circumference of
the radiation area. In addition, in populated work areas, a
rope or tape barrier shall be erected around the radiation
area. The area will be monitored with approved survey
meter to ensure safe area for non-radiation workers is
maintained. Further guidance on industrial radiography is
provided in GI 150.003-4 and 00.AIP-08.

A weekly report on the condition of all equipment should

be passed to the supervisor.

2.4 Shipping and Transportation

Government Permits are required for shipping radioactive
materials into and out of Saudi Arabia. Additional information is
available from Purchasing Services Division.

February 1993 - 2.0 Ionizing Radiation Page 457

 Transporting radiation sources to work locations requires a
locked container located out of the passenger compartment.
The vehicle shall have radiation signs on the front and rear.

2.5 Storage Areas

Upon completion of work or at the end of each work period,
every sealed source must be returned to a storage area approved
by the Saudi Aramco Radiation Protection Committee. Storage is
usually within fenced area. All permanent or temporary storage
areas (bunkers) must be approved of by the Saudi Aramco
Radiation Protection Committee. Sources may not be stored in
the back of a truck whether or not they are under lock and key.
Radiation readings must be taken at the perimeter of the storage
area and the radiation level must be within the acceptable limits
given in GI 150.003. Radiation signs must be fixed to the barriers
of all storage areas. (See Figure IV.3.)

· A log shall be maintained of radiation sources in storage,

logged in or out, by source and responsible competent
person in charge of source.

February 1993 - 2.0 Ionizing Radiation Page 458

FIGURE IV.3: STANDARD SIGN - RADIATION

February 1993 - 2.0 Ionizing Radiation Page 459

V. Chemicals And Operations

February 1993 - Construction Safety Manual: V. Chemicals And Operations Page 460
1.0 LIQUEFIED PETROLEUM GASES
Liquefied Petroleum Gases (LPG) are now being widely used in the
construction industry. The precautions covered in this section are
directed to those industrial operators who handle these gases, i.e., stores
personnel and the actual operators using the gases. LPG is a term applied
to combinations of hydrocarbons known under various trade names and
also widely known as propane and butane.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 355.020 Control of Compressed Gas Cylinders

Saudi Aramco Engineering Standards:

SAES-D-5 Liquefied Petroleum Gas Equipment, Installation

SAES-B.057 Safety Requirements: Refrigerated and Pressure Storage

Vessels

Saudi Aramco Bottled Gas Manual:

Part 1.7 Liquid Petroleum Gas

American National Standards:

NFPA 54-88 Fuel Gas Code

ANSI A10.10-81

Safety Requirements for Temporary and Portable Space

Heating Devices & Equipment Used in the Construction
Industry

NFPA 58-89 Liquefied Petroleum Gases, Storage and Handling

February 1993 - Construction Safety Manual: Liquefied Petroleum Gases Page 461
1.1 General
These gases are colorless, heavier than air, and normally
odorless, but for commercial usage, an odorizing agent is added
for the obvious reason of facilitating detection in the event of
accidental escape of the gas.

At normal temperatures, they are gaseous and can be changed

into a liquid by the application of moderate pressure. In the
liquid form, relatively large quantities of LPG can be safely
transported and stored in suitably designed containers. The
approximate ratios of gas volume to liquid volume are 275:1 for
propane and 240:1 for butane.

Both gases are heavier than air at normal temperatures. Any

leakage will form a gas cloud which will settle at the lowest
possible level. It may ignite if a flame or sparks are present. This
could happen at some considerable distance from the source of
leakage. The gases form an explosive mixture with air, and they
react vigorously with oxidizing materials. These gases can be
highly dangerous; if the container is exposed to heat or flame,
there is a high risk of explosion. To reduce the risk of explosion,
the cylinders must be equipped with relief valves or fusible plugs.

1.2 Storage
1.2.1

Cylinders, whether empty or full, should be stored under

cover for protection against the elements. The storage
place should be detached from any other buildings and
constructed of non-combustible material. It should
preferably be a well-ventilated one-story building with all
doors leading directly to the outside.

LPG cylinders must be stored at least 6.1 meters (20 feet)

away from oxygen or oxidizers or must be separated from
them by a fire wall rated at 30 minutes.

February 1993 - 1.0 Liquefied Petroleum Gases Page 462

 1.2.2

The building should be fenced-off and signs should be

displayed both in Arabic and English: "No Smoking".

Water and dry chemical fire extinguishers shall be

available.

1.2.3

Natural ventilation points should be positioned at both

high and low levels.

1.2.4

All electrical fixtures should be of an explosion-proof type.

1.2.5

All gas valves, fittings, connections, and piping shall be

made of stainless steel, brass or copper; rubber/plastic
hoses are prohibited.

1.3 Handling of Cylinders

1.3.1

Cylinders must not be dropped or allowed to come into

violent contact with each other.

1.3.2

They must be stored and used in an upright position, thus

preventing the liquid from passing through the relief valve
regulator and into the equipment.

February 1993 - 1.0 Liquefied Petroleum Gases Page 463

 1.3.3

They must not be placed in or near excavations or any low

level area.

1.3.4

They must be placed on level ground and secured to

prevent accidental tipping over.

1.3.5

Care should be taken that the valve assemblies are not

damaged. The main valve should be closed and the valve
cap in position when the cylinder is not in use.

1.3.6

Smoking is not permitted when handling cylinders.

1.4 Leakage
1.4.1

Cylinders, valves, connections, hoses, and pipings should

be regularly inspected for damage or leakage. Detection
can be carried out by the following methods, if flammable
gas meter is unavailable:

1 Smelling
2 Touching: Leaking cylinder may be colder than those
around it.
3 Listening: Sound of escaping gas.
4 Looking: Localized condensation or frosting.

1.4.2

Small leaks may be confirmed by using soapy water.

February 1993 - 1.0 Liquefied Petroleum Gases Page 464

 1.4.3

A leaking cylinder must be immediately removed to an

open space, clear of all buildings and people or any
potential source of ignition.

1.4.4

The cylinder must be placed with the leak uppermost.

February 1993 - 1.0 Liquefied Petroleum Gases Page 465

 1.4.5

The supplier must be notified immediately.

1.5 Transportation
1.5.1

Full or empty cylinders which are loaded on vehicles must

be placed in an upright position, be adequately secured to
prevent movement, and have valve caps in place.

1.5.2

The vehicle should have fire fighting and first aid

equipment.

1.5.3

The vehicle must also display all the necessary warning

notices.

1.6 Operation
1.6.1

In permanent or semi-permanent installations, the

cylinder must be placed outside the building out of direct
sunlight and the gas piped to appliances inside.

1.6.2

The cylinder must be secured in an upright position, away

from excavation, pits, and other low lying areas.

1.6.3

The regulator and other equipment is to be connected

and a test made to ensure that all joints are gas tight.

February 1993 - 1.0 Liquefied Petroleum Gases Page 466

 1.6.4

The regulator capacity must be suitable for the equipment

being used.

1.6.5

Before lighting, a check is to be made to ensure that there

is sufficient ventilation for the burner and that all
combustible materials are removed from the work area.

1.6.6

Once the burner has been lit, it should burn with a steady
blue flame with blue-green base cones.

1.6.7

A dry chemical fire extinguisher must be readily available

at the work area.

1.6.8

Shut off valves shall be installed at the main tank supply

and at the operating source. (See Loss Prevention
Booklet, "Hazards of Gas Cylinders")

February 1993 - 1.0 Liquefied Petroleum Gases Page 467

1.7 Action in Case of Fire
1.7.1

When cylinders are exposed to severe fire conditions and

are engulfed in flames, no attempt should be made to
extinguish the fire. In such condition, cylinders are likely
to explode immediately.

1.7.2

The action to be taken in such an instance is to evacuate

the area immediately and call the Fire Protection
Department.

1.7.3

Cylinders which have been exposed to fire conditions

must be adequately cooled with water before any
attempt is made to remove them.

February 1993 - 1.0 Liquefied Petroleum Gases Page 468

 1.7.4

If cylinders are equipped with automatic relief valves and

the fire exposure is severe, ignited jets of gas from these
valves can extend as far as 6 meters (20 feet).

1.7.5

In the case of a small fire arising from gas leakage, it is

possible to extinguish the fire by immediately turning off
the cylinder valve. The cylinder should be approached
from the opposite direction to the source of fire.

1.7.6

If a fire does not directly involve other cylinders in the

vicinity, water hoses played on those cylinders will
prevent increased internal pressure and minimize the risk
of explosion.

1.7.7

All cylinders which have been involved in a fire must be

returned immediately to the supplier, alerting the supplier
that the cylinder was involved in a fire.

February 1993 - 1.0 Liquefied Petroleum Gases Page 469

1.8 Bulk Installations
Before any bulk storage installation is undertaken, the LPG
supplier should be consulted on the size of the tank required and
the most suitable fittings for that particular installation, including
relief capacity.

1.8.1

Temporary tanks are to be installed above ground on a

dry, hard foundation away from drains, culverts, or
hollows where it would be possible for any leaking gas to
collect.

1.8.2

Tanks should not be exposed to heat or direct rays of the

sun and they must be adequately protected against
accidental or unauthorized interference.

1.8.3

Only trained personnel are to install bulk tanks and

equipment. All items used must be of approved design
and comply with the appropriate standards.

1.8.4

All pipeline systems must be tested to a safe working

pressure after completion of the assembly.

1.8.5

Fire water protection shall be provided.

1.9 First Aid

If LPG has been inhaled, the affected person must be removed
from the area, kept warm and rested, and not allowed to move
about. If the affected person is not breathing, mouth-to-mouth

February 1993 - 1.0 Liquefied Petroleum Gases Page 470

 resuscitation should be applied. No attempt should be made to
give an unconscious person anything to drink. If the person is
breathing, oxygen must be administered by a competent person.
If liquid has gone to the eyes, they must be thoroughly washed
out with water.

Medical aid must be obtained as soon as possible.

February 1993 - 1.0 Liquefied Petroleum Gases Page 471

2.0 PLANT OPERATIONS
The safe processing and movement of oil from underground to ship or
transmission pipeline is the primary Saudi Aramco objective. Any
construction operation which could affect the safety of oil processing and
movement must be planned and performed in accordance with the
operating procedures of the area in which the job is located.

Every plant area in Saudi Aramco operations has a specific set of

operating instructions and the operating supervisor for that area has full
responsibility for safety precautions. With this responsibility, he also has
authority to issue work permits and stop any work if it is not in
accordance with proper procedures.

It is therefore necessary for anyone expecting to work in an area where

oil or gas is handled to know the rules and regulations and obey them.

Failure to follow the operating rules can result in not only destruction of
Saudi Aramco property but also death of construction and operating
personnel. This type of disaster must be prevented.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 2.100 Work Permit System

GI 2.710 Mechanical Completion & Performance Acceptance of

Plant/Unit

GI 441.014 Repair Procedures on Hydrocarbon Pipelines

SAES-A-005 Safety Instruction Sheet

Schedule 'D':

Saudi Aramco Safety, Health and Environmental

Requirements - Plant Operations

February 1993 - Construction Safety Manual: Plant Operations Page 472

2.1 Additional Information On Saudi Aramco Instructions
and Standards
There are a number of additional instructions and standards
which apply to construction operations, either inside or outside
Restricted Areas. The contractor must determine which of these
apply to him and ensure that his supervisory staff is familiar with
them. This can be accomplished through discussions with
operations management for the area and with the construction
engineer. A meeting of all concerned prior to starting a job shall
be conducted and a Hazard Identification Plan shall be prepared
for review by Saudi Aramco Loss Prevention Department.

Because of the large number of instructions which might be

applicable to a specific job, it is not practical to list all of them.
The following, however, will be helpful in locating applicable
instructions and standards.

2.1.1 General Instruction Manual

This manual is one which provides general instructions

applicable to all Saudi Aramco areas and operations. The
contractor will find most of the instructions applying to
him in this manual.

2.1.2 Producing Instruction Manual

This manual is designed to provide producing operating

personnel with instructions on operating practices and
procedures for specific operations. The contractor would
find it useful to know in advance what these procedures
are and how they affect him.

2.1.3 Refinery Instruction Manual

This manual is designed for use in refinery operations. Its

design and use is similar to the Producing Instruction
Manual except that it applies to refinery operations.

February 1993 - 2.0 Plant Operations Page 473

 2.1.4 Saudi Aramco Engineering Standards

These provide detailed instructions on how to do specific

jobs and establish minimum standards to follow. The
contractor must use all applicable engineering standards
in the performance of his job. Failure to do so will result
in immediate shutdown, a delay for which the contractor
will be responsible. The Saudi Aramco construction
engineer is familiar with the Engineering Standards and
will assist the contractor. Saudi Aramco Loss Prevention
personnel will advise and provide guidance on fire and
safety problems.

2.2 Work Permit System

Any contractor planning to do work in a restricted area must
obtain a work permit from the operations supervisor for the
area.

To obtain this permit, the contractor must have personnel with a

valid certificate to receive work permits. GI. 2.100, Work Permit
System, provides the information needed to obtain such
certificates and explains how to use them.

The work permit is a written permission to proceed with the

work in accordance with the plans and the restrictions written on
the form. Without a proper permit, work will not be allowed in
the area. (See Work Permit System, Section II.1 of this Manual.)

2.3 Operation of Plant Equipment

It is expressly forbidden for any construction personnel to
operate any valves, switches, push buttons, or other devices in
an operating area. If the work dictates such action, the
contractor personnel must call the operations supervisor to
perform the service.

If the job involves work on equipment which is in service, a

specific set of written procedures will have to be prepared and

February 1993 - 2.0 Plant Operations Page 474

 approved in advance by Operating and Safety personnel. The
contractor must strictly follow these procedures. No deviations
will be permitted without the prior approval of the operation
supervisor. Close contractor supervision will be required in these
types of jobs.

2.4 Shutdown and Maintenance in Plant Operations

Shutting down a plant is the sole responsibility of operating
personnel. Construction personnel should not, under any
circumstances, be involved in any operational activity.

In certain emergency situations, it may be necessary for the

contractor to shut down the job and even move his equipment to
permit access for operating and maintenance personnel. This
emergency activity must be done as requested.

2.5 Commissioning
GI 2.710, Mechanical Completion and Performance Acceptance
of Plant/Unit, outlines the procedures and requirements for
accepting new plants or additions to plants after they have been
completed by the contractor. This is to assure that the plant is
safe to operate in every respect. The contractor should
familiarize himself with this instruction before he starts work.

If there is any question on the fire and safety aspects of this

instruction, the contractor should contact the Saudi Aramco Loss
Prevention Department for clarification and assistance.

2.6 Emergency Procedures: Saudi Aramco Disaster Plan

It is necessary for all contractors to familiarize themselves with
the Disaster Control Plan for the plant and area in which the job
is located. Each person working for the contractor must know
exactly what to do when the emergency evacuation or stop work
alarms are sounded and do it without delay.

February 1993 - 2.0 Plant Operations Page 475

 The Disaster Control Plan does not normally require the
assistance of any construction personnel. Saudi Aramco
personnel are trained to handle the emergency.

If the emergency is the result of a construction operation,

construction personnel will notify operating personnel
immediately. The operating personnel will initiate alarm
procedures and direct activities in controlling the emergency.

When the emergency alarm is sounded for any reason, all

contractor personnel will immediately shut down their job, make
it safe, and proceed in an orderly manner to the designated
assembly point. They will be checked out by Security and should
assemble at a point outside the area and await further
instructions from the Saudi Aramco Disaster Commander.

Periodically, Saudi Aramco holds Disaster Drills to ensure the

smooth functioning of its Disaster Plan. The contractor is
required to participate in these drills just as if it were an actual
emergency.

2.6.1 Gas Release Emergency Procedures

If there is a reason to suspect a gas release in the area

through which you are driving:

1. Immediately shut off the vehicle engine and do not

try to restart it.
2. Check the wind direction by looking at the windsock.
3. Get out of the vehicle and walk to a safe location
generally in a crosswind direction away from the
point of release.
4. Inform plant operation employees of the situation.
5. Do not go and investigate, leave this to operations.

February 1993 - 2.0 Plant Operations Page 476

3.0 PRESSURE TESTING
It is essential that safe practices be observed during pressure testing, due
to the potential hazards associated with high pressure liquids and gases.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 2.100. Work Permit System

GI 2.102. Pressure Testing Safely

GI 2.710 Mechanical Completion And Performance Acceptance Of

Plant/Unit

GI 432.00 Pipeline Hydrotest Water Disposal

GI 434.000 Pipeline Repair and Maintenance

GI 447.002 Pressure Relief Valves - New Installation, Change in Set

Pressure, or Retirement from Service

GI 447.003. Pressure Relief Valves - Routine Test, Inspection, Quality

Assurance And Regulation

Saudi Aramco Engineering Standards:

SAES-K-001 Refrigerant Piping

SAES-A-004 Pressure Testing

SAES-A-005 Safety Instruction Sheet

SAES-A-007 Hydrostatic Testing Fluids And Lay-Up Procedures

SAES-B-55 Plant Layout

Construction Specification Manuals:

Form Saudi Aramco 2642

February 1993 - Construction Safety Manual: Pressure Testing Page 477

 Engineering (Pressure Test Report - 11/90)

Form Saudi Aramco 2642-1

Engineering (Pressure Test Information Sheet - 11/90)

American Petroleum Institute Standards:

API-STD-600-91

Steel Gate Valves - Flanged And Butt-Welding Ends, Ninth

Edition

API-STD-620-90

Design and Construction of Large, Welded, Low Pressure

Storage Tanks, Eighth Edition

February 1993 - 3.0 Pressure Testing Page 478

American National Standards Institute:

ANSI B 16.5-88

Steel Pipe Flanges and Flange Fittings

ANSI B 31.3-90

Chemical Plant And Petroleum Refinery Piping

ANSI B 31.4-89

Liquid Transportation Systems For Hydrocarbons, Liquid

Petroleum Gas, Anhydrous Ammonia, And Alcohols

ANSI B 31.8-89

Gas Transmission and Distribution Piping System

American Society of Mechanical Engineers Standards:

Section VIII. ASME Boiler and Pressure Vessel Code

3.1 Preparation
3.1.1 SAES-A-004 (Pressure Testing)

The person in charge of hydrostatic testing should have

read SAES-A-004 and GI 2.102, and fully understand the
safety requirements and procedures involved with
pressure testing. All persons who will work on the
pressure test must be informed of the potential hazards
and the necessary safety precautions. A work permit shall
be issued prior to commencement of hydrostatic test
operations.

3.1.2 Supports

Piping, vessels, supports and foundations designed for gas

service shall not be overloaded by the extra weight of the

February 1993 - 3.0 Pressure Testing Page 479

 test liquid. Temporary supports and braces may be
required.

3.1.3 Vents and Drains

Vents of adequate capacity shall be installed at high

points, to vent air / gas from the item while it is being
filled with the test liquid. Hazardous gases or vapors must
be vented clear of any area where personnel are working
or where there is any possible source of ignition. Drains
must be installed at a suitable location to allow removal
of the test liquid.

3.1.4 Valves

Where isolation valves are used to contain test pressures,

they must be of adequate rating for the pressure to be
encountered. If isolation valves are used in lieu of blinds,
provisions shall be made to ensure that no over-
pressurizing can occur in equipment that is not being
tested, due to possible valve leak.

3.1.5 Pipings And Joints

Prior to testing, investigations shall be carried out to

verify whether or not temporary restraints are required to
restrict the movement of pipings and joints during testing;
when necessary, adequate restraints shall be provided.

February 1993 - 3.0 Pressure Testing Page 480

 3.1.6 Vacuums

On vessels or tanks which could collapse if subjected to a

vacuum, there must be sufficient vent relief capacity to
assure that the vessel cannot be subjected to a vacuum by
draining the test fluid or by sudden cooling.

3.2 General Requirements

3.2.1

Do not approach system never previously tested,

corroded piping or vessels, or vessels with welds never
previously tested during the stepwise increase in pressure
to the strength test pressure. After the strength test
pressure has been reached and held for a specified
interval, in accordance with SAES-A-004, the equipment
may be approached. The actual pressure at which the
system under test will be approached for close inspection
shall be specified in the test procedure.

3.2.2

Pressure relief valve(s) shall be used to prevent over

pressuring of the equipment.

3.2.3

Any ancillary equipment not under test must be isolated

by valves (subject to part 3.1.4) or blind flanged and
vented or disconnected.

3.2.4

Only calibrated test gauges shall be used and they should

be mounted in the upright position. Pump discharge
gauges must be visible to the pump operator for the
duration of the test.

February 1993 - 3.0 Pressure Testing Page 481

 3.2.5

The equipment / vessel shall have adequate vacuum relief

capacity to avoid damage or collapse, when draining the
test liquid.

3.2.6

Lines should be drained and dried mechanically when the

test liquid is corrosive or otherwise hazardous.

3.2.7

The pressure rise during a pressure test should be gradual

and under control to allow time for material to strain, and
time for personnel to check for leaks, see SAES-A-004 and
GI 2.102.

3.2.8

A system under test shall be depressurized (with the

exception of pressure due to a liquid head) before any
work is done to stop leaks or repair weakness, including
the tightening of bolts. In tightness tests, bolts may be
tightened without depressurizing, if specifically approved
in the written test procedure.

3.2.9

A block valve is required on the line from the test pump to

the equipment under test.

3.2.11

Air shall not be used to displace test fluid from

underwater equipment unless it has been determined
that the equipment will not float.

February 1993 - 3.0 Pressure Testing Page 482

3.3 Test Liquid
3.3.1

Water is a normally the preferred test liquid. Alternatives

must be approved by a deviation from standard or they
may be used if they are specifically permitted by SAES-4-
004.

3.3.2

Salt water must not be used for testing any material

subject to stress corrosion cracking in the presence of
chloride ions (such as stainless steel type 304 or 18.8 -
CrNi).

3.3.3

Pneumatic (gas) testing may be required as per SAES-A-

004. Pneumatic testing other than as specified in SAES-A-
004 may be done only with the explicit permission of the
Consulting Services Department. Testing with air or other
gases under pressure can be hazardous due to the
explosion potential.

3.3.4

Possible changes in pressure due to thermal expansion,

contraction or hydrostatic heads must be taken into
account.

3.3.5

Written procedures approved prior to testing shall be

followed for the disposal of test mediums containing
chemical additives for control of corrosion or bacteria, as
per the requirements of GI 432.000.

February 1993 - 3.0 Pressure Testing Page 483

4.0 CHEMICALS
There are thousands of chemicals in existence and hundreds of new ones
are being developed for commercial use every year. While almost all of
these chemicals are beneficial in some way, they can be dangerous too.
In fact, of the thousands of chemicals in existence, it is difficult to find any
that are absolutely harmless.

When dealing with an unfamiliar chemical, it is always wise to assume

that it is hazardous. The exposure to hazards associated with a material
depends largely on its proper identification, handling, usage, transport,
storage and disposal. In addition, materials which may be completely
harmless in one application may be deadly in another.

There are too many chemicals and too many possible combinations to
deal with them individually here. In the references listed, there are many
sources of information on the identification, storage, transportation, use,
and disposal of hundreds of chemicals. In the literature there are tables
of hazardous chemical reactions. If the name of the chemical is known,
the names of others with which it is likely to react dangerously can be
found. The proper identification and labeling of chemicals is a very
important safety precaution.

When dealing with a potentially harmful chemical, precautions should be

taken to ensure that employees do not swallow it, inhale it, or allow it to
contact their skin. The chemical must not be allowed to accidentally mix
with other substances in transportation, storage, or use. It must not be
subjected to undue shock, pressure, or heat. When the chemical is no
longer needed, it must be safely disposed of or recycled.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 150.001. Asbestos Regulation

GI 330.87. Bulk Deliveries of Oil Field Treatment Chemicals from Local

Vendors

February 1993 - Construction Safety Manual: Chemicals Page 484

GI 355.001. Identifying, Cataloging, Ordering And Tracking Of Hazardous
Materials

GI 355.002 Receiving, Storing, And Issuing Hazardous Material

GI 355.003 Disposing Of Hazardous Materials

GI 355.004 Handling And Storing Polychlorinated Biphenyls (PCBs) For

disposal

GI 355.015. Requisitioning, Receiving, Storing and Issuing Explosives

GI 355.015-1 Deterioration And Disposal Of Explosives

Refinery Instruction Manual:

No. 5.001. Caustic And A Dip Diluting Plant 20 - Safety Regulations

No. 10.740. LPG Plant, Salt Water Chlorination

No. 13.850. Sulfuric Acid Safety Regulations - Air And Water Unit

Operating Instruction Manual:

No. 5.244. Inhibitor, Handling Procedure

Saudi Aramco Engineering Standards:

Saudi Aramco Bottled Gas Manual

Saudi Aramco Chemical Hazard Bulletins (CHBs)

American National Standards:

ANSI 288.2. Standard Practice for Respiratory Protection

American Petroleum Institute:

API 2202-91

Dismantling And Disposing Of Steel From Tanks Which Have

Contained Leaded Gasoline

February 1993 - 4.0 Chemicals Page 485

National Fire Protection Association Standards:

NFPA 321. Basic Classification of Flammable and Combustible Liquids

NFPA 325M. Fire Hazard Properties of Flammable Gases, Liquids,

and Volatile Solids

NFPA 49. Hazardous Chemical Data

NFPA 491M. Manual of Hazardous Chemical Reactions

NFPA 704. Standard System For The Identification of Fire Hazards of

Materials

Threshold Limit Values for Chemical Substances and Physical Agents in the
Work Environment - American Conference of Government Industrial
Hygienists (ACGIH)

Material Safety Data Sheets (MSDS) - Manufacturer's literature on

chemicals approved by US. Department of Labor

Dangerous Properties of Industrial Materials - Dr. N. Irving Sax

4.1 Hazard Identification System

The hazardous nature of a material is related to the manner in
which it is transported, stored or used; the materials with which
it may come in contact; and how it is disposed of or recycled.
There is no single identification system which can briefly indicate
the hazards for all these conditions. Saudi Aramco uses NFPA
704 Identification of Fire Hazard Materials, which indicates the
fire hazards associated with any chemical and also describes the
hazards which might be encountered in storage, transportation,
use or disposal of the chemical.

Many of the materials in the Chemical Section, Class 26, of the

Saudi Aramco Material System Catalog are marked by the use of
hazard identification labels. The container may not be so
marked, but it is indicated in the catalog description of the

February 1993 - 4.0 Chemicals Page 486

 chemical. The system is based on four different symbols or
numbers arranged in a diamond pattern (see Figure V.1).

The degree of possible injurious health effects, susceptibility of

the materials to burning and to release of energy are rated by
numbers (see Figures V.2 and V.2.A.). A zero (0) rating indicates
little or no hazard and a four (4) indicates a high degree of
hazard. It should be remembered that although a zero health
hazard rating indicates that the material offers no hazards to fire
fighters beyond that of ordinary combustible material subjected
to fire, it does not mean that the material is harmless if inhaled
or swallowed.

4.2 Health Hazards

Hazards to health arise from inhaling, swallowing, or skin
contact. The severity of the hazard ranges from nuisance
chemicals that produce no injury, to chemicals that on short
exposure can cause severe injury or death. For industrial
workers, the most prominent means of entry of a hazardous
chemical into the human body is through the respiratory tract by
inhalation. The next most important means of entry is through
skin absorption. The least hazardous pathway is through
swallowing the chemical, as this seldom occurs in industry.
(Reference: Chemical Hazard Bulletins.)

4.2.1 Inhalation Pathway Hazard

Chemicals may be in the form of gases, vapors, dusts, or a

mixture of these. The senses of sight or smell cannot be
depended upon to warn of chemical hazards. Some gases
are harmful in concentrations which cannot be detected
by their odor. Furthermore, some gases paralyze the
sense of smell. Hydrogen sulfide, at low concentrations,
can very quickly paralyze the olfactory nerves so that
harmful concentrations cannot be detected through
smell. Ordinary automotive gasoline, to some extent,
does the same thing.

February 1993 - 4.0 Chemicals Page 487

 When handling a volatile liquid, the maximum allowable
concentration (MAC) of the vapor should be known and
not exceeded. Where exhaust ventilation is not available,
good mechanical ventilation must be provided or the
work must be done outdoors.

In the case of a chemical spill, it may not be possible to

control the maximum allowable concentration. Therefore
it is necessary to keep the worker from breathing the
vapor by limiting the amount of vapor through careful
handling or through the use of local exhaust ventilation. If
the concentration of the chemical in the air exceeds the
threshold limit value (TLV) or MAC, then respiratory
protective devices are needed. It is important that the
right kind of device for the particular hazard be obtained.
(See Breathing Apparatus, Section I.10 of this Manual.)

Dust is a common hazard. Whenever dusty material is

handled, a respiratory hazard may exist. Exhaust
ventilation, fans, blowers, and proper handling
procedures must be used to keep the dust from entering
the worker's breathing zone. If these methods fail, dust
masks must be provided and their use enforced.

Fine droplets of liquid form whenever liquids are sprayed

or splashed so suitable precautions must be taken to
prevent the fine droplets of liquid from entering the
worker's breathing zone. Ventilation is also
recommended. If such methods are not adequate,
suitable respiratory protection must be provided.

February 1993 - 4.0 Chemicals Page 488

 4.2.2 Skin Hazards

Skin contact/exposure hazard may not be as dangerous to

life as respiratory hazards, but they are far more common.
Dermatitis resulting from contact with harmful chemicals
is a common work injury. Proper handling methods are
the first step in protection. The second step, in the case
of materials which act rapidly on the human body, such as
corrosive chemicals (i.e. acids and caustics) is to provide a
physical barrier in the form of goggles, face shields,
hoods, gloves, aprons, suits, etc. The third step is to
provide eyewash fountains and safety showers, which
flush the material from the eyes or skin.

The type of personal protective equipment required

depends on the hazardous characteristics of the chemical
and the way it is used. Personal cleanliness is important.
Thorough washing of the hands and face before meals,
daily bathing, and a regular change of clothing will reduce
harmful contact with chemicals.

4.2.3 Hazards of Swallowing Chemicals

In industry, swallowing chemicals does not occur

frequently. The main precaution is to ensure that
employees know that the material is hazardous if
swallowed, and that they must wash their hands free of
harmful chemicals before smoking, drinking or eating.
Never store harmful chemicals in food containers or
handle chemicals near food.

4.3 Emergency Treatment

4.3.1 Artificial Respiration

Persons overcome by harmful gases and vapors must be

taken out into the fresh air and, if they have stopped
breathing, given artificial respiration; if there is no

February 1993 - 4.0 Chemicals Page 489

 heartbeat, commence cardiopulmonary resuscitation
(CPR). Call emergency assistance immediately by
telephoning 110.

4.3.2 First Aid

In case of accidental swallowing of chemicals, it is not

wise to induce the patient to vomit. The hospital must be
informed of the chemical injury or chemical swallowed
and the person should be moved to the hospital
immediately for medical treatment. In the case of
caustics or corrosives, drinking a large amount of water,
followed by medical treatment, is recommended.
Telephone 877-8056, Saudi Aramco Emergency Medical
Services, for poison information.

4.3.3 Showers and Eyewash Fountains

For skin hazards, the best treatment is thorough water

washing under the emergency shower or eyewash
fountain. Field treatment should only consist of flushing
away the chemical. The patient should then be taken to
the hospital for treatment.

These water flushing devices are required, because

working procedures and personal protective equipment
may fail. In the case of materials that are immediately
harmful to the eyes or skin, safety showers or eyewash
fountains should be provided. They should be within 6
meters (20 feet) of the exposure site and accessible in an
unobstructed straight line from the work location.
Emergency showers shall be properly identified with signs
and color background in accordance with SAES-B-55. A
person who is blinded by a chemical must immediately be
taken to the shower or eyewash fountain. Some
emergency showers or eyewash fountains are designed so
that standing under or near them activates the water

February 1993 - 4.0 Chemicals Page 490

 supply. Others have hinged gates which are pushed to
activate the shower, but all should be easily activated.

If the water piping to the shower or fountain is exposed to

the sun, the water will become so hot during summer that
it could scald the user. The piping must be buried,
insulated or shaded from the sun or the line must be only
a very short branch from a main water line that is used
frequently enough to keep the water from overheating in
the sun. Emergency showers and eyewash fountains
should be checked daily.

February 1993 - 4.0 Chemicals Page 491

 CAUTION:

There are two important points that workers must be

taught about the correct use of emergency fountains and
shower:

1 Before removing goggles, face shields, or other

personal protective equipment, the user must get
under the shower or use the eyewash fountain to
wash off as much of the chemical as possible.

2 It is a mistake to start for the hospital without first

doing everything possible to flush out the harmful
chemical. The eyes or skin must be washed for quite
a long time to remove the chemical. It is necessary
to wash the eyes holding the eyelids open with the
fingers for at least fifteen minutes to free the eyes of
bases or caustics. This will be painful, but it is
absolutely necessary. In the case of acids, water will
remove the acid quickly, but it is necessary to hold
the eyelids open with the fingers, painful as this may
be, and roll the eyes around under the shower or in
the eye fountain to make sure that all acid is
removed. At least fifteen minutes of thorough
washing are required in the case of acid contact to
skin or eyes.

Caustic alkalis such as sodium hydroxide and potassium

hydroxide are much more difficult to wash from the skin
or eyes. Strong alkalis of this type mixed with water feel
slippery to the touch. The skin should be washed until the
slippery feeling has gone and washing should be
continued for at least 15 minutes.

February 1993 - 4.0 Chemicals Page 492

4.4 Fire Hazards
4.4.1

Only the necessary amount of hazardous materials should

be brought into the work place, usually not more than
one day's supply. Hazardous materials must not be
allowed to accumulate, and any extra amounts should be
cleared from the work area. Slop liquids or trash should
be cleared away immediately. All flammable materials
should be stored according to the specifications of their
Chemical Hazard Bulletins, (CHBs) or Material Safety Data
Sheets (MSDS).

4.4.2

Smoking and the use of sparking devices near flammable

liquids or finely divided combustible solids must be
prohibited.

4.4.3

Blocking off air to a burning object is often possible in acid

dip tanks or rubbish containers where a cover can be
provided and dropped down on the container to smother
the flames.

4.4.4

The use of fire fighting equipment, such as fire

extinguishers or water streams, must be available in case
all effective fire prevention measures fail to prevent a fire.
(See Fire Prevention, Section I.11 of this Manual).
Ordinary sand is a good extinguishing agent for
smothering small fires. The fire hazards of most common
materials can be found in the references given in this
section. The proper fire extinguisher should be at the job
site and readily available at all locations where a fire
hazard is possible.

February 1993 - 4.0 Chemicals Page 493

4.5 Reactivity Hazards
The manual of Hazardous Chemical Reactions, NFPA 491M, lists
many of the chemicals which are likely to have dangerous
reactions with other chemicals. As a general precaution, rough
handling and shock should be avoided. Chemicals should not be
allowed to mix with other chemicals unless it is known that no
harmful reaction will occur.

4.6 Transportation, Storage and Disposal

4.6.1 Transportation

During transportation, hazardous materials must be

protected against shock, accidental mixing with other
materials, damage to containers, undue heat from the sun
or other sources, and theft, which could allow the
hazardous materials to come into contact with people
who are unaware of the dangers. Specific
recommendations for the particular material may be
obtained from the Area Loss Prevention Office. The Saudi
Aramco Chemical Engineering Response Team or Fire
Protection Department also handles spills which occur
during transportation. A vehicle transporting hazardous
chemicals must be suitably labeled.

4.6.2 Storage

The NFPA fire codes contain recommendations for safe

storage of flammable liquids, compressed gases, and
typical highly combustible or explosive solids. Precautions
must be taken to avoid shock, undue heat, or unplanned
mixing. There are some cases where separating walls or
specified distances are required.

Specific storage recommendations for hazardous

materials contained in the Saudi Aramco Chemical Hazard
Bulletins (CHBs) and manufacturer-provided Material

February 1993 - 4.0 Chemicals Page 494

 Safety Data Sheets (MSDS) should be followed.
Incompatible chemicals should not be stored together.

A list of hazardous materials shall be kept by the

contractor indicating type and quantity of materials used
in each case, its hazardous classification rating and the
quantity disposed of.

4.6.3 Containers

Hazardous materials must be stored in containers that are

safe for the transportation and use of the material.
Containers must be labeled with the appropriate
hazardous materials label to indicate the actual contents.
All safety factors must be observed when transferring
material from one container to another and the receiving
container must be labeled to correctly describe the
contents. Empty containers previously used to hold
hazardous material must be washed free of the material
or destroyed.

4.6.4 Disposal
(See GI 355.003 and 355.004)

Hazardous/toxic waste is liquid, solid and semi-solid

material, which, because of the quantity involved, the
concentration, and/or the biological, physical, chemical or
infectious characteristics, pose a hazard to human health
and/or the environment if it is improperly managed.

The following are some examples of waste materials

which are considered hazardous/toxic, and are to be
disposed of in accordance with established Saudi Aramco
procedure.

· Waste paints and related products

· Asbestos
· Resins
· Wood preservative products

February 1993 - 4.0 Chemicals Page 495

 · Insecticides and pesticides
· Flushing fluids / chemicals
· Compressed gases (acetylene, oxygen, chlorine)
· Flammable / combustible liquids (gasoline, diesel oil)
· Corrosive liquids (acid)
· Cleaning fluids
· Explosives
· Flammable solids
· Poisons and infectious chemicals
· Radioactive materials
· Magnetized materials
· Polychlorinated Biphenyl (PCB (electrical transformer
oil)

The disposal of hazardous material must be conducted by

the contractor/user (c/u). The latter is obligated to
perform the following:

Step 1:

The hazardous material must be identified by composition

or content. If this is not possible, prior to arranging for
disposal of the material the contractor/user should notify
the AM&RD (Al Midra and Reclamation Division). The
material will be provided to AM & RD in containers clearly
marked "Hazardous Material" only, with no other
conflicting or confusing words.

Step 2:

The c/u must follow manufacturers or literature safety

guidelines (Material Safety Data Sheets, MSDS, Chemical
Hazard Bulletins, CHBs, etc.) in addition to the Saudi
Aramco procedures contained here. In cases where
procedures overlap, the c/u should use the more
conservative methods of disposal. Hazard rating codes
assigned to SAMS material indicate the degree of hazard.
(See Figure V.2A.) Obtain advice as needed from the

February 1993 - 4.0 Chemicals Page 496

 Hazardous Materials Advisor, MHED (Materials Handling
Engineering Division) at telephone number 872-7419 or
from individual specialist units listed below:

Specialist Unit Telephone Number

Central Area Storehouse Dept. 872-7419
(CASD)
Laboratories Dept. (LP) 876-6725
Loss Prevention Dept. (LPD) 873-8779
Process And Control Systems Dept. 875-3131
(P&CSD)
District Medical And Support 877-8425
Services (DM&SS)
Industrial And Environmental 874-1402
Affairs Dept. (I&EAD)
Fire Protection Dept. (FPD) 874-3345

Step 3:

The hazardous waste material must be adequately sealed

up in containers to prevent leakage and labeled to denote
composition or content.

Step 4:

Request a safety inspection of the material by the

Hazardous Material Advisor.

February 1993 - 4.0 Chemicals Page 497

 Step 5:

When a large quantity of hazardous material needs to be

disposed of, inform the:

a). Chemical Storage Segment, Material Disposal Unit,

Reclamation Operations Section, AM&RD.
b). Hazardous Materials Advisor, MHED.

Step 6:

Follow the directives of the Hazardous Materials Advisor.

(See GI 355.003.)

Step 7:

Transport the hazardous material to Dhahran Reclamation

Yard using own truck or request suitable vehicle from the
Transportation Department by following their established
procedure.

Step 8:

Contact Assistant Superintendent, Reclamation

Operations Section (ROS), AM & RD before a large volume
of hazardous waste material is to be delivered. This
person may request that the material be delivered
directly to Delivery Point Code (DPC), 280 Reclamation
Chemicals Storage And Handling Facility located near
Abqaiq GOSP 3.

Note:

See GI 355.004 for any deviation from this established

procedure for the handling, storage and disposal of
Polychlorinated Biyphenyls (PCBs).

February 1993 - 4.0 Chemicals Page 498

4.7 Work on Equipment Which Has Contained Tetraethyl
Lead (Organic Lead Compounds)
4.7.1 Introduction

Tetraethyl lead (TEL) is an organic compound of metallic

lead which is used to improve the octane rating of
gasoline. This compound is highly poisonous. The hazard
with tetraethyl lead is that, being a liquid it gives off
vapors which can come into contact with the body by
breathing or skin contact. Tetraethyl lead is very
hazardous as its vapors can be inhaled, absorbed through
the skin, or ingested through contaminated food or
cigarettes. The best protection is to avoid any contact.

To make it easier to detect spills of tetraethyl lead, it has

been dyed a bright orange color.

February 1993 - 4.0 Chemicals Page 499

 Tetraethyl lead, or sludges containing organic lead
compounds, are likely to be found in the following places:

1. Wherever drums of the compound are transported,

stored, or used. Leaking drums can contaminate
ships' holds, trucks, and storage areas.

2. Wherever leaded gasoline is blended, handled, or

stored.

3. In controlled disposal sites designated to receive

organic-lead-containing materials. The sludge
removed from leaded gasoline tanks is
decontaminated by spreading and weathering prior
to mixing with inert solids to reduce the total lead
concentration to no more than 0.5% and transfer to a
final burial site. Since tetraethyl lead is delivered
dissolved in organic solvents, it also presents a fire
hazard.

4.7.2 Precautions

Tanks that have once contained leaded gasoline (TEL) are

considered dangerous thereafter even though they may
have been used in other service for years. Such tanks
should be permanently marked on the manholes with a
sign warning that the tank has contained leaded gasoline
and must not be entered without special precautions.
Sludge pits where lead-bearing sludge from the leaded
gasoline tanks has been buried must be marked with
permanent warning signs.

Before entering any tank, an inquiry should be made as to

the tank's previous service and a work permit obtained.
Likewise, before marking excavations in or around
refineries or gasoline storage depots, it is wise to
determine whether leaded gasoline (TEL) sludge may be
encountered. Work in cleaning, repairing, or dismantling

February 1993 - 4.0 Chemicals Page 500

 tanks which have contained leaded gasoline requires
special training and special precautions.

The workers must be medically certified and periodically

examined before and during the course of the work.
Using regular monitoring of TEL workers, any over-
exposure to TEL should be reported to the Saudi Aramco
proponent department, the Saudi Aramco Loss Prevention
Department and the Industrial Hygiene Services.

The Saudi Aramco Industrial Hygiene Services and the Loss

Prevention Department should be notified when work is
to be done in TEL tanks or in areas with TEL contaminated
equipment.

February 1993 - 4.0 Chemicals Page 501

FIGURE V.1: IDENTIFICATION OF MATERIALS BY HAZARD SIGNAL DIMENSIONS AND
ARRANGEMENT

February 1993 - 4.0 Chemicals Page 502

FIGURE V.2: EXPLANATION OF HAZARD RATING CODES

February 1993 - 4.0 Chemicals Page 503

FIGURE V.3: IDENTIFICATION OF HEALTH HAZARD, FLAMMABILITY AND REACTIVITY

February 1993 - 4.0 Chemicals Page 504

VI. Marine

February 1993 - Construction Safety Manual: VI. Marine Page 505

1.0 COFFERDAMS
A cofferdam is an enclosure constructed to exclude water from a work
area during construction. Cofferdam construction ranges from simple
dikes to complicated timber or steel structures. Cofferdams must satisfy
two basic requirements:

1. They must be strong enough to withstand the forces caused

by water, soil conditions, and floating debris.

2. They should be as watertight as practicable, although some

leakage, requiring pumping, must always be expected.

The most common type of cofferdam encountered in Saudi Aramco is

constructed from steel sheet piling. The piles must be driven to design
and penetration specifications and must encounter the pre-specified
driving resistance. The steel piling is generally braced by a system of
horizontal wales and struts which are designed to resist external forces.

INSTRUCTIONS AND STANDARDS

Saudi Aramco Instructions and Standards:

Schedule 'D': Saudi Aramco Safety, Health and Environmental

Requirements

Part 19 Excavations

Part 20 Work Over Water

1.1 Design
All cofferdams in excess of 1.2 meters (4 feet) in depth must be
designed by a qualified engineer. Any deviations from the design
encountered in the actual construction of the cofferdam must
have the approval of a qualified engineer.

February 1993 - Construction Safety Manual - Cofferdams Page 506

1.2 Before Work Starts
Any cofferdam which is to be constructed in a navigable
waterway or which would constitute an obstruction or hazard to
the operation of small boats or pleasure crafts must be approved
in advance by the Manager, Saudi Aramco Marine Department.
The latter will be responsible for coordinating its approval with
the approval of required Government agencies.

1.3 Construction
All cofferdam construction work must be performed in strict
compliance with the design drawings and specifications. All work
must be accomplished by qualified craftsmen in accordance with
accepted trade practices. Any unexpected soil or hydrographic
conditions encountered during the construction must be
reported immediately to the design engineer for evaluation and a
possible modification of the structure.

1.3.1

If overtopping of the cofferdam by high waters is possible,

means shall be provided for controlled flooding of the
work area.

1.3.2

Emergency evacuation warning signals shall be provided

and procedures developed. Notices shall be posted at the
entrance to the job site, and throughout the area.

1.3.3

Walkways, ramps or bridges on cofferdams shall have at

least two exit points. These shall be provided with
standard guardrails.

February 1993 - 1.0 Cofferdams Page 507

1.4 Potential Hazards
The construction and the use of cofferdams have three primary
hazards which merit special consideration.

1.4.1 Structural Collapse

Cofferdam structures may collapse as a result of the

imposition of unexpected structural loads or the failure of
the soil inside the cofferdam structures as evidenced by
an upward heave or "blow-out" of the bottom. Such
failures often occur with little or no warning, therefore a
means of rapid exit from the enclosed cofferdam
structures must be provided for all workmen engaged in
work inside the structures.

1.4.2 Overhead Loads

Sump pumps, equipment, and machinery shall be

mounted on a cantilevered platform outside of a
cofferdam. This will eliminate overhead obstructions,
which could present a hazard to the workmen engaged in
construction within the confines of the cofferdam.

1.4.3 Dislodgment of Struts and Wales

All internal supporting structures must be secured against

accidental dislodgment. The use of locking devices on
wedges will prevent their accidental removal and the
resulting collapse of the structure.

1.5 Inspection
1.5.1

General inspection should be carried out daily or after any

weather condition or incident which might affect the
safety of the cofferdam.

February 1993 - 1.0 Cofferdams Page 508

 1.5.2

The security of all wedges should be carefully checked at

the start of each shift.

1.5.3

Leaks can indicate a movement of the piles. Serious leaks

should be reported at once to the engineer in charge of
operations.

1.5.4

Pump intake fastenings and the pumping sump should be

carefully checked at the start of each shift.

1.6 Leaks
1.6.1

Small leaks can be sealed by lead caulking in the clutches

from the inside of the cofferdam. Minor leaks over a large
area can be sealed by dropping light granular material
into the water surrounding the cofferdam. The material
will be sucked into the gap between the piles where it will
form a seal.

1.6.2

Where large leaks are encountered which cannot be

sealed as described above or there is an indication that
the piling has moved, the cofferdam area shall be
immediately evacuated of all personnel and the problem
brought to the attention of the design engineer for
correction.

February 1993 - 1.0 Cofferdams Page 509

2.0 MARINE OPERATIONS
This section, Marine Operations, is only concerned with the
transportation of material, equipment, and personnel to off-shore job
sites. This is carried out through the Saudi Aramco Marine Department by
using company-owned and/or contractors' crafts.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions :

GI 6.020. Personal Flotation Devices for Work Over, On or Near Water

GI 1185.003. Death or Injury Aboard Seagoing Vessels

GI 1186.502. Marine Craft Fueling, Tanajib or West Pier

GI 1186.504. SAG Regulations and Practice as Applied to All Types of

Marine Craft at the Port of Ras Tanura

GI 1187.001. Collision & Damage By or To Marine Equipment or

Craft

GI 1192.001. Operating Practices for Harbor Tugs, Offshore Vessels

and Launches, Including Safety Rules

GI 1192.002. Operating Procedures for Barges Including Safety Rules

GI 1192.502. Operating Procedures for Marine Oil Recovery and

Storage Barge/Vessel, Including Safety Rules

GI 1193.001. Marine Port Information and Regulations

GI 1193.002. Navigation Warnings

GI 1194.001. Requesting, Assigning and Dispatching Pollution

Control Vessels, Tugs, Launches and Barges

GI 1196.001. Whistle Signals for Use Between Tugs and Barges or

Tugs and Self-Propelled Vessels When Berthing

February 1993 - Construction Safety Manual - Marine OperationsPage 510

GI 1198.001. Rig/Barge Moving

GI 1199.001. Safe Operation of Self-Propelled Jack-Up Barges

2.1 Other Publications

US. Coast Guard - 257

International Maritime Organization - Safety of Life at Sea

International Labor Office - Accident Prevention on Board Ship, at

Sea, and in Port.

2.2 General
All safety precautions that are applicable onshore apply and must
be enforced while offshore, including the wearing of personal
safety equipment. In addition, life vests must be worn while
working on, over or near the water. Work over water may be
either offshore or on a site connected to the shore. The hazards
and the precautions for both situations are similar.

2.3 Behavior on Floating Craft

Personnel embarked on floating craft must obey the instructions
of the person in charge of the vessel. In particular they must not
obstruct his view or movements. They must travel in the
passenger designated areas. They should not enter or climb on
top of the pilot house and machinery space are similarly out of
bounds. Personnel are expected to act in a responsible manner
at all times.

2.3.1

Unexpected movements of the vessel even in good

weather must be anticipated and guarded against.
Personnel should keep away from the ship's side and
make use of handrails at all times.

February 1993 - 2.0 Marine Operations Page 511

 2.3.2

Life vests must be available for all personnel. Each person

shall wear and know how to inflate a life vest (see Figure
VI.1).

2.4 Preparation for Transportation by Sea

2.4.1

Loose and movable parts of material and equipment must

be properly secured against movement. Such material
and equipment must always be prepared as if for very
rough weather. Sea conditions can change rapidly. Even
with no wind, a swell can produce violent movement.
Lashing must be adequate. Tank compartments being
transported should be either empty or completely full.
Tarpaulins or plastic coverings must be of adequate
strength and well secured.

2.4.2

The Marine Department must be informed in advance so

that they may prepare for the transportation of any
hazardous cargo (acids, explosives gases, etc.) or cargoes
with special characteristics (e.g., sensitive to water,
delicate, or pilferage). Information on weights and
measurements must be included for any shipment that
requires a manifest (Saudi Aramco Form 9063).

2.4.3

Although the actual loading may be performed by another

department, the Marine Department carries the ultimate
responsibility for the safe loading and distribution of
cargo on the floating craft under its jurisdiction.

February 1993 - 2.0 Marine Operations Page 512

2.5 Tide and Sea Effects
During pile driving and general offshore work, allowance must be
made for wave action and the rise and fall of the tide, especially
when erecting stages and platforms. Tidal predictions and
weather forecasts are not completely accurate so a generous
safety margin must be allowed.

2.6 Care of Tools and Equipment

2.6.1

Protective coatings reduce the corrosive effects of salt

water and salt-laden air on tools and equipment. Nuts,
bolts, and threads should be covered with grease or a
similar protective coating.

2.6.2

Electrical and radio equipment must not be left exposed.

When not in use, they should be protected by being
returned to their boxes or being covered.

2.6.3

Objects that are dropped from any height can cause injury
or damage, and they may be impossible to recover. For
this reason, small hand tools should be secured by
lanyards when working over or near water.

2.7 Housekeeping
Because of the confined space frequently encountered in Marine
Operations, housekeeping is even more important offshore than
onshore.

2.7.1

Tools must not be scattered around. Any spilled grease or

oil must be cleaned up. Fire hose and rope must be coiled

February 1993 - 2.0 Marine Operations Page 513

 or flaked down clear of passageways. Doors and drawers
should be kept closed.

2.7.2

Rags, papers, cigarette butts, and scrap must be properly

disposed of. Proper disposal does not mean throwing the
unwanted items overboard, thus polluting the
environment. Trash cans and ashtrays should be used.

February 1993 - 2.0 Marine Operations Page 514

FIGURE VI.1: IF YOU WORK OVER, ON OR NEAR WATER

February 1993 - 2.0 Marine Operations Page 515

3.0 DIVING OPERATIONS
Accidents involving divers and their equipment are generally serious,
because diving operations are undertaken in an element unnatural to
man. What would be considered to be a minor incident on land could
cause crippling injury or even death in a diving operation.

Due to the extreme hazards of this occupation, divers must rely on their
training, experience, and initiative to avoid accidents. For this reason, the
strictest compliance with regulations, standards, and instructions must be
observed at all times in order that everything possible is done to minimize
the possibility of an accident.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 1197.001 Procedures and Safety Rules for Diving Operations (See

Appendix G)

The US. Navy Diving Manual is to be used as the standard for all Saudi
Aramco diving operations.

US. Navy Diving Manual:

NAVSHIPS 0994-001, March 1970

British Admiralty Diving Manual:

B.R. 181, 1972

United Kingdom Statutory Instruments

S.I. NO. 1229 Offshore Installations (Diving Operations) Regulations,

1981

Saudi Aramco Instructions and Standards

Saudi Aramco Bottled Gas Manual

February 1993 - Construction Safety Manual: Diving Operations Page 516

TM 6.1 Medical Diving Emergencies (Technical Memorandum -
Saudi Aramco Medical Services Organization {SAMSO})

3.1 Employment of Qualified Divers

All divers shall be at least twenty-one (21) years old.

3.1.1

Divers must be qualified and experienced in all aspects of

underwater inspection, construction, repairs, and salvage
works, including oxy-arc cutting, thermal lancing, and the
use of pneumatic and hydraulic tools.

3.1.2

Divers shall be fully conversant with the use and

operation of US. Navy Decompression Tables,
recompression chambers, and therapeutic decompression
procedures.

3.1.3

Familiarity with the use of SCUBA, Hookah, and surface

supplied helmets (Swindel, Aquadyne, Kirby-Morgan, etc.)
and knowledge of their maintenance and repair is
required.

3.1.4

Divers will be required to show evidence of their training

and experience by providing certificates from a
competent authority.

3.1.5

All divers must be fluent in both reading and writing the

English language and be able to depict the results of an
underwater inspection by the use of sketches.

February 1993 - 3.0 Diving Operations Page 517

 3.1.6

Evidence of medical fitness in accordance with 3.4 must

be produced at the prescribed intervals.

3.2 Diving Equipment

All equipment used in connection with diving and submarine
operations shall be produced by a reputable manufacturer. They
must be of good quality and constructed of sound material, in
accordance with appropriate and accepted standards.
Equipment should be able to operate efficiently in the prevailing
high temperatures of the Arabian Gulf.

3.2.1 Compressors

Compressors for supplying breathing air must be fitted

with adequate filtration and purification devices. They
must be able to provide the air at a rated pressure and
capacity to cover the maximum depth required during the
operation.

3.2.1.1

The air intake of compressors shall be remotely

located with reference to any exhaust system in
the area to prevent contaminants from entering
the compressor intake.

3.2.1.2

All the safety devices and relief valves on high

pressure compressors must be operating
properly.

3.2.1.3

Detergent lubricating oils or oils with viscosity

less than SAE 30 must not be used. Care must be
taken not to overfill.

February 1993 - 3.0 Diving Operations Page 518

 3.2.1.4

Compressed air supplied for breathing shall be

certified Compressed Gas Association grade D or
better.

3.2.2 Reserve Air Supply

A reserve supply of air must be provided, maintained, and

immediately available in the event of a primary air supply
failure, whether in the form of a standby compressor or
high pressure cylinders (or volume tanks) on the surface.
If the reserve is in the form of high pressure cylinders (or
volume tanks), it should be of sufficient capacity to enable
the diver or divers to reach the surface safely while
carrying out any necessary decompression step on the
way. Reserve supply for recompression chambers should
be sufficient to allow required surface decompression to
be carried out.

3.2.3 Bail-Out Equipment

In case there might be a ruptured, cut, or irretrievably

fouled hose, each diver should be equipped with "bail-
out" equipment, either in the form of a "bail-out"
cylinder, a diver's life vest, or a pneumo hose.

3.2.4 Maintenance

All plant (including safety) and diving equipment must be

regularly maintained. Correct records must be kept of
this maintenance.

3.2.4.1

All SCUBA tanks, recompression chambers,

volume tanks, high pressure cylinders, and
storage vessels must be regularly checked and
tested at the prescribed intervals in accordance

February 1993 - 3.0 Diving Operations Page 519

 with the manufacturer's instructions and Saudi
Aramco regulations.

3.2.4.2

As indicated in the Saudi Aramco Bottled Gas

Manual, air cylinders not in sea water use are to
be inspected internally and hydrostatically
tested, at intervals not to exceed five years. They
should be appropriately stamped to denote this
inspection.

3.2.4.3

Each item of plant and diving equipment should

be regularly inspected by a competent person at
periodic intervals, and after the equipment has
been modified. The maximum period between
inspections should be three months.

3.2.4.4

All hoses used for carrying compressed air or

other gases must be checked for wear and
abrasion and subjected to test pressures at least
once every three months.

Hose, fittings and connections should be of the

screw thread type and properly fitted to the
hoses. Hoses used in oxygen breathing systems
must be grease and oil free.

3.2.4.5

Any pressure gauge showing an error of more

than two and one half percent (2.5%) must be
adjusted or replaced.

February 1993 - 3.0 Diving Operations Page 520

 3.2.4.6

Communication systems must be checked for

correct operation. Every wire must be checked
for continuity and, if they are combined with the
life line, for wear.

3.2.4.7

A supply of suitable protective clothing such as

diving suits, coveralls, gloves, and hoods must be
available at all times. Insulated gloves shall be
provided to divers performing welding and
burning operations.

3.2.4.8

Gas cylinders taken under water shall be

hydrostatically tested, inspected and stamped
every two years.

3.3 Safeguards
When divers are preparing to enter or leave the water, or are in
the water, or diving operations are underway, the International
Code Flag "A" ("I have a diver down, keep well clear of area and
maintain a low speed.") must be flown. (See Figures VI.2 and
VI.3.)

Communications - A two-way voice communication system shall

be used between:

1. Each surface-supplied air or mixed-gas diver and a dive team

member at the dive location.

2. Two-way communication system shall be available at the

dive location to obtain emergency assistance.

February 1993 - 3.0 Diving Operations Page 521

 In addition, special lights and day marks for "vessels engaged in
surveying or underwater operations" should be shown in
accordance with Maritime Regulations (Figure VI.3).

3.3.1

Any person involved in an activity which could be a hazard

to divers in the vicinity, such as those in charge of
submarine blasting or masters of vessels about to move,
start propulsion engines, or operate pumps, must be
forewarned.

3.3.2

Adequate arrangements must be made to provide a safe

means of access to and egress from the water. It must be
kept in mind that a diver may be unconscious as a result
of an accident.

3.3.3

Proper surface support and other facilities for the safe

conduct of diving operations must be provided.

3.3.4

In all cases of emergency, the diving supervisor, the

foreman diver, or the person in charge of a diver or divers
must be the sole arbiter as to action to be taken. All
personnel, whether connected with the diving operation
or not, should take instructions from him.

3.3.5 Safe Operation of Divers

3.3.5.1

Bottom time and decompression time will be

controlled by the diving supervisor or person in
charge of diving.

February 1993 - 3.0 Diving Operations Page 522

 3.3.5.2

On all work requiring four divers or more, a

diving supervisor shall be present to facilitate
coordination between divers and the surface.

3.3.5.3

All diving operations requiring more than two

divers (using air for breathing) in water of a
depth greater than 30 meters (100 feet), require
the presence of a diving supervisor.

3.3.6

At all times when a diver is in the water, a stand-by diver

must be on deck with a stand-by rig, fully dressed and
ready to dive.

3.3.7

No diver working in water 9 meters (30 feet) or less shall

be required to work longer than a twelve (12) hour shift
without having a proper rest except for emergencies.

3.3.8

Repetitive diving should not be done as a routine. If the

task necessitates the use of "repeats", efforts should be
made to obtain additional divers. When this is
impracticable, the tables must be strictly adhered to in
order to avoid decompression sickness, which could
require therapeutic treatment and could endanger the
health of divers and delay operations.

3.3.9

Therapeutic decompression must take precedence over

all other operational requirements.

February 1993 - 3.0 Diving Operations Page 523

 3.3.9.1

Divers must remain in the vicinity of a

recompression chamber for a period of twelve
(12) hours after the last dive.

3.3.9.2

In the case of therapeutic decompression the

period in 3.3.9.1 shall be extended to twenty-
four (24) hours.

3.3.9.3

In mild cases of decompression sickness which

have been treated under Tables 1, 1A, 2, 2A and
5 (US. Navy Diving Manual), a diver can be
returned to work at the discretion of the diving
supervisor.

After treatment for a case of "bends" under

Tables 3, 4, 6 and 6A, a diver will not be
permitted to dive again until he has been
examined and passed as fit by a physician.

3.3.9.4

Each diver will maintain a personal logbook.

Entries shall include but are not limited to the
following:

· Diver's name.
· Name and address of the employer of divers.
· Date.
· Name of the Diving Supervisor.
· Name of the vessel, barge, or installation from
which the diving operation is carried out.
· Maximum depth reached on each occasion.
· Time he spent under water on each occasion.

February 1993 - 3.0 Diving Operations Page 524

 · Type of equipment used by the diver.
· Work carried out by him on each occasion.
· Details of decompression sickness or other
illness/injury suffered by the diver.
· Any other factor relevant to health.
· Each daily entry will be signed by the diver
and also by the diving supervisor.
· Divers must retain their logbooks for a period
of not less than two years from the date of
the last entry in the logbook.

3.3.10 Recompression Chamber

A recompression chamber must be on site during all

diving operations in excess of 18.5 meters (60 feet).
Whenever a recompression chamber is not available, only
"no decompression" dives are permitted.

3.3.10.1

The maximum rate of ascent is 18.5 meters (60

feet) per minute in the case of air decompression
and 7.6 meters (25 feet) per minute in the case of
oxygen decompression.

3.3.10.2

Only necessary articles are allowed in the

recompression chamber. No tobacco or any
ignition source, including electrical shall be
allowed in the chamber. Smoking shall never be
permitted in the chamber whether under
pressure or not.

3.3.10.3

The chamber shall be kept clean and dry.

February 1993 - 3.0 Diving Operations Page 525

 3.3.10.4

Personnel in a chamber under pressure shall

ensure that both they and all loose materials are
kept clear of all atmosphere inlet and exhaust
openings. The exhaust, which is under pressure,
is especially dangerous because it subjects
anything near it to a high suction pull capable of
causing extreme bodily harm .

3.3.11 SCUBA Special Care

The use of SCUBA equipment in water over 18 meters (60

feet) in depth should be restricted.

3.3.11.1

SCUBA equipment shall not be used to depths

greater than 45 meters (150 feet).

3.3.11.2

SCUBA equipment should never be used for dives

requiring decompression.

February 1993 - 3.0 Diving Operations Page 526

 3.3.11.3

In open water, SCUBA divers shall always be

attached to a clearly visible float by a life line. In
no case shall SCUBA divers be allowed to swim
free.

3.3.11.4

In enclosed or restricted water such as beneath

structures, either a lifeline or the "buddy" system
must be used. There will be no untethered solo
diving.

3.3.11.5

When using SCUBA equipment, divers will always

wear an inflatable life jacket of the approved
type.

3.3.11.6

No SCUBA diving should be carried out during

darkness.

3.4 Physical Fitness

All divers must be physically fit for diving and have a certificate to
this effect issued by a qualified medical practitioner: one who
has experience and knowledge of the medical requirements for
diving.

3.4.1

The medical certificate should state "Fit for Diving" and be

not more than twelve months old.

February 1993 - 3.0 Diving Operations Page 527

 3.4.2

Doctors carrying out medicals for divers should be aware

of the importance of the condition of heart, lungs, chest,
ears, nose, throat, and teeth. An EKG and chest X-ray are
mandatory on an annual basis, while a long bone X-ray
should be performed every three years.

3.4.3

For British divers, a current British Diving Fitness Register

is acceptable and, likewise, any recognized fitness register
for other nationalities.

3.4.4

All divers should be trained in First Aid/CPR, and on all

diving operations, there should be an approved First Aid
Kit suitable for use under hyperbaric conditions on site as
recommended in the US. Navy Diving Manual.

3.5 Medical Diving Emergencies: Procedures and

Responsibilities
Every incident/accident involving diving personnel shall be
reported on Saudi Aramco Form 3208 with the responsible
supervisor submitting a follow-up report on Saudi Aramco Form
681. Offshore emergency response procedures are given in
Appendix B. Specific responsibilities are as follows:

3.5.1 Sports Divers

All divers must have an experienced person in charge with

good knowledge of decompression sickness. He has to
know the following two diving emergencies numbers to
call if requiring help: 678-1248 from 6 a.m. until 6 p.m. 7
days per week; and 378-3691 from 6 p.m. until 6 a.m. 7
days per week. He should state his exact location and

February 1993 - 3.0 Diving Operations Page 528

 follow the instructions given to him by the coordinator
answering the number.

3.5.2 Commercial Divers

The diving supervisor will immediately arrange

recompression according to the appropriate table and
report the incident to the coordinator manning the diving
emergencies numbers.

3.5.3 Coordinator, Diving Emergencies

The coordinator, on call at either of the above numbers,

will receive the information on diving medical
emergencies. In the case of sports divers, he will direct
them to the nearest available recompression chamber
and alert its operator. He shall also inform the duty diving
medical consultant who can be at the Saudi Aramco
Preventive Medicine Services Division on 877-8916 (after
work hours on 878-1697 or 878-0890).

In commercial diving incidents, the coordinator may elect

to proceed with treatment using the appropriate table
without notifying the diving medical team in cases of
minor decompression sickness. In all type II bends and
possible gas embolism cases, the duty diving medical
consultant shall be notified immediately.

He shall send a monthly report of all incidents involving

therapeutic decompression to the senior Occupational
Medicine specialist.

3.5.4 Diving Medical Team

This will come under the jurisdiction of the director of

Preventive Medicine Services and will be a multi-
disciplinary group headed by the senior Occupational
Medicine specialist. It will be comprised of a group of
physicians with an interest and training in hyperbaric

February 1993 - 3.0 Diving Operations Page 529

 medicine who shall rotate as duty diving medical
consultants. Nurses with special training will also be
integrated in this group which shall constantly keep
abreast with current practices. The diving medical team
will provide this service to the Marine Department.

3.5.5 Marine Department

The Marine Department is responsible for the provision,

maintenance, and manning of the recompression
chambers.

3.6 Personnel Transfer at Sea

The following is to be used as guidelines for the transfer of
persons at sea from vessel to vessel or from vessel to platform
(or structure).

A. Personal Flotation Devices. These references are pertinent

items from Loss Prevention Department GI 6.020 - Personal
Flotation Devices for Work Over, On or Near Water.

3. Requirements.

3.1. Wearing of personal flotation devices are

required as follows:

3.1.7

When working or riding on the deck of a marine

vessel or craft during rough seas at the discretion
of the person in charge of the vessel or craft.

3.1.11

When transferring to or from any water craft or

to or from one water craft to another.

3.1.17

February 1993 - 3.0 Diving Operations Page 530

 At any time when deemed necessary by the boat
skipper, ship captain, supervisor, or the person in
charge of the marine vessel, installation or craft.

4.1.3

Marine craft skippers, ship captains and aircraft

pilots shall enforce the wearing of personal
flotation devices in their vessels or aircraft.
Failure of an employee to heed the instructions
given by the person in charge of the marine craft
or aircraft shall require the passenger to be
removed from the craft with disciplinary action to
follow by the employee's department.

4.1.4

Supervisors or persons in charge of personnel in

facilities, installations, or work activities shall be
responsible for having their personnel follow the
requirements regarding the wearing of personal
flotation devices.

4.2.

Contractors shall provide (fully functional, no

defect) personal flotation devices for each of
their personnel. They shall also provide their
personnel with the necessary instructions or
training on the proper way of wearing personal
flotation devices. The proponent Saudi Aramco
organization shall be responsible for ensuring
that contractors comply with the applicable
requirements of this GI 6.020.

B. Saudi Arab and contractor vessel crews shall also be issued

with proper working uniforms and personal protective
equipment such as shoes, gloves, glasses and hard hats. The
Marine Department expects all Saudi Aramco and contractor

February 1993 - 3.0 Diving Operations Page 531

 personnel working around marine facilities to strictly adhere
to Company safety rules and regulations.

February 1993 - 3.0 Diving Operations Page 532

FIGURE VI.2: INTERNATIONAL CODE FLAG "A"

FIGURE VI.3: SIGNALS

February 1993 - 3.0 Diving Operations Page 533

Appendix A

February 1993 - Construction Safety Manual: Appendix A Page 534

INDEX TO APPENDIX A
This Appendix contains the following information:

* Project Management And Contractor's Safety Competition Site

Registration Form;
* Contractor Safety Competition, Rules Of Competition;
* Contractor's Competition Job Safety Evaluation;
* Saudi Aramco Safety, Health and Environmental Requirements;
* Hazard Identification Plan (H.I.P.).

February 1993 - Construction Safety Manual: Index to Appendix A Page 535

A.1 PROJECT MANAGEMENT AND CONTRACTOR'S
SAFETY COMPETITION SITE REGISTRATION FORM
To: Saudi Aramco Loss Prevention Department Date:
____________________________

Name Of Contractor: Contractor's Address: Contractor's Phone

Number:

Job Description: Job Number: Starting Date:

Estimated Completion
Date:
B.I. Number:
Peak Number Of
Employees:

Contractor Site Saudi Aramco Site Project Mgmt.

Representative: (PMT) Engineer: Department:

Telephone Number: Telephone Number: Org. Code:

Name Of Contractor's Contractor's Site Site Location:

Safety Representative: Phone Number:

Signed:____________________________________________________(C
ontractor's Representative)

Job Title:__________________________________________________

Company:__________________________________________________

February 1993 - Construction Safety Manual: Safety Competition Site Registration Form Page 536
Date:_______________________________________________________

Saudi Aramco Proponent

Department:__________________________________________________
__

This form is to be completed and sent to the local Saudi Aramco Loss
Prevention Office with a copy to the designated senior Project Engineer,
who is a member of the proponent Project Management Team (PMT).

Signed:________________________________________
Saudi Aramco Project Manager

February 1993 - A.1 Safety Competition Site Registration Form Page 537
A.2 CONTRACTOR SAFETY COMPETITION, RULES OF
COMPETITION

CONTRACTOR SAFETY COMPETITION JOB SAFETY EVALUATION

RULES OF COMPETITION

1. The competition shall be run over a six-month period

(January to June and July to December) and shall be assessed
according to the requirements of Schedule 'D' of the contract
documents.

2. A contractor on a Budget Item (BI) who meets the following

criteria shall be registered in the competition by the
responsible Proponent (PMT).

a. Contractor and related sub-contractor exceed 50 for

the entire six month period.
b. Estimated completion time exceeds the competition
time period.

3. An unscheduled site inspection will be carried out by the Loss

Prevention Department once before the 25th day of every
even month. A contractor shall have a minimum of three
ratings within the six month period. The Saudi Aramco Loss
Prevention representative will report to the site office before
he starts his inspection. Representatives of Project
Management and the contractor shall be invited to
accompany the Loss Prevention representative during the
inspection. If it is inconvenient for a member of the Project
Management Team or contractor's personnel to accompany
the Loss Prevention representative during the inspection, the
Loss Prevention representative will conduct the inspection
alone - awarding appropriate scores. These scores shall be
final. If during the inspection there is a difference of opinion

February 1993 - Construction Safety Manual: Contractor Safety Competition Rules Page 538
 over the points awarded, then the Loss Prevention
representative will make the final decision.

4. The Saudi Aramco Project Management Team shall receive a

copy of the inspection sheet, and they should distribute it to
the appropriate contractor. Remedial steps shall be taken to
rectify faults and improve the score rating. At the end of the
competition, a copy of the six-month summary sheet will be
provided to any contractor.

5.
a. A contractor working on one BI at one location shall
be evaluated, scored and ranked separately.
b. A contractor working on more than one BI shall have
an entry in the competition for each BI.
c. A contractor working on the same BI at separate sites
shall be evaluated by site but the final score will be
averaged.
d. Multiple contractors working on the same BI shall be
entered, evaluated, scored and ranked separately.
(This also applies to consortium partners - provided
they meet requirements in 2 above.)

e. For those rare cases where there are multiple sites

and multiple contractors on a BI, each site under the
BI will be scored separately but averaged with all
sites for that BI by contractor.

Exceptions to the above guidelines shall be reviewed by

Project Management Team and Loss Prevention during initial
registrations.

6. Following each inspection by the Loss Prevention

representative, the original copy of the form SA-6710 shall be
submitted to the superintendent, Central Area Loss
Prevention Division, Building 3121, Room 113, Dhahran, not
later than the 25th day of each even month. In cases of

February 1993 - A.2 Contractor Safety Competition Rules Page 539

 holidays or rescheduled days off, the first work day after the
25th is acceptable.

7. Any contractor who experiences a job related fatality, or

serious incident that results in the hospitalization of five or
more employees, and fire resulting in SR 10,000 worth of
damage on any one of their sites within the competition
period, will cease to be eligible for an award.

8. Should a registered contractor not retain an average of 50 or

more employees for the entire competition period, they will
be dropped from the competition.

9. Any item of concern not specifically covered on the

Evaluation Form A-6710, shall be reflected in column #18
under Special Items.

10. Should any contractor find he has completed the project

before the end of the competition period due to meritorious
performance or reasons beyond his control, then he will still
be eligible to compete in the final assessment.

11. Should it be found that the contractor has not entered into
the required logs details which at a later date are determined
to have occurred, e.g. restricted duty, lost work day cases,
accidents, fires, etc., then he would be deemed to have
broken the rules and forfeit the right to be included in the
awards for the duration of that competition for which he was
eligible.

12. Every hazard report Saudi Aramco Form 3744 issued and not
corrected within 24 hours, a penalty of 500 points shall be
deducted from the total score.

13. Should a contractor incur a second hazard report,

disqualification for the rest of the competition period shall
result.

February 1993 - A.2 Contractor Safety Competition Rules Page 540

 14. Violations noted during an initial inspection which have not
been corrected by the next general and/or follow-up
inspection shall be deemed a repeat violation and a "0" score
will be given for the entire section under consideration.

SCORING:

Where a section is inapplicable to a particular site, e.g. no

scaffolding, cranes, etc., then that section will OK from the
possible percentage score.

POINT ASSESSMENT:

Points will be assessed based on the gravity/severity of violations

encountered and will range from 0 to 100. Points can be given
from 0 to 100, depending on the judgment of the Loss Prevention
Department representative.

OVERALL PERFORMANCE RATING:

Unsatisfactory= 0 - 65
Fair= 66 - 80
Good= 81 - 95
Excellent= 96 - 100

Overall percentage performance will be calculated as

follows:
Points Scored x 100 = Contractor Rating:
___________
Points Possible

Every endeavor will be made to provide an accurate

assessment at each inspection. Any questions that may
arise concerning this job safety evaluation may be
submitted to the proponent department for resolution.
Any contractor who persistently returns poor scores or
violates the competition rules may be subject to
corrective action by the proponent department.

February 1993 - A.2 Contractor Safety Competition Rules Page 541

 Please Note:
For more information on the Contractor Safety
Competition, and for the current competition rules,
please contact your Area Loss Prevention Office.

February 1993 - A.2 Contractor Safety Competition Rules Page 542

FIGURE A.1: CONTRACTOR'S COMPETITION JOB SAFETY EVALUATION

February 1993 - A.2 Contractor Safety Competition Rules Page 543

FIGURE A.1: CONTRACTOR'S COMPETITION JOB SAFETY EVALUATION CONTINUED.

February 1993 - A.2 Contractor Safety Competition Rules Page 544

A.3 SAUDI ARAMCO SAFETY, HEALTH AND
ENVIRONMENTAL REQUIREMENTS
1. Compliance With Safety Rules - Schedule 'D'

CONTRACTOR shall at all times comply with, and ensure that its
employees, agents and subcontractors comply with, applicable
Saudi Arab Government Safety Regulations and all SAUDI
ARAMCO Safety and Loss Prevention rules and regulations.
Specifically, CONTRACTOR shall comply with the provisions of the
SAUDI ARAMCO Construction Safety Manual and SAUDI
ARAMCO's publication entitled "Loss Prevention Requirements
for Contractors", Paragraphs 5 through 27 of this Schedule
(which supplement but do not limit the requirements of the
Construction Safety Manual), and such other related
requirements; specifications and standards as are made known
to CONTRACTOR by SAUDI ARAMCO. CONTRACTOR may request
copies of all applicable rules and regulations from SAUDI
ARAMCO's Loss Prevention Department. CONTRACTOR shall also
take, or cause to be taken, any additional measures which
Company Representative may direct to protect against injury to
or death of any person or damage to or loss of any property
during CONTRACTOR's performance of the work. CONTRACTOR
shall maintain the SAUDI ARAMCO Construction Safety Manual
and applicable SAUDI ARAMCO GIs at the WORK Site.

2. Deviations From Safety Rules

Any deviation by CONTRACTOR from SAUDI ARAMCO's Loss

Prevention rules and regulations must be approved in writing in
advance by Company Representative.

3. Failure To Comply

Should CONTRACTOR fail to comply with the requirements of this

Schedule 'D', SAUDI ARAMCO shall notify CONTRACTOR in
writing. CONTRACTOR shall, upon being advised of its

February 1993 - Construction Safety Manual: Contractor Safety And Loss Prevention Requirements Page 545
 noncompliance, immediately take all corrective action required
to comply. Such corrective action shall, unless provided
otherwise in this Contract, be taken at CONTRACTOR's expense.
If CONTRACTOR fails to take such corrective action promptly,
Company Representative may direct CONTRACTOR to suspend all
or part of the WORK pursuant to Schedule "A" until satisfactory
corrective action has been taken. Costs incurred by
CONTRACTOR as a result of such WORK suspension shall be for
CONTRACTOR's account and any resultant CONTRACTOR
performance delays shall not be deemed excusable here-under.

4. Saudi Aramco Assistance

CONTRACTOR may request assistance from SAUDI ARAMCO with

respect to the implementation of its Loss Prevention
requirements. Company Representative, or such party or parties
designated by him, will assist CONTRACTOR by explaining good
safety practices, pointing out unsafe WORK Site conditions, and
by applying his/their experience and judgment in order to assist
CONTRACTOR in improving WORK safety. It is understood,
however, that rendition of such assistance by SAUDI ARAMCO
will in no way relieve CONTRACTOR of its responsibilities as set
forth in this Schedule 'D'.

5. Loss Prevention Program

CONTRACTOR shall prepare and submit a Loss PREVENTION

Program to Company Representative, for SAUDI ARAMCO's
approval, not later than fifteen (15) working days following the
execution of this Contract. CONTRACTOR shall ensure full
implementation of the Program. CONTRACTOR shall appoint a
qualified full-time Safety Supervisor approved by SAUDI
ARAMCO, to coordinate the Program. The name and address of
the Safety Supervisor shall be submitted to Company
Representative no later than the Program's submission:

The Program shall outline specific essential measures to be taken

by CONTRACTOR to prevent injuries to persons and damage to

February 1993 - A.3 Contractor Safety And Loss Prevention Requirements Page 546
 property and to ensure compliance with this Schedule 'D'. The
Program shall be organized and implemented by each craft or
crew supervisor. It shall include a specific plan to hold a ten
minute safety discussion organized and implemented by each
craft or crew supervisor on at least one day in each working
week.

6. Work Permits

CONTRACTOR shall obtain a work permit (SAUDI ARAMCO Form

924) each shift for any WORK to be carried out during such shift
in any SAUDI ARAMCO specified "Restricted Area". It shall be the
CONTRACTOR's responsibility to ascertain, in advance, whether
the WORK area is designated a Restricted Area. Company
Representative shall give guidance on Restricted Area locations.
All work permit procedures shall be carried out by CONTRACTOR
in accordance with SAUDI ARAMCO GI 2.100 (Work Permits) and
GI 6.012 (Isolation, Lockout and Use of Hold Tags), which by this
reference is made part of this Contract.

7. Welding And Cutting Equipment

All welding and cutting equipment shall be of a SAUDI ARAMCO

approved type and maintained in good condition.

8. Personal Protective Equipment

CONTRACTOR shall, as a minimum, provide, maintain and

enforce the use of the items of personal protective equipment
listed in SAUDI ARAMCO's Construction Safety Manual, other
applicable GIs and Operator Instruction Manuals (OIMs).

9. Tools And Portable Power Tools

CONTRACTOR shall ensure that all tools provided by

CONTRACTOR are of the best quality with proper safeguards and
are suitable for the use intended. Electrical hand tools shall be
properly grounded or be of the double insulated type. All tools

February 1993 - A.3 Contractor Safety And Loss Prevention Requirements Page 547
 shall be free from defects and maintained in good condition.
Saudi Aramco will reject tools which are found to be defective.

10. Cartridge Operated Tools

Cartridge operated tools shall be used only with the prior written
approval of Company Representative. Furthermore,
CONTRACTOR shall ensure that only SAUDI ARAMCO approved
tools shall be used and that they shall be maintained in good
condition in compliance with the SAUDI ARAMCO Construction
Safety Manual.

11. Ladders

CONTRACTOR shall ensure that only metal or timber ladders of

SAUDI ARAMCO approved type are provided and used for ingress
to and egress from WORK places where other means of ingress
and egress are not available.

12. Scaffolding

CONTRACTOR shall provide and cause to be used scaffolding,

platforms or temporary floors for all WORK which cannot be
done safely from the ground, from a ladder or from a boatswain's
chair. All scaffolding shall be constructed of SAUDI ARAMCO
approved metal components and erected to comply with the
requirements of the SAUDI ARAMCO Construction Safety
Manual.

13. Electrical Installations And Equipment

All material and equipment used in temporary electrical

installations shall be of SAUDI ARAMCO approved type and
maintained in good condition.

CONTRACTOR shall ensure that all 120 volt single phase 15 and
20 ampere receptacle outlets which are not a part of the
permanent wiring of any building or structure shall have ground
fault circuit interrupters for personal protection.

February 1993 - A.3 Contractor Safety And Loss Prevention Requirements Page 548
14. Cranes And Rigging Equipment

CONTRACTOR shall ensure that all lifting appliances and every

part thereof, including all working gear, and all other plant or
equipment for anchoring or fixing such appliances shall be of
good mechanical construction, sound material, adequate
strength and free from defect and are properly inspected and
maintained. All chains, hooks, slings, shackles and other
equipment used for raising or lowering on a lifting appliance shall
be of a SAUDI ARAMCO approved type and maintained in good
condition. All mobile heavy equipment and crane operators
must possess a valid Kingdom of Saudi Arabia heavy equipment
operator's license and be certified by SAUDI ARAMCO to operate
such equipment (GI 7.025). All cranes and lifting equipment
must be inspected and certified by SAUDI ARAMCO before being
permitted to operate on SAUDI ARAMCO property (GI. 7.030).
Certified riggers shall be provided (GI. 7.030).

15. Mechanical Equipment

CONTRACTOR shall ensure that all mechanical equipment

provided is of a SAUDI ARAMCO approved type and maintained
in good condition.

All moving parts of any equipment shall be securely guarded so

as to prevent access to the moving parts by persons working on
or passing through the WORK Site.

16. Saudi Aramco Plant Operations

CONTRACTOR shall ensure that CONTRACTOR's personnel and

the personnel of its subcontractors do not open or close any
valves or electrical switches, or operate any other piece of SAUDI
ARAMCO plant without the prior approval of SAUDI ARAMCO and
then only under the direct supervision of the supervising
operator or plant foreman.

February 1993 - A.3 Contractor Safety And Loss Prevention Requirements Page 549
17. Transportation

CONTRACTOR shall ensure that passengers shall travel only in

vehicles that are provided with SAUDI ARAMCO approved
passenger seats. This requirement shall apply while traveling to
and from the WORK Site and during travel on the WORK Site.
Seat belts shall be installed and used in all vehicles carrying
personnel (except in the case of buses where seat belts are
mandatory only for the driver).

18. Injury And Damage Reporting

CONTRACTOR shall ensure that an immediate oral report is made

to Company Representative in the case of all:

· Fatal injuries;
· Injuries requiring medical attention which result in lost time;
· Damage over SR 10,000 to CONTRACTOR's plant or
equipment;
· Damage, in any amount, to SAUDI ARAMCO's equipment or
property;
· Fire;
· Damage and near misses to cranes and heavy equipment (GI.
7.026).

For accidents involving CONTRACTOR employee fatalities, serious

injury to five or more CONTRACTOR employees, or damage to
SAUDI ARAMCO equipment or property, a written report shall be
submitted promptly to Company Representative. In addition,
SAUDI ARAMCO may convene an engineering review or
investigation committee in accordance with the requirements of
GI 6.001 and GI 6.003..

CONTRACTOR shall maintain, in a format approved by Company

Representative, a current record showing all:

· WORK injuries
· Fires
· Incidents of property damage over SR10,000

February 1993 - A.3 Contractor Safety And Loss Prevention Requirements Page 550
 · Motor vehicle collisions
· Incidents involving damage to SAUDI ARAMCO equipment
and property
· Damage and near misses to cranes and heavy equipment (GI
7.026)

This record shall be available for inspection at all reasonable

times and shall be submitted to SAUDI ARAMCO on request.

19. Excavations

CONTRACTOR shall ensure that any excavation work carried out

during the course of the WORK is done according to the
requirements of SAUDI ARAMCO GI 1021.010 and OIM. 1.108
which are by this reference made part of this Contract.

20. Work Over Or Adjacent To Water

Adequate lifesaving and rescue equipment shall be provided by

CONTRACTOR on every seagoing vessel, and at every work
station where WORK is being carried out over or adjacent to
water. Life vests shall be worn by CONTRACTOR's personnel
when working over water as prescribed in SAUDI ARAMCO GI
6.020, which by this reference is made part of this Contract.

21. Fire Prevention

CONTRACTOR shall provide and maintain in good working order

adequate fire fighting equipment. All CONTRACTOR's personnel
shall be properly trained in the use of such equipment. Store
yards shall be laid out in accordance with SAUDI ARAMCO
Standards (SAES-B-7A, SAES-B-7C) and NFPA 231 A with respect
to spacing of rows, fire lanes and compatibility of materials.

22. Formwork

CONTRACTOR shall ensure that all formwork supports are

constructed to SAUDI ARAMCO approved standards. As far as
practicable, steel units shall be used.

February 1993 - A.3 Contractor Safety And Loss Prevention Requirements Page 551
 Where the WORK requires a timber supporting structure, the
timber shall be of suitable quality and of adequate strength.
CONTRACTOR shall obtain prior written approval from Company
Representative before any timber supporting structure is
erected.

CONTRACTOR shall ensure that prior to any concrete being

poured into any supported formwork structure, approval is
obtained from Company Representative.

23. Ionizing Radiation

CONTRACTOR shall ensure that radioactive sources shall be used

in compliance with the "General Rules and Regulations for the
Use and Handling of Radioactivity and Radioisotopes" as
promulgated by the Saudi Arabian Atomic Energy Department
and with prior written approval of SAUDI ARAMCO. Where the
WORK requires the use of ionizing radiation either by the
CONTRACTOR or by some other organization approved by SAUDI
ARAMCO, CONTRACTOR shall ensure that all employees are
made aware of the precautions to be taken.

24. First-Aid Facilities

The CONTRACTOR shall provide and maintain first-aid facilities at

the WORK Site in accordance with Articles 134 and 135 of the
Saudi Labor Laws. When a CONTRACTOR employs 50 or more
workmen at a WORK Site the CONTRACTOR shall provide a
qualified nurse and a dedicated emergency vehicle (ambulance),
properly supplied and marked, to transport injured personnel to
the nearest health care facility.

25. Handling, Transportation And Disposal Of Hazardous Materials

And Waste

25.1

When a CONTRACTOR, in the course of performing his

obligations under the Contract, handles hazardous

February 1993 - A.3 Contractor Safety And Loss Prevention Requirements Page 552
 materials, the CONTRACTOR shall ensure that the
handling of such materials is performed in accordance
with currently accepted industry practices for the
handling of such material. CONTRACTOR shall ensure that
in handling of hazardous materials, especially liquids, such
material is properly containerized and labeled in
accordance with SAUDI ARAMCO GI 355.001.

25.2

Subject to any specific requirements in Schedule "B",

CONTRACTOR shall include in its Loss Prevention Program
its procedure for the disposal of solid and liquid wastes.
The procedure shall detail specific locations for the
disposal of each type of waste (construction, chemical,
sludge, sanitary, scrap and sewage) and shall also identify
the steps to be taken to treat the wastes or otherwise
prevent them from polluting the ground water or the sea
or from becoming a public nuisance. SAUDI ARAMCO
shall approve such procedure before disposal of any
waste by CONTRACTOR.

25.3

In addition to the requirements of sub-paragraph 25.2

above, where the CONTRACTOR is required to dispose of
wastes determined to be hazardous, the CONTRACTOR
shall:

25.3.1

Follow Saudi Arab Government regulations in

disposing of hazardous waste materials.
CONTRACTOR must provide SAUDI ARAMCO
proof that the hazardous wastes have been
properly disposed of at a licensed hazardous
waste disposal facility.

February 1993 - A.3 Contractor Safety And Loss Prevention Requirements Page 553
 25.3.2

CONTRACTOR shall also provide SAUDI ARAMCO

proof of an established land treatment/disposal
program which is designed to ensure that
hazardous constituents placed in or on the
treatment/disposal zone are degraded,
transformed or immobilized within the treatment
zone to prevent migration to ground and/or
surface waters. The CONTRACTOR shall submit
this program to SAUDI ARAMCO for approval
prior to the disposal of any hazardous material by
the CONTRACTOR.

26. Explosives

CONTRACTOR shall promptly advise Company Representative of

any requirements for explosives and only use such explosives
after the written approval of Company Representative.
Contractor shall comply with the general rules and requirements
for the handling and use of explosives issued by the Ministry of
the Interior and all Saudi Aramco requirements per the Saudi
Aramco Construction Safety Manual for the storage,
transportation and use of explosives.

27. Sandblasting

CONTRACTOR shall comply with SAUDI ARAMCO GI 6.021 and

Construction Safety Manual requirements on sandblasting.

February 1993 - A.3 Contractor Safety And Loss Prevention Requirements Page 554
A.4 HAZARD IDENTIFICATION PLAN (HIP)
INTRODUCTION

In reviewing the safety requirements for our design and

construction activities (i.e. new, modified or rebuilt plants or
facilities), it is difficult for even the most experienced engineer
and/or contractor to identify all the potential safety hazards that
may be encountered unless a systematic potential-hazard review
is conducted as a part of a Hazard Identification Plan (HIP).

The attached Hazard Identification Plan (HIP) provides the

method for conducting such a review. The hazards identified are
classified as A, B or C according to their degree of potential
human impact considering severity and probability (i.e. from
most severe and probable to least severe and probable) during
the initial design phase. This allows for a change in the
methodology or operating procedure in the direction of reducing
the risk associated with the hazard to an acceptable level, or
eliminating it altogether.

February 1993 - Construction Safety Manual: Hazard Identification Plan Page 555
HAZARD IDENTIFICATION PLAN:

Brief description of work to be accomplished.

I. Conduct Hazards Identification Review.

(To include on-site tour)

Record hazards identified on location map.

II. List Potential Hazards

· Each hazard will be classified A, B, or C.

· Statement of corrective action to be taken.
· Hazard areas identified on a location map and color
coded.
· Contractor will submit this list to Saudi Aramco
representative.

Consideration will be given to the following potential

hazards:

· Potential hazards to P.M.T. and contractor personnel.

· Potential hazards to the general public.
· Incompatible interface with existing plants, facilities,
procedures, regulations, engineering specifications,
ground condition, etc.
· Potential hazards that may be encountered from
outside sources.
· Hazardous materials identification/handling/storage.
· Potential fire / electrical hazards.

III. Hazard Classification

Once the hazards are identified, they are classified as

Class A, B, or C.

February 1993 - A.4 Hazard Identification Plan Page 556

 · Class "A" Hazards:

A condition or practice likely to cause permanent

disability, loss of life or body part and/or
extensive loss of structure, equipment or
material.

· Class "B" Hazards:

A condition or practice likely to cause serious

injury or illness (resulting in temporary disability)
or property damage that is disruptive, but less
severe than Class "A".

· Class "C" Hazards:

A condition or practice likely to cause minor

(non-disabling) injury or illness or non-disruptive
property damage.

February 1993 - A.4 Hazard Identification Plan Page 557

 IV. Corrective Action

List all hazards identified in the HIP outline, and

determine what corrective action should be taken.

Example: "A" Hazards

Overhead electrical power lines over building site

· Electrical power rating, (KV)

· Show power lines on location map.

Corrective Action

Example: "A" Hazard. "Overhead Power Lines"

Corrective Action:

· Obtain work permit before starting any work

under or near electrical power lines.
· No activity in area under power line until
power lines have been disconnected and/or
relocated.

Following are examples of typical hazards that can be

encountered:

1) Above Ground Potential Hazards

· Overhead power lines, list KV rating

· Bridges, by-passes
· Micro wave / communication towers
· Houses
· Traffic flow
· Facilities close-by
· Aircraft flight path
· Trees, poles
· High cliffs / dangerous overhangs
· Fuel / chemical / pressure vessels and systems

February 1993 - A.4 Hazard Identification Plan Page 558

 2) Ground Level Potential Hazards

· Electrical wires
· Roadways
· Ditches
· High water table
· Tie-downs
· Obstruction
· Unstable soil
· Fences/walls
· Traffic flow
· Guide wires
· Nearby buildings, schools, houses
· Possible flood or wash out areas
· Adverse weather conditions
· Hazards from nearby plants or operations, etc.

3) Underground Potential Hazards

· Buried utilities
· High water table
· Building foundations
· Underground water waste
· Unstable soil
· Chemical / trash dump area
· Voids in the earth (caves)
· Underground fuel / chemical / pressure
systems and vessels

4) Interface Potential Hazards

· Existing emergency evacuation plans

· Emergency communication system
· Traffic flow
· Special personnel
· Protective equipment requirements
· Hazardous waste disposal
· Hazards from other outside operations

February 1993 - A.4 Hazard Identification Plan Page 559

 · Escape routes
· Evacuation alarms
· Access control
· Flammable liquid / chemical / pressure vessel
storage
· Gas release into proposed area

5) Off-Shore Potential Hazards

· High wind / sea conditions

· Night time operations
· Inclement weather conditions
· Fog
· Rain
· Lightning
· Marine vessels and materials adrift
· Electrical hazards

February 1993 - A.4 Hazard Identification Plan Page 560

Appendix B: Emergency/Disaster
Planning And
Response

February 1993 - Construction Safety Manual - Appendix B: Emergency/Disaster Planning And Response Page 561
B.1 SEARCH AND RESCUE PROCEDURES
This Appendix outlines Saudi Aramco search and rescue procedures for
on- and off-shore facilities. Included in this appendix are the following:

· Control of Remote Area Travel And Search And Rescue Procedures

(GI 6.025);

· Offshore Emergency Response;

· Fire and Other Serious Emergency Response Procedures

(Supplement No. 1-503-1).

Any further questions on search and rescue procedures should be

forwarded to your area Loss Prevention Department office or the Saudi
Aramco contract proponent.

Effective emergency planning requires that employees be familiar with

emergency procedures before a crisis. It is the responsibility of
management to ensure that all employees are familiar with the proper
response to fire and other serious emergencies.

February 1993 - Construction Safety Manual: Search And Resuce Procedures Page 562
B.2 EMERGENCY/DISASTER PLANNING AND RESPONSE
It is the responsibility of every contractor employee to become familiar
with emergency response procedures for both offshore and onshore
operating facilities.

The following Operating Instructions Manuals (OIMs) give facility-specific

emergency response guidance/procedures:

Saudi Aramco Operating Instruction Manual (OIM):

OI 1.501 Overall Disaster Control Procedure - Safaniya/Tanajib Area

OI 1.501-1 Tanajib Disaster Control Center Commander

OI 1.501-2 Safaniya Support Personnel Assignment

OI 1.501-3 Disaster Control Command Center - Tanajib Personnel

Assignment

OI 1.502 Onshore Control Unit - Safaniya Producing

OI 1.503 Offshore Disaster Control Plan - Safaniya Producing

OI 1.503-1 Offshore Emergency Response

OI 1.503-2 Offshore Emergencies Only

OI 1.503-3 Safaniya Offshore Jack-Up Test Barge/Well Platform Disaster

Control Plan

OI 1.503-4 Safaniya Offshore - Offshore Casualty Evacuation

OI 1.503-5 Personnel Accountability Offshore Facilities

OI 1.527 Safety Zones and Safety of Navigation Around Offshore

Installation

OI 10.011 Work Around Offshore Producing Facilities

February 1993 - Construction Safety Manual - B.3: Emergency/Disaster Planning And Response Page 563
General guidelines for preparing emergency response plans can be found
in the following Saudi Aramco Loss Prevention Department publication:

GI 70.500 Disaster Contingency Plan, Dhahran Area

Guidelines for Preparing Emergency Response Plans, October 1989

Other references include:

Saudi Aramco Corporate Loss Prevention Manual (CLPM)

Mobil Oil Corporation - Guidelines for Emergency Response and Disaster

Contingency Planning for Saudi Aramco, May 1991

The potential for emergencies and disasters exists at all construction sites
and facilities and their associated costs can be devastating in terms of
employee casualties, business interruption, loss of capital investment, etc.
These events cannot be avoided but the contractor can reduce their
frequency of occurrence and severity of damage with effective
preparation/planning. This can be accomplished by developing
emergency response plans that address immediate concerns within the
contractor's operations and which also interface, as required, with
emergency response procedures developed by Saudi Aramco
organizations.

The following guidelines (B 3.1 and B 3.3 and Figures) are extracted from
the publication "Guidelines For Preparing Emergency Response Plans".
These are generally used by Saudi Aramco operations as a framework for
plan development. Contractors should refer to these guidelines for
developing their own plans as appropriate, paying particular attention to
the need for interfacing with local Saudi Aramco emergency planning
procedures. Contractor's plans will need to be tailored to their specific
operations and resources and the nature of their work with Saudi
Aramco.

B.2.1 General Provisions

1. The purpose of the emergency plan is to provide guidance on
the following:

February 1993 - B.3 Emergency/Disaster Planning And Response Page 564

 · A facility/site emergency response organization's
structure and responsibilities
· Development of credible emergency/disaster scenarios
and their consequences
· Establishment of emergency control resources (human,
equipment, etc.) and procedures
· Emergency response training and drills

2. Ensure that the emergency plan with the latest issue date is
being used and it incorporates all amendments to date. It
must have provision for any future amendments as
addendum or reissues.
3. The emergency reporting instructions must be provided in
the front of the plan.
4. The emergency telephone numbers must be provided in the
front of the plan.
5. The disaster preparedness policy must be provided in the
front of the plan.

B.2.2 Definitions
1. Emergency:

An emergency is an abnormal incident posing a threat to

the safety of workers, residents, the environment or
property at a facility or site and which can be brought
under control using the resources and procedures for
emergency response in place for the facility or site.

2. Disaster:

A disaster is an emergency which poses a more serious

threat to the safety of workers, residents, the
environment or property at a facility or site and which
cannot be brought under control using the resources and
procedures for emergency response in place for the
facility or site. Whether an emergency becomes a
disaster depends on the following:

February 1993 - B.3 Emergency/Disaster Planning And Response Page 565

 · the type of facility;
· the hazards of the facility operations;
· the proximity of neighboring communities or other
facilities;
· the capabilities of emergency personnel; and
· mutual aid capabilities of outside agencies.

3. Emergency Planning:

This involves the development of a specific plan which

details actions to be taken by trained personnel during an
emergency in an effort to efficiently control it and
minimize its net negative impact on workers, residents,
the environment or property at a facility or site. This type
of planning also extends to developing emergency control
strategies and instituting training and drills for all facility
personnel.

4. Disaster Command Center (DCC):

The location where the Emergency Manager and support

staff assemble to respond to an emergency. It is a
centralized location for monitoring the facility response
and also serves as a command center for coordinating all
communications, including the allocation and distribution
of information. (This will also remain an onshore
centralized location for an offshore emergency response
episode.) During an offshore search and rescue (SAR)
operation, this will become the SAR control center. A
designated helicopter pilot will report to SAR control
center to act as a search coordinator. Staffing from
pertinent technical and support groups assures
accessibility to all required resources for an overall
effective emergency response.

February 1993 - B.3 Emergency/Disaster Planning And Response Page 566

 5. Disaster Command Post (DCP):

A designated safe location near the emergency site from

which the Incident Commander directs emergency control
efforts. He directs operations and coordinates fire
fighting, rescue and medical treatment activities during
the emergency episode.

At some onshore facilities, the DCP is a specially equipped

vehicle outfitted with facility maps, communication
equipment and support information similar to a DCC. This
equipment provides the means for contact with the DCC
and for field coordination. At offshore facilities, the DCP
would be a safe location designated by the Incident
Commander which should be equipped with a telephone,
radio communication and personal
protective/identification equipment, at a minimum.

6. Table Top Exercise:

This is a disaster management simulation where key

personnel face a hypothetical disaster situation developed
by a skilled moderator. Weaknesses are identified by
evaluating the results of the exercise and corrected by
revising the plan.

7. Planning Committee:

A planning committee is a body comprising of members

from key functional groups within the organization. This
is set up to develop an emergency plan using the broad
expertise of its members.

8. Planning Coordinator:

An individual who is qualified to develop an emergency

plan to direct its development through a planning
committee. This individual is required to process great
depth of knowledge of emergency response and disaster

February 1993 - B.3 Emergency/Disaster Planning And Response Page 567

 control practices and procedures, and manpower
organizational capabilities for his facility or site. He can
review and use Saudi Aramco approved emergency plans
from other similar facilities or sites in the development or
modification of his facility/site plan.

9. Emergency/Disaster Response Organization:

The Emergency/Disaster Response Organization is a

structured working group whose function is to control an
emergency or disaster. The structure of this group is
typified in Figure B.1. The organization is basically
comprised of the following positions with their delegated
responsibilities.

A. Key Positions

(a) Emergency Manager

The Emergency Manager is responsible for the

overall organization and strategy of the
emergency response, coordinates logistical
efforts and has the authority for the final decision
in any emergency action. He is usually, but not
always, the senior management person at the
facility. His specific responsibilities are to:

(1) assume control of the DCC

(2) implement the Emergency Plan
(3) receive updates on control measures
taken by the Incident Commander
(4) assess the situation and direct actions to
minimize damage and loss of life
(5) maintain contact with upper management
(6) declare the emergency "under control"
and authorize the "all clear" signal

(b) Incident Commander

February 1993 - B.3 Emergency/Disaster Planning And Response Page 568

 The Incident Commander is responsible for
suppression and control tactics at the site. The
Shift Superintendent usually fills this position and
provides direction to all personnel at the scene,
including the senior fire officer. His specific
responsibilities are to:

(1.) establish the Disaster Control Post (DCP)

at a safe location near the emergency site
(2) develop and implement control tactics
(3) approve use of all emergency related
resources
(4) keep the Emergency Manager informed
(5) evaluate mutual aid needs, and request
assistance through the Emergency
Manager
(6) coordinate mutual aid personnel and
equipment
(7) determine the need for evacuation

All normal plant functions and emergency

support services report directly to one of the
above positions according to their reporting
relationships given in Figure B.1.

B. Emergency/Disaster Support Staff/Teams

(a) Fire Protection/Rescue

This function is usually performed by a combined

team of facility/site fire protection personnel.
They take directions from the Incident
Commander through the appointed senior fire
officer at the DCP. The responsibilities of the
senior fire officer are as follows:

· Fire-Fighting

February 1993 - B.3 Emergency/Disaster Planning And Response Page 569

 (1) provide initial evaluation to the Incident
Commander
(2) deploy fire fighting personnel and
equipment
(3) advise Incident Commander of the need
for outside resources
(4) keep Incident Commander current on fire
control status
(5) direct outside fire fighting organizations
(6) clean-up and restore fire protection
equipment and supplies

· Rescue

(1) locate and rescue missing persons

(2) render essential first aid and life support
(3) remove victims to designated safe
locations for medical treatment

(b) Process

This function is usually performed by an

operations representative who is responsible for
advising the Emergency Manager in the following
areas:

(1) operations, hydrocarbon movement, unit

isolation and emergency shutdown
activities
(2) special fire protection needs
(3) materials or process in the affected area
(4) actions taken affecting the process
(5) process equipment involved in the control
of the incident

(c) Maintenance

February 1993 - B.3 Emergency/Disaster Planning And Response Page 570

 This function is usually performed by a
maintenance representative who is responsible
to:

(1) assemble maintenance manpower in the

maintenance shops
(2) assist operators in isolating and shutting
down units as directed
(3) repair of emergency equipment
(4) assist utilities personnel in bypassing or
repairing critical utility components
(5) provide fuel for emergency vehicles and
firewater pump engines
(6) transport foam and other emergency
supplies

(d) Engineering

This function is usually performed by an

operations engineering representative whose
responsibilities are as follows:

(1) provide mechanical and process related

information
(2) keep the Emergency Manager, Incident
Commander, and Process Coordinator
advised of factors influencing emergency
activities.
(3) assign an engineer to serve as an
emergency events recorder
(4) prepare damage assessment reports
(5) collect and preserve evidence for the
incident investigators
(6) perform post-incident engineering for
repair work

(e) Security

February 1993 - B.3 Emergency/Disaster Planning And Response Page 571

 This function is usually performed by the facility
Security Supervisor whose responsibilities are as
follows:

(1) ensure integrity of the plant perimeter

(2) provide necessary staffing to control use
of emergency gates
(3) prevent entry of unauthorized personnel
(4) direct the flow of traffic away from the
disaster scene
(5) direct emergency resources to the
appropriate staging area
(6) provide escorts for emergency vehicles
when requested
(7) advise Incident Commander on security
matters
(8) act as liaison between the Frontier Force,
the Incident Commander and Government
Affairs

(f) Loss Prevention

This function is usually performed by the Loss

Prevention Advisor/Engineer whose
responsibilities are as follows:

(1) help evaluate hazardous situations and

materials
(2) recommend actions and equipment
necessary to protect personnel
(3) direct Loss Prevention staff to perform gas
testing or other emergency/disaster
services and interface as needed with
Industrial Hygiene
(4) assign Loss Prevention staff to record or
log emergency/disaster activities for
future use

February 1993 - B.3 Emergency/Disaster Planning And Response Page 572

 (5) coordinate with services as necessary
regarding safety equipment

(g) Services

This function is usually performed by a staff

engineer who coordinates support services and
obtains a cost code from the area Finance
representative to account for all financial,
purchasing, and cost analysis aspects of the
incident. His responsibilities are as follows:

(1) contact the on-call Area Representative

who will provide safe and sanitary food,
potable water, and field sanitation
facilities on request of the Incident
Commander
(2) purchasing and contracting requirements
(3) coordinating claims actions
(4) providing necessary accommodations for
emergency response personnel

(h) Medical

This function is usually performed by district

medical personnel whose responsibilities are as
follows:

(1) establish a triage area at the scene

(2) provide on-site emergency medical care
(3) advise the Emergency Manager of the
number of injured and any need for
additional medical assistance
(4) notify appropriate hospitals and clinics of
the anticipated number of casualties
(5) advise the Emergency Manager of special
medical transportation needs

February 1993 - B.3 Emergency/Disaster Planning And Response Page 573

 (6) keep records of victims and their
treatment

(i) External Relations

This function is usually performed by the area

Government Affairs representative whose
responsibilities are as follows:

(1) establish and maintain communications

with civil authorities
(2) communicate the incident status to
government organizations as appropriate
(3) request approval from the Emergency
Manager for any government inspections
and/or investigations during the
emergency
(4) inform community leaders of incident
status, potential dangers which might
require evacuation and recovery efforts

(j) Operations/Utilities

This function is usually filled by plant/site

foremen who direct the activities of plant
operators. Their responsibilities are as follows:

(1) account for personnel by head count

procedures
(2) report missing persons
(3) implement the facility emergency
operating plan for a specific situation (i.e.
isolation and shutdown unit(s) as
instructed and stabilize units not involved)
(4) await further orders after the units have
been shutdown and secured
(5) assign an operator to check firewater
mains pressure and start fire pumps

February 1993 - B.3 Emergency/Disaster Planning And Response Page 574

 (6) control the plant air systems, steam
systems, and other utilities and advise the
Incident Commander on their status
(7) inform the Incident Commander and
Maintenance of system failures
(8) evacuate personnel if instructed by the
Incident Commander

(k) Communications

This function is usually performed by an

operations employee who reports to the DCC to
manage radio transmissions, telephone lines,
operate special equipment such as DVD, EARS,
etc., and record all message traffic.

(l) Environmental

This function is usually performed by an assigned

environmental specialist whose responsibilities
include providing environmental monitoring
services and spill containment/recovery advice to
the Emergency Manager and Incident
Commander.

B.2.3 Plan Development Action Items

Task 1:Assign (or Establish) Planning Coordinator (or Team)

1. A planning coordinator must be assigned; or

2. A planning committee/coordinator team must be

established.

Task 2:Establish Scope and Objectives

3. A scope and written objectives must be developed

for the site.

February 1993 - B.3 Emergency/Disaster Planning And Response Page 575

 Task 3:Identify Emergency/Disaster Scenarios

4. Develop emergency/disaster scenarios specific to

the facility or site as follows. (Use Figure B.2 for
scenario development):

· Planning Coordinator/team to identify

emergency/disaster situations.
· Group these situations into generic scenarios
(e.g. tank fires, pump fires, liquid releases, vapor
releases, explosions, natural disasters, etc.)
· For each generic scenario, select the credible
worst case emergency/disaster situation to
represent that scenario (e.g. the largest tank
fire) and fill out Part A (Description) and Part B
(Possible Causes) of the Scenario Analysis Sheet
(Figure B.2). Similarly, describe all scenarios on
separate sheets and assign a rank order to each
in Part E (Evaluation) based on likelihood of
occurrence. (The "consequences" of Part E will
be developed as part of Task 4, "Assess the
Consequences of Scenarios".)

The following information is useful in identifying

emergency/disaster situations (initiated on-site or off-site)
within each generic scenario:

· Fire

Fires are generally caused as a result of ignition of a

gas (or liquid) hydrocarbon leak under pressure.
Unburned liquid hydrocarbon pools in the ground and
fuel the fire to increase its intensity and spread. All
situations within this scenario can lead to disasters if
fire spreads beyond the capabilities of the fire fighting
systems/personnel in place. Generally, this occurs if
the response is not quick to contain the fire to a
manageable limit before it approaches a disaster

February 1993 - B.3 Emergency/Disaster Planning And Response Page 576

 level. Some examples of potential
emergency/disaster situations for the fire scenario
are:

· congested multiple process unit area fire

· flammable liquid tank storage area fire
· wharf loading and unloading area fire

· Explosion

Flammable vapor releases are one of the most

significant sources of explosions and the potential for
casualties and property damage is high. Some
examples of potential emergency/disaster situations
for the explosion scenario are:

· boiling liquid expanding vapor explosion (BLEVE)

of storage, sphere, bullet or process vessel
· runaway (exothermic) process chemical reaction
· gas explosion from a large volume release of
refrigerated LPG
· unconfined vapor cloud explosion (UVCE) from a
flammable vapor release

· Flammable Vapor Release (FVR)

In the petroleum industry, the possibility of release of

flammable vapor poses a great risk. Some examples
of potential emergency/disaster situations for the FVR
scenario are:

· failure of piping connection to pressurized

storage sphere (or bullet), or refrigerated tank
· tank overfill
· LPG tanker accident resulting in containment
failure
· high pressure gas pipeline rupture

· Toxic Vapor Release (TVR)

February 1993 - B.3 Emergency/Disaster Planning And Response Page 577

 Toxic materials may or may not be flammable but
could be in a high enough concentration to pose a
health risk when released as a vapor. Some examples
of potential emergency/disaster situations for the TVR
scenario are:

· rupture of pipeline or well blowout releasing

H2S vapor
· rupture of storage container releasing
chlorine/ammonia vapor
· rupture or leak of amine regenerator overhead
accumulator piping/flange to release H2S vapor
· failure of H2S compressor seal releasing the
vapor

· Hazardous Materials Spill

Hazardous materials are used as solvents, reagents,

and catalysts in various processes. A likely situation
for a hazardous material spill is from the tanker
vehicle transporting it to the facility or during its
transfer from the tanker vehicle to its process usage
or storage point. Other examples of potential
emergency/disaster situations for the Hazardous
Materials Release/spill scenario are:

· TEL/TML gasoline antiknock compound liquid

release
· rupture of storage container or associated piping
releasing chlorine/ammonia liquid
· rupture of storage container or associated piping
releasing sulfuric acid liquid

· Natural Disaster

Each facility or site is susceptible to natural disasters

(e.g. high winds, flooding, etc.). The impact of natural
disasters to cause other related process disasters

February 1993 - B.3 Emergency/Disaster Planning And Response Page 578

 should be recognized in the planning stage. Historical
data on disasters at similar facilities or sites coupled
with weather data can help in predicting the
frequency of natural disasters for the area. Another
source of such information is the Saudi Aramco Risk
Analysis Manual.

Task 4:Assess the Consequences

5. Complete each scenario analysis sheet started in

Task 3 by describing the incident size, duration and
effect on operations.

6. Enter an estimate of the magnitude of potential

consequences in Part E (Evacuation) of the Scenario
Analysis Sheet (Figure B.2) after considering the
following factors for each scenario:

· Size (including explosive potential, maximum fire

areas, maximum spill volume and area,
maximum vapor cloud volume).
· Growth spread of impact area resulting from the
spread of a fire, toxic vapor cloud, or other
undesirable product of the emergency/disaster
episode.
· Amount of advance warning.
· Impact (including severity of potential damage,
potential casualties, effect on surrounding
population, domino effect of sequential
explosions, and total duration).
· Controllability of incident based on level of
emergency/disaster training of personnel and
adequacy of equipment available within a facility
or site.
· Reaction (or response) time and effectiveness of
facility resources to control incident.

February 1993 - B.3 Emergency/Disaster Planning And Response Page 579

 After the Scenario Analysis sheets have been
completed for each scenario, assign a rank order in
Part E based on consequences. The plan
coordinator selects the scenario which represents
the most likely event with the severest
consequence(s) as the basis for developing the
emergency response plan. This choice should be
approved by Contractor management.

Task 5:Review Emergency Control Needs

7. Use the Disaster Control Tasks Checklist to

determine all tasks required (see Figure B.3).

8. Assign a team member to develop the facility's

response.

9. Develop and document the assigned response.

Task 6:Available/Needed Resources

10. The methods to identify, estimate, and establish

available needed resources are as follows:

(a) Develop an inventory list of critical supplies and

equipment needed to control the emergency
disaster scenarios in Tasks 3 and 4.

(b) Ensure that these critical items are stored

together at one easily accessible location (or the
critical items store itself if accessible).

(c) Display the list of critical items on the entrance

to the critical items store.

11. Identify and list the entities responsible for supplying

food, water, shelter, transportation, emergency
equipment, additional manpower, external mutual
aid, medical support and cost accounting.

February 1993 - B.3 Emergency/Disaster Planning And Response Page 580

 12. Determine that the resource needs in item number
10. (above) have been met List contingencies to
cover failure of any of those entities indicated in
item 11. to supply the needed items.

13. Survey alternate outside sources to determine their

ability to supply resources which may be in short
supply.

14. If a mutual aid agreement has been established,

develop an inventory of equipment and supplies
that any mutual aid entity is expected to bring with
them when they respond.

15. Establish a telephone and personnel list of 24-hour

contacts at all mutual aid entities.

16. Determine and document that the equipment and

supplies provided through mutual aid are
compatible with emergency/fire protection
equipment at the site.

17. Measure the response/travel time needed by all

mutual aid entities to respond to an
emergency/disaster at the site. Establish the
needed time range for all outside resources to reach
the site.

18. List and detail all high cost items and their
corresponding authorization levels.

19. List emergency response skills required to control all

scenarios selected in Tasks 3 and 4.

20. Compare required skills with available skills of

construction/site personnel.

21. Establish a Disaster Command Center (DCC).

February 1993 - B.3 Emergency/Disaster Planning And Response Page 581

 22. Consider the need to provide an alternate location
for the DCC in case the original location is rendered
unusable.

23. Supply the DCC (and alternate) with:

· telephone, fax, and other radio

communication/alarm equipment
· emergency power and lighting
· reference materials (e.g. emergency response
manuals, call out lists, Material Safety Data
Sheets (MSDSs), drawings, photographs, maps,
etc.) and emergency equipment (e.g. flashlights,
spare batteries, camera, battery powered
megaphones, etc.
· office equipment (e.g. dictating machines, tapes,
flip charts, stationery items, etc.)

24. Establish a Disaster Command Post (DCP)

vehicle/safe location near the emergency site..

25. Ensure that the DCP is set up with supplies similar to

the DCC (except on offshore facilities where the DCP
may only have a telephone, radio communication
and personal protective/identification equipment).

26. Additionally, ensure that the DCP also has the

following:

· self-contained breathing air

· megaphone
· binoculars
· safety/environmental monitoring equipment
· means of identification (vest, hat)

Task 7:Emergency Response Organization

27. Establish an emergency/disaster response

organization.

February 1993 - B.3 Emergency/Disaster Planning And Response Page 582

 28. Ensure there are sufficient personnel to fill all
assigned positions and alternates/substitutes
identified and on standby to fill critical positions
should it become necessary.

29. Ensure that each assigned position has a

documented detailed description of its
responsibilities. Such a description must include:

· duties of the position

· reporting relationship
· reporting location

30. Verify and document that all assigned individuals are

aware of their responsibilities.

31. Develop a physical method to identify each

individual in the organization chart by position (ID.
badges, vests).

Task 8:Develop Emergency Response Procedures

32. Ensure that the planned facility/site emergency

response procedures are structured according to the
logical progression of action items given in Figure
B.4.

(a) Reporting Emergencies:

(1.) Report to senior operations person in control

room using radios, telephones, manual pull
box alarms, or public address systems.
(Emergency telephone numbers or local 110
instructions should be posted near or on all
telephones.)

(2.) Determine how significant does an incident

have to be to be reportable.

February 1993 - B.3 Emergency/Disaster Planning And Response Page 583

 (3.) Suggested wording for reporting emergencies
(or drills) is shown in Figure B.5 (Emergency
Reporting Instructions). Also see section
VII.A (Reporting Emergencies) of the plan
(see Task 9: Write the Plan).

(4.) Details of the telephone and radio systems

(i.e. different dialing and radio frequencies)
should be in the appendix of the plan.

(b.) Initiate The Alarm:

All emergency related signals (i.e. "stop-work",

"evacuation", and "all clear") and expected
actions relating to each signal alarm must be
established and followed.

Authority and criteria for sounding the different

alarms must be clearly stated in the plan.

(c.) Assess The Situation:

The Incident Commander must follow-up on

every emergency declared by reporting to the
incident site to assess:

· the emergency response actions taken or

being taken
· additional actions and resources required to
control the situation
· extent of damage to property and harm or
negative impact to life.
· existing hazardous conditions and their
likelihood to escalate.

(d.) Mobilization Of Resources:

1. Actions are taken by facility/site personnel to

mobilize the facility's internal resources

February 1993 - B.3 Emergency/Disaster Planning And Response Page 584

 (human, equipment, etc.) and, if needed,
contact external groups to mobilize their
resources to the scene as developed in Task 6
(Available/Needed Resources).

2. Plant personnel assigned to the emergency

response organization are to proceed to their
preassigned locations and await instructions
from the Emergency Manager or Incident
Commander, as applicable.

3. Non-essential plant personnel are to be

evacuated to preassigned assembly areas at a
safe distance from the incident scene.
Supervisory or assigned personnel are to take
head count and DCC is to organize search and
rescue for any missing personnel.

4. Support groups such as Security, Medical and

Fire Protection are to report to their
preassigned locations and must commence
any preauthorized emergency response
related actions.

5. At least two methods of in-plant

communication should be available (e.g.
radio and telephone). One in-plant radio
channel is reserved as the main
communication link between the Emergency
Manager and Incident Commander. At least
two methods of communication are
necessary for external contacts (e.g.
telephone, radio, Direct Voice Dispatch -
DVD, Emergency Alert and Response System -
EARS, etc.).

February 1993 - B.3 Emergency/Disaster Planning And Response Page 585

 A telephone number with a pre-recorded
message providing essential up-to-date
information on the incident (e.g. 113 in
Dhahran) will be established.

(e) Suppression/Control Of Incident:

A separate control procedure must be

written for each generic incident scenario
developed in Task 3 (Identify Emergency
Scenarios). This procedure is based on
facility operating instructions detailing the
rapid and safe sequential shut down of
process units/equipment involved or affected
by the particular incident scenarios.

(f) Post Incident Actions:

There are follow-up actions needed once an

emergency is declared under control by the
Emergency Manager. These actions are:

1. Stand Down And Fire Watch

The Emergency Manager gives the "stand

down" order to emergency response
personnel. At this time, some personnel are
released from duty, some are assigned to
gather evidence, on the emergency episode
and others are to maintain a fire watch if
there is danger of reignition. The fire watch
is set up by Fire Protection following
consultation with the Emergency Manager.

2. Investigate And Report

Incident investigation of causes and reporting

can be made according to prescribed
procedures. GI. 6.001 (Notification

February 1993 - B.3 Emergency/Disaster Planning And Response Page 586

 Requirements For Incidents) and GI 6.003
(Guide For Committees Investigating Major
Incidents) are two sources which provide
guidance for developing such procedures.

3. Restore Operations

This covers all post-emergency control

actions which must be followed to restore
normal operations at the facility. This
includes, but is not limited to:

· demands of caring for injured and

homeless
· repairing damaged equipment to bring
process equipment on-line
· collecting evidence for the reporting
requirement
· determining secondary hazards that may
have developed

4. Revise The Plan

All new information gained as a result of the

incident should be analyzed to determine
what improvements could be made to the
facility's Emergency Response Plan. These
improvements should be integrated into the
Plan and all emergency response personnel
should be retrained and drilled to ensure that
they are familiar with and proficient in
following upgraded procedures.

33. Develop procedures for the following

emergencies/disasters (onshore/offshore as
applicable):

· emergency unit shutdown

· individual equipment isolation

February 1993 - B.3 Emergency/Disaster Planning And Response Page 587

 · process unit fire
· tank farm fire
· marine dock fire
· off-site pipeline leak
· personnel rescue
· medical emergencies
· toxic/flammable/corrosive gas leak
· evacuation from units and buildings
· process upsets
· breaches of security (including terrorism or
sabotage)
· For more information refer to the Saudi Aramco
Loss Prevention Department "Guidelines for
Preparing Emergency Response Plans" manual.

34. Complete the emergency reporting form given in

Figure B.5 and follow the instructions contained
therein to report such event(s).

Task 9 - Write the Plan

35. Ensure that the plan has a Corporate Policy

Statement on emergency/disaster preparedness,
and is prepared in conformance with the format and
instructions presented in the Saudi Aramco Loss
Prevention Department "Guidelines for Preparing
Emergency Response Plans" manual.

A typical Emergency Response Plan will follow the

outline given in Figure B.6.

36. The plan manual must be reviewed and signed off by

all outside mutual aid entities expected to respond
to an emergency at this site.

Task 10 - Emergency Response Training and Drills

37. Develop, document and follow the emergency

response training/drill items given below to ensure

February 1993 - B.3 Emergency/Disaster Planning And Response Page 588

 that all personnel expected to participate in
emergency response are proficient in its theory and
practice.

· table top exercise

· classroom training of personnel
· simulation of DCC operations during an
emergency
· field simulations/drills of credible scenarios

38. Ensure that alternates (or standby) personnel are

also trained and drilled on emergency response

39. Train and familiarize all personnel with the

provisions of your emergency response manual.

40. (a) develop a document and drill schedule in your

manual

(b) ensure that these include full scale disaster

simulations

41. Hold and document critique sessions following all

drills, simulations and/or actual incidents.

42. Establish a procedure to ensure that all suggestions

from the critique sessions are incorporated into your
manual.

Task 11 - Review and Revise the Plan

43. Provide for regular reviews (e.g. documented tickler

date) and update the plan at least once a year
through the plan coordinator.

44. Keep a record of all amendments and maintain it in

the front of the plan document manual.

February 1993 - B.3 Emergency/Disaster Planning And Response Page 589

 45. Keep a current list of all document manual holders
and periodically forward them copies of any
amendments.

February 1993 - B.3 Emergency/Disaster Planning And Response Page 590

FIGURE B.1: TYPICAL EMERGENCY ORGANIZATION CHART

EMERGENCY MANAGER
(DCC)

LOSS
PROCESS ENGINEERING MEDICAL
PREVENTION

EXTERNAL
MAINTENANCE SERVICES COMMUNICATIONS
RELATIONS

INCIDENT COMMANDER
(DCP)

OPERATIONS/
FIRE PROTECTION SECURITY MEDICAL ADVISOR
UTILITIES

LOSS PREVENTION
ENVIRONMENTAL
ENGINEER

February 1993 - B.3 Emergency/Disaster Planning And ResponsePage 591

FIGURE B.2: SCENARIO ANALYSIS SHEET FOR (LOCATION)

Unit/Equipment: ____________________________________ Scenario

No.: _________

Type of Emergency:
· ______Fire
· ______Explosion
· ______Flammable Gas
· ______Toxic Gas
· ______Hazardous Materials Spill
· ______Natural Disaster

A. Description of the Scenario:

_____________________________________________________
_____________

_____________________________________________________
_____________

_____________________________________________________
_____________

_____________________________________________________
_____________

B. Possible Causes:

_____________________________________________________
_____________

_____________________________________________________
_____________

_____________________________________________________
_____________

_____________________________________________________
_____________

February 1993 - B.3 Emergency/Disaster Planning And ResponsePage 592

 C. Expected Size or Duration:

_____________________________________________________
_____________

_____________________________________________________
_____________

D. Effect on Operations:

_____________________________________________________
_____________

_____________________________________________________
_____________

_____________________________________________________
_____________

E. Evaluation and Ranking:

_____________________________________________________
_____________

_____________________________________________________
_____________

· Likelihood: (1 = most likely)

·

No.____of____scenarios

· Consequences: (1 = most severe)

·

No.____of____scenarios

F. Location/equipment-specific notes:

____________________________________________________
______________

February 1993 - B.3 Emergency/Disaster Planning And Response Page 593

 ____________________________________________________
______________

Reviewed by: _________________________________ Date:

____________

February 1993 - B.3 Emergency/Disaster Planning And Response Page 594

FIGURE B.3: EMERGENCY/DISASTER CONTROL TASKS CHECKLIST

1. Warning

· Alarm/communication systems to alert employees and local

community of an emergency/disaster.

· "Alert", "Evacuation" and "All-Clear" signals must be

recognized by all affected population, and they must know
how to proceed in each case.

2. Pre-impact Preparation

If time permits, facility personnel must do the following to

minimize negative impact of an emergency/disaster:

· Notify emergency response organization.

· Call for all available material reserves and resources.

· Contact appropriate resource for weather data and other

emergency/disaster information

· Evacuate all affected areas.

3. Evacuation

· Evacuation of persons from affected areas and non-essential

workers from adjacent areas lowers the risk of casualties.

· Evacuation system testing and training.

· Control of access and exit points.

· Dead count requirements.

4. Mobilization and Utilization of Human and Material Resources

The effectiveness of an emergency response depends on the

quality and supply of human and material resources. These
resources must be:

February 1993 - B.3 Emergency/Disaster Planning And Response Page 595

 · Known in advance.

· Available on demand.

· Compatible with each other.

· Used in an organized and controlled manner.

5. Incident Suppression/Control

· Selective use of assembled resources.

· Training and experience of emergency response team

(especially Incident Commander).

6. Search and Rescue

· Identify likely search and rescue situations from generic

scenarios.

· Establish resources (qualified personnel and equipment) and

procedures to locate victims - and transport them to safety.

7. Care for Casualties

Factors to be addressed in the care, treatment and relocation of

casualties are:

· Access of medical personnel to site.

· Temporary hospital facilities and equipment.

· Transportation to move casualties to such facilities.

8. Communications

Efficient and accurate communications are a necessary part of

effective emergency response actions.

· Communication equipment/system in place.

· Back-up communications equipment/system.

February 1993 - B.3 Emergency/Disaster Planning And Response Page 596

 · Compatibility of facility communication equipment with that
used by mutual aid organizations.

9. Continuing Assessment

· Continuing assessment of the situation by knowledgeable

observers to redirect emergency/disaster response actions as
needed.

10. Coordination

· Coordination of call-out personnel and staging of resources to

ensure proper level of support is available where needed.

11. Control and Authority

· System of overall control and distribution of authority by

chain of command.

· Call-out list for management personnel.

· Personnel responsible to contact outside agencies and/or

mutual aid organizations.

12. Security

Adequate security personnel/system be in place to:

· Control traffic.

· Control access to scene of emergency/disaster.

13. Continuity of Operations

· Plan to continue operations unaffected by

emergency/disaster by manpower reassignment.

· Ensure that sufficient manpower/equipment is on standby to

handle escalation of emergency/disaster to other units.

February 1993 - B.3 Emergency/Disaster Planning And Response Page 597

14. Outside Community Order

Request Government Affairs representative to contact

appropriate law enforcement authorities and community leaders
to address the following:

· Evacuation, traffic and crowd control, guarding property and

patrolling dangerous areas.

15. Secondary Hazards

· The plan should identify hazards created as a result of the

emergency/disaster (e.g. structural damage to buildings,
isolated fires from explosions, downed electrical lines, etc.)

· Determine and plan to provide additional resources needed

to control these hazards.

16. Restore Normal Operations

· Maintenance personnel should maintain a current status list

of plant utilities and services lost during the
emergency/disaster and the estimated time to restore them.

17. Emergency Teams and Equipment Recovery

· System to check and replace emergency equipment damaged

during or immediately after the emergency/disaster.

· System to provide shift relief to emergency/fire fighting crews

and replenishment of fire fighting materials and other
consumables.

18. Personnel Needs

· Plan to provide emergency/disaster workers and other

affected personnel with sanitary food, water, clothing, shelter
and financial assistance as needed.

February 1993 - B.3 Emergency/Disaster Planning And Response Page 598

FIGURE B.4: FLOW DIAGRAM OF TYPICAL OFFSHORE EMERGENCY RESPONSE

EMERGENCY INCIDENT

1. INITIATE THE ALARM

2. REPORT THE EMERGENCY

3. ASSESS THE SITUATION

4. MOBILIZE RESOURCES

5. CONTROL THE INCIDENT

6. POST-INCIDENT ACTIONS

February 1993 - B.3 Emergency/Disaster Planning And Response Page 599

FIGURE B.5: EMERGENCY REPORTING INSTRUCTIONS

TELEPHONE: XXX-XXXX (if busy see below)

I have an emergency to report:

I am calling from
_____________________________________________________

My name is _________________________ My badge number is

_______________

I see a _____________________________________at
________________________
(fire, gas leak, etc.) (north/south/east/west)

There are ___________(no.) of people hurt and requiring medical

assistance.

DO NOT HANG UP. ENSURE THAT YOU HAVE A RESPONSE THEN

IF NECESSARY REPEAT THE ABOVE INFORMATION AND ANSWER
QUESTIONS.

1. If the number is busy or unavailable, try the following in the

order listed:

2. telephone xxx-zzzz

3. radio frequency xxx.xx

4. (other for the facility)

After the message has been given successfully, the reporting individual, if
an operator, should return immediately to the emergency site to do
whatever he can safely do to improve the emergency situation.

February 1993 - B.3 Emergency/Disaster Planning And Response Page 600

FIGURE B.6: EMERGENCY PLAN - SAMPLE TABLE OF CONTENTS

Suggested headings are shown below. Sections should be separated by

dividers with extended tabs naming each section.

I. Title Page
II. Reporting Emergencies
II. Emergency Response Personnel Roster
IV. Table Of Contents
V. Introduction
A. Scope
B. When To Implement
C. Definitions
VI. Emergency Response Organization
A. Chain Of Command
B. Functional Responsibilities
VII. Emergency Response Actions
A. Reporting Emergencies
B. Initiating The Alarm
C. Assess The Situation
D. Mobilization Of Resources
1. Internal Resources
a. Plant Personnel
b. Support Groups
c. Contractors
2. External Resources
a. Saudi Aramco
b. Non-Saudi Aramco
E. Suppression/Control of Incident
1. Vapor Release
2. Toxic Vapor Release
3. Fire
4. Explosion
5. Hazardous Materials Release
6. Natural Disaster

February 1993 - B.3 Emergency/Disaster Planning And Response Page 601

 7. Other Site Specific Incidents
VIII.Post-Incident Actions
A. Stand Down And Fire Watch
B. Investigate And Report
C. Restore Operations
D. Revise The Plan
IX. Appendices
A. Materials And Equipment Inventory
1. Emergency Equipment
2. Fire Fighting Supplies
3. Facility Maps, Plans, Drawings
4. Communication Equipment
5. Mutual Aid
a. Saudi Aramco
b. Non-Saudi Aramco
B. Exceptions To Generic Scenarios
C. Operating Instruction Manuals (OIMs) And Other
References

February 1993 - B.3 Emergency/Disaster Planning And Response Page 602

Appendix C: Fire Safety Checklist
For Evaluating
Construction Materials
Store Yard

February 1993 - Construction Safety Manual - Appendix C: Fire Safety Checklist Page 603
C.1 FIRE SAFETY CHECKLIST FOR EVALUATING
CONSTRUCTION MATERIALS STORE YARD
(Based on NFPA 231-APPENDIX C)
PROTECTION OF OUTDOOR STORAGE

I. SELECTION OF A SITE

A. Adequate fire department protection.

1. Travel time to site, primary factor.

B. All-weather roads adequate to carry fire department

apparatus.

1. Kept clear at all times.

C. Available water supply of sufficient pressure and quantity.

D. Sufficient clear space from combustible structures or other

storage which could be an exposure hazard.

E. No danger of flooding.

1. Run-off from fire fighting water should be

considered.

2. Drainage from fuel spills should travel away from all

storage.

F. Enough clearance from storage site to highways or major

roads.

II. FENCING SITE

A. Entire site should be fenced to control access.

B. Two 15' gates, directly opposite each other (180 o) are

required to permit ready access of fire apparatus to any part of
the storage area regardless of wind direction and location of fire.

February 1993 - C.1 Fire Safety Checklist Page 604

III. PILING OF MATERIALS

A. LOW HEIGHT and SMALL AREA are the ideal conditions.

1. Reasons for this are -

(a) stability of the pile under normal and fire

conditions (containers maximum: 2 high).

(b) access to the seat of the fire with hose

streams from the ground.

B. AISLES must be maintained between individual piles;

between piles and buildings, and between piles and the
boundary line fence for the storage site, to allow access to all
sides of the piles.

1. Aisles minimum of 10 feet wide.

C. DRIVEWAYS of minimum 15 feet width are required to

permit travel of fire apparatus to all parts of the storage area.

1. Driveway and aisle widths should be increased to at

least equal the height of piles of goods, since they
also act as firebreaks to limit the spread of fire.

D. ARRANGEMENT OF MATERIALS is important to reduce the

speed of the spread of fire.

1. Generally less hazardous materials should be stored

upwind and more hazardous materials downwind.

2. Piles or "blocks" of small piles are arranged with

combustibles and non-combustibles in alternate
locations -

(a) This technique tends to isolate a fire, allowing

greater chance to contain it within the pile or
"block" of origin.

February 1993 - C1 Fire Safety Checklist Page 605

 (b) This checker board pattern of materials also
helps reduce reliance on wind direction to
control the spread of a fire.

IV. BUILDINGS

A. Buildings within storage yards should be at least 50 feet from

the nearest storage pile.

1. This space should remain clear and free of

combustible materials, at all times.

B. ARRANGEMENT OF BUILDINGS should also consider the

effects of wind on the spread of fire.

1. One approach is to have less hazardous shops and

sheltered activities upwind, more hazardous ones
downwind.

2. In addition to the above, leave plenty of clear fire-

break space between buildings (50 feet minimum),
and alternate hazardous shops or stored goods with
those structures housing less hazardous goods or
activities. Again, this will help counteract
unfavorable winds.

V. FIRE PROTECTION

A. Communications -- a reliable means of communication with

the Saudi Aramco Fire Protection Department shall be
provided. Normally this will be a Saudi Aramco system
telephone.

WARNING: Prompt NOTIFICATION of the Fire Protection

Department is mandatory and absolutely necessary to
prevent out-of-control fires.

B. Portable fire extinguishers shall be provided throughout the

storage area and the buildings located as to be quickly
available for use at any point.

February 1993 - C1 Fire Safety Checklist Page 606

 C. Standard Live Hose Reels shall be provided throughout the
storage areas to allow fast application of firewater onto any
location within the store yard. These hoses are easily
handled by one man and can deliver significant quantities of
water. Full coverage of the interiors of all buildings must also
be provided.

WARNING:

1. The need to notify the Fire Protection Department

and man these live hose reels as fast as possible
cannot be over-emphasized.

(a) Fire areas increase as an increasing multiple of

time, not at a constant rate. The longer you wait
to apply water on a small fire, the more you will
be surprised at the size the fire has attained.

(b) These 1-1/4" diameter hoses allow one person to

apply about 100 gallons/minute without
difficulty.

2. Two inch steel (galvanized) lines shall be used to feed

these hoses. Each hose reel will have a valve at the
tie-in to the 6" loop.

D. Standard Fire Hydrants - Saudi Aramco Engineering Standard

B-7C requires type 509-G hydrants for protection of outdoor
storage. Depending on system pressure, the 2-1/2" hoses
used by the Fire Protection Department can require 4 to 5
trained men to handle. It is for this reason that fire hydrants
are not normally provided with hose or used by construction
yard personnel.

1. In areas where there is no Fire Protection

Department within reasonable distance, sufficient 2-
1/2" hose, and other equipment such as nozzles,
hydrant wrenches, etc. shall be kept on the site,

February 1993 - C1 Fire Safety Checklist Page 607

 suitably located, housed, and maintained ready for
use.

2. Hydrants and all fire fighting equipment shall be

accessible for use at all times. No temporary storage
will be allowed to obstruct access for fire fighting.

E. Details of Water Supply

Connect to main with gate valve.

Provide a looped system valved to feed hydrants from

either direction.

(Block valve(s) to isolate either 50% of the piping and

hydrants.)

Materials - carbon steel pipe, okay for temporary yards.

(Good mechanical strength, repairable.)

Size of loop piping, 6" diameter minimum.

VI. GUARD SERVICE

A. Guards trained in the use of live fire hose reels, fire

extinguishers and the fire warning system shall be on site at
all times when the yard is otherwise unoccupied.

1. Supervised rounds are suggested to verify the entire

property is periodically observed.
2. Means of communication necessary to summon
assistance during emergency situations shall be
provided.

VII. YARD MAINTENANCE AND OPERATIONS

A. The site shall be kept free from accumulation of unnecessary

combustible materials such as empty cartons or other
packing or packaging materials.

February 1993 - C1 Fire Safety Checklist Page 608

 B. All electrical equipment and installations to comply with
National Electrical Code.

C. Employees' smoking areas shall be clearly designated and no

smoking strictly enforced outside these "safe" areas.

D. Motor vehicles shall be garaged and repaired outside the

yard area, in a non-combustible structure or unsheltered.
Fuel handling shall comply with NFPA 30, Flammable and
Combustible Liquids Code, at a safe distance from the
storage yard.

A site layout plan of the materials storage yards shall be

submitted to the Loss Prevention Department Area Fire
Prevention Engineer for review. All essential features of this
"Checklist" shall be clearly illustrated on a site drawing of the
proposed yard. Two copies of this drawing (done accurately to
scale) will be submitted and once approved, one signed copy
shall be kept at the site for periodic review. Changes to the
original storage yard layout must be reviewed and concurred by
Loss Prevention Department.

February 1993 - C1 Fire Safety Checklist Page 609

Appendix D: Saudi Aramco Crane
Safety Handbook

February 1993 - Construction Safety Manual - Appendix D: Crane Safety Handbook Page 610
D.1 CRANE SAFETY HANDBOOK
Notice:

For utility, the crane safety handbook is bound under separate

cover. One copy will be distributed to each holder of the
Construction Safety Manual. Additional copies may be acquired
by contacting the Support Services Unit, Loss Prevention
Department, E-1660, Dhahran.

February 1993 - Construction Safety Manual - Appendix D: Crane Safety Handbook Page 611
Appendix E: Suggestion Form

February 1993 - Construction Safety Manual - Appendix E: Suggestion Form Page 612
 SUGGESTIONS FOR THE SAUDI ARAMCO
CONSTRUCTION SAFETY MANUAL

MANAGER, Loss Prevention Department

Saudi Arabian American Oil Company
E-1770
Dhahran, Saudi Arabia

Please consider the following suggestion(s) relative to the Saudi Aramco

Construction Safety Manual:
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
_________________

February 1993 - Appendix E: Suggestion Form Page 613

_______________________________________
(Signature)

________________________________________
(Date)

________________________________________
(Address)

________________________________________
Contact Telephone Number

________________________________________
Contact FAX Number

February 1993 - Appendix E: Suggestion Form Page 614

Appendix F: Distribution Form

February 1993 - Construction Safety Manual - Appendix F: Distribution Form Page 615
 Address For Distribution
Construction Safety Manual

MANAGER
Loss Prevention Department
Saudi Arabian Oil Company
E-1770
Dhahran, Saudi Arabia

Please continue to send me changes or additions to the Saudi Aramco

Construction Safety Manual.

My present address is:

Name:_______________________________________________________
___________________

Company:____________________________________________________
___________________

Address:_____________________________________________________
___________________

_____________________________________
(Signature)

____________________________________
(Date)

________________________________________
Contact Telephone Number

________________________________________
Contact FAX Number

February 1993 - Appendix F: Distribution Form Page 616

Appendix G: Sanitary Code

February 1993 - Construction Safety Manual: Appendix G: Sanitary Code Page 617
IMPLEMENTING THE SAUDI ARAMCO SANITARY CODE -
GI 151.006

SASC-A-010 INDOOR AND OUTDOOR RECREATION

AREAS AND FACILITIES, INCLUDING
BEACHES, CAMPGROUNDS AND MARINAS

SASC-C-010 CAMPS AND COMMUNAL LIVING

FACILITIES

SASC-F-010 FOOD ESTABLISHMENTS

SASC-P-010 SWIMMING POOLS, WADING POOLS AND

SPAS

SASC-R-010 SOLID WASTE MANAGEMENT

SASC-S-010 WASTE WATER AND SEWERAGE SYSTEMS

SASC-W-010 WATER

February 1993 - Appendix G: Sanitary Code Page 618

Appendix H: General Instructions
Master Index

February 1993 - Construction Safety Manual: Appendix H: GI Master Index Page 619
GENERAL INSTRUCTIONS (GI) MASTER INDEX

GI Number Title

2.100 Work Permit System

2.102 Pressure Testing Safely

2.702 Electrical Safety for Boom or Derrick Type Hoisting

Equipment

2.708 Gas Testing Procedures

2.710 Mechanical Completion & Performance Acceptance of

Plant/Unit

2.711 Fire and Safety Watch

2.718 Contractor Sites Allotment Procedure

5.002 Loss Prevention Policy Implementation

6.001 Notification Requirements for Incidents (Including Fires)

6.003 Guide for Committees Investigating Major Incidents or

Engineering Reviews of Other Incidents

6.012 Isolation, Lockout and Use of Hold Tags

6.020 Personal Flotation Devices for Work Over, On or Near

Water

6.021 Safety Requirements for Abrasive Blast Cleaning

6.025 Control of Remote Area Travel and Search/Rescue

Procedures

6.029 Reporting and Recording of Motor Vehicle Accidents

6.030 Traffic and Vehicle Safety

February 1993 - Construction Safety Manual - Appendix H: GI Master Index Page 620
 7.025 Mobile Heavy Equipment Operator Testing and
Certification

7.026 Lifting/Elevating and Mobile Equipment Accident

Reporting Procedures

7.027 Personnel Work Platform Operations

7.028 Heavy Crane Lift, Multiple/Tandem, Critical Crane Lifts

7.029 Inspection, Testing and Maintenance of Wire Rope Slings

7.030 Inspection and Testing of Cranes, Elevators, Powered

Platforms, and Mobile Aerial Baskets

8.001 Safety Requirements for Scaffolding

8.002 Prescription Safety Glasses

8.003 Air-Supplied Breathing Apparatus

8.005 Protective (Safety) Footwear

70.500 Disaster Contingency Plan - Dhahran Area

80.500 Disaster Control - Refinery and Terminal - Ras Tanura

150.001 Asbestos Regulations

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

150.003 Ionizing Radiation

151.006 Implementing the Saudi Aramco Sanitation Code

330.87 Bulk Deliveries of Oil Field Treatment Chemicals from Local

Vendors

355.001 Identifying, Cataloging, Ordering and Tracking Hazardous

Materials

February 1993 - Appendix H: GI Master Index Page 621

 355.002 Receiving, Storing and Issuing Hazardous Material

355.003 Disposing of Hazardous Material

355.004 Handling and Disposing of Polychlorinated Biphenyls

(PCBs)

355.015 Requisitioning, Receiving, Storing and Issuing Explosives

355.015-01 Deterioration and Disposal of Explosives

355.020 Control of Compressed Gas Cylinders

401.081 Performance Qualifications For Welders and Welding

Operators

402.001 Operational Chemical Cleaning of Boilers

432.00 Pipeline Hydrotest Water Disposal

434.00 Pipeline Repair and Maintenance

441.014 Repair Procedures on Hydrocarbon Pipelines

447.002 Pressure Relief Valves - New Installation, Change in Set

Pressure, Replacement or Retirement from Service

447.003 Pressure Relief Valves - Routine Tests, Inspection, Quality

Assurance and Regulation

475.001 Blasting Near Existing Facilities

475.002 Use of Explosives in Construction

520.001 Confined Space Entry Procedure

618.001 Special Regulations for the Use of Explosives in Seismic

Operations

1021.000 Street and Road Closure, Excavation, Reinstatement and

Traffic Controls

February 1993 - Appendix H: GI Master Index Page 622

 1127.700 Transportation Engineering Procedures for Heavy-
Lift/Over-Sized Equipment

1130.013 Vehicle Loading

1131.165 Use of Trailer Brakes

1131.921 Use of Trailer Safety Chains

1183.215 Transporting Explosives in Company

Owned/Leased/Rented Motor Transport Vehicles

1185.003 Death or Injury Aboard Seagoing Vessels

1186.502 Marine Craft Fueling, Tanajib or West Pier

1186.504 SAG Regulations and Practice as Applied to All Types of

Marine Craft at the Port of Ras Tanura

1187.001 Collision & Damage By or To Marine Equipment or Craft

1192.001 Operating Practices for Harbor Tugs, Offshore Vessels and

Launches, Including Safety Rules

1192.002 Operating Procedures for Barges Including Safety Rules

1192.502 Operating Procedures for Marine Oil Recovery and Storage

Barge/Vessel, Including Safety Rules

1193.001 Marine Port Information and Regulations

1193.002 Navigation Warnings

1194.001 Requesting, Assigning and Dispatching Pollution Control

Vessels, Tugs, Launches and Barges

1196.001 Whistle Signals for Use Between Tugs and Barges or Tugs
and Self-Propelled Vessels When Berthing

1197.001 Procedures and Safety Rules for Diving Operations

February 1993 - Appendix H: GI Master Index Page 623

 1198.001 Rig/Barge Moving

1199.001 Safe Operation of Self-Propelled Jack-Up Barges

1310.000 Transportation of Dangerous Articles Onboard Saudi

Aramco Aircraft

1321.015 Request for Air Medical Evacuation

1600.003 Destruction of Obsolete/Damaged, Unneeded

Communication Equipment

1601.002 Radio Asset Control And Accountability Program (RACAP)

1602.001 Residential Telephone Service

1602.002 Business Telephone Service Inside Aramco Communities

and Facilities

1602.003 Business Telephone Service Outside Aramco Communities

and Facilities

1603.001 Data Circuits, Message Switch And Facsimile Terminals

1781.001-1 Inspection/Maintenance - Fire Protection Equipment

1787.00-1 Fire Reports

February 1993 - Appendix H: GI Master Index Page 624

Appendix I: List Of Figures

February 1993 - Construction Safety Manual - Appendix I: List Of Figures Page 625
LIST OF FIGURES
I. Administration:
Figure I.1 Preliminary Accident Report 14
Figure I.2 Contractor Monthly Safety Report 15
Figure I.3 Injury Summary 41
Figure I.4 Protective Goggle, Spectacles, Face 48
Shields And Helmets
Figure I.4A Protection Against Radiant Energy 49
Figure I.5 Specialized Hand Protectors 50
Figure I.6 Typical Self-Powered Platform For 51
Building Maintenance
Figure I.7 Respiratory Protection 58
Figure I.8 Clearance Considerations For Safety 59
Equipment
Figure I.9 Know Your Fire Extinguisher 66

II. General And Civil:

Figure II.1 Hold Tag 94
Figure II.2 Lockout Clip (Typical) 95
Figure II.3 Excavations Made In Type A Soil 106
Figure Simple/Multiple Bench 107
II.3A
Figure Unsupported Vertically Sided l08
II.3B
Figure II.4 Excavations Made In Type B Soil 109
Figure Single/Multiple Bench 110
II.4A
Figure II.5 Excavations Made In Type C Soils 111
Figure II.6 Excavations Made In Layered Soils 112
Figure Excavations Made In Layered Soils 113
II.6A
Figure II.7 Examples Of Trench Shields 114

February 1993 - Appendix I: List Of Figures Page 626

 Figure II.8 Guide To Safe Distance Back From Top Of 115
Slope For Storage Of Materials Or Placing
Equipment
Figure II.9 Examples Of Screw Trench Jacks 116
Figure Aluminum Hydraulic Shoring Typical 117
II.10 Installations
Figure Aluminum Hydraulic Shoring 118
II.11
Figure Aluminum Hydraulic Shoring Waler 119
II.12 Systems For Soil Type B
Figure Example Of Timber Shoring Protective 120
II.13 Systems
Figure Timber Trench Shoring - Minimum Timber 121
II.14 Requirements
Figure Timber Trench Shoring - Minimum Timber 122
II.15 Requirements
Figure Timber Trench Shoring - Minimum Timber 123
II.16 Requirements
Figure Standard Coupler 167
II.17
Figure Adjustable Coupler 167
II.18
Figure Typical End To End Coupler 167
II.19
Figure Screwjack 167
II.20
Figure Typical Reveal Pin 167
II.21
Figure Typical Base Plate 167
II.22
Figure A Typical Independent Tied Scaffold 185
II.23 Constructed Using Tube And Coupler
Scaffolding
Figure A Typical Tube And Coupler Scaffold 186
II.24
Figure Plan View Of Two-Way Tie 187
II.25

February 1993 - Appendix I: List Of Figures Page 627

 Figure Plan View Of Column Box Tie 187
II.26
Figure Plan View Of Reveal Tie 187
II.27
Figure A Typical System Scaffold 188
II.28
Figure A Typical System Scaffold Being 189
II.29 Assembled
Figure A Typical System Scaffold Base In The 189
II.30 Process Of Being Assembled And Leveled
Figure A Typical Fabricated Tubular Frame 190
II.31 Manually Propelled Mobile Scaffold
Figure A Typical Tube And Coupler Mobile Access 191
II.32 Tower
Figure Cross Tube Anchor 192
II.33
Figure Outriggers In Use 192
II.34
Figure Driven Tube Anchor 192
II.35
Figure Abrasive/Grinding Wheel 200
II.36
Figure Grinder Guards 201
II.37
Figure Bench Grinder - Machine Guarding 202
II.38
Figure Ring Test 211
II.39
Figure Correctly Mounted Wheel 212
II.40
Figure Wire Conversion Chart 213
II.41
Figure Self Adjusted Guard 214
II.42
Figure Table Saws 215
II.43

February 1993 - Appendix I: List Of Figures Page 628

 Figure Table Saw - Machine Guarding 216
II.44
Figure Radial Saws 217
II.45
Figure The Woodworking Machine Regulations 218
II.46
Figure Cartridge/Tool Issuance Control 219
II.47

III. Mechanical Equipment And Materials:

Figure III.1 Pre-Lift Operation Checklist 241-242
Figure III.2 Lift Plan For Cranes 243
Figure III.3 Identification Tags 252
Figure III.4 Installing A Wedge Socket On A Rope 253
Figure III.5 Two-Legged Chain Sling: Major 253
Components
Figure III.6 Sling Fixings 253
Figure III.7 Synthetic Webbing Slings 254
Figure III.8 Sling Loading 255
Figure III.9 Eyebolts 255
Figure Crane Hooks 255
III.10
Figure Shackles 255
III.11
Figure Wire Rope Sling Inspection Log 256
III.12
Figure Typical Construction Materials Store Yard 272
III.13

IV. Electrical And Radiation:

Figure IV.1 Temporary Crossing For Construction 293
Equipment
Figure IV.2 Proper Use Of Insulating Tools And 294
Protective Apparel
Figure IV.3 Standard Sign - Radiation 299

February 1993 - Appendix I: List Of Figures Page 629

V. Chemicals And Operations:
Figure V.1 Identification Of Materials By Hazard 326
Signal Dimensions And Arrangement
Figure V.2 Explanation Of Hazard Rating Codes 327
Figure V.3 Identification Of Health Hazard, 328
Flammability And Reactivity

VI. Marine:
Figure VI.1 If You Work Over, On Or Near Water 336
Figure VI.2 International Code Flag "A" 348
Figure VI.3 Signals 348

Appendix A:
Figure A.1 Contractor's Competition Job 355-356
Safety Evaluation

Appendix B:
Figure B.1 Typical Emergency Organization Chart 387
Figure B.2 Scenario Analysis Sheet For (Location) 388
Figure B.3 Emergency/Disaster Control Tasks 389
Checklist
Figure B.4 Flow Diagram Of Typical Offshore 393
Emergency Response
Figure B.5 Emergency Reporting Instructions 394
Figure B.6 Emergency Plan - Sample Table Of 395-396
Contents

February 1993 - Appendix I: List Of Figures Page 630

Appendix J: List Of Tables

February 1993 - Construction Safety Manual: Appendix J: List Of Tables Page 631
LIST OF TABLES
I. Administration:
Table I.1 Basic Personal Protective Equipment 48

II. General And Civil:

Table II.1 Maximum Allowable Slopes 105
Table II.2 Wood Scaffold Plank Loading 166
Table II.3 Tube And Coupler Scaffolds - Light 176
Duty
Table II.4 Tube And Coupler Scaffolds - Medium 177
Duty
Table II.5 Tube And Coupler Scaffolds - Heavy 178
Duty
Table II.6 Ventilation Requirements For 223
Confined Spaces
Table II.7 Personal Protective Equipment To Be 227
Worn Or Used During Surface
Preparation And Paint Application

III. Mechanical Equipment And Materials

Table III.1 Wind Speed (Miles Per Hour) vs. Force 244
Of Wind In Pounds Per Square Foot
Table III.2 Wind Speed Definition 244

February 1993 - Construction Safety Manual: Appendix J: List Of Tables Page 632
Appendix K: Forms

February 1993 - Construction Safety Manual: Appendix K: Forms Page 633

· Appendix K contains originals of many of the forms which have
appeared as figures throughout the Manual. Please copy these for
use in your safety program.

February 1993 - Construction Safety Manual: Appendix K: Forms Page 634

PRELIMINARY ACCIDENT REPORT:

Detailed Report Required Within 3 Days Control No_________________

Accident Location: Date Of Accident: Time Of Accident:

Company: Personnel Injured: Badge Number:

Type Of Injuries: Property Damage And Estimated

Cost Damage:

Description Of Accident:

Witness Statement(s)

What Caused The Accident:

What Corrective Action Has Been Taken

Signed:_______________________________________________________________
Badge No:________________________

Date Of Report:________________________________________________

Name
(Printed):______________________________________________________________
_______

Company:___________________________________________________ Job
Title:_________________________________
CONTRACTOR MONTHLY SAFETY REPORT
PROJECT TITLE:___________________________________
LOCATION:_________________________________

CONTRACTOR:___________________________________________________________________
____________________

BUDGET ITEM No:._______________________________________ CONTRACT

No.:________________JOB No:_______

1. Work Injuries:

2. Fires:

3. Incidents Or Property Damage (Over SR 10,000):

4. Motor Vehicle Accidents:

5. Incidents Involving Damage To Saudi Aramco Equipment:

6. Crane, Heavy Equipment & Manlift Accidents:

7. Safety Meeting:

(A) Topics Discussed:

1.
2.
3.
4.
5.
(B) Attendance:
 (C) Instructor(s):

Prepared By:_____________________________ Contractor Safety

Officer:_____________________________________

Signed By:____________________________________ Saudi Aramco

Representative:____________________________

Date:___________________________
INJURY SUMMARY (PAGE ___OF___)
Project:__________________________________Project No.:________________________Month &
Year:____________________
Contractor:__________________________________File No.:_________________________

Injur Name Of Badg Craft Date Of Carry Days Nature Of Injury Brief Description Of Accident
y No. Injured e Accide Over Lost And Part Of Body State What, Where, How, Why
Num nt Yes/No This Affected
ber Mon
th
 Total Lost Time Total Total Man-hours
Injuries This Days Worked This Month:
Month: Lost:

Report Prepared By:________________________________

Signature:_________________________________

Title And Telephone:_______________

LIFT PLAN FOR CRANES
1. Contractor:__________________________________________________ J.0.
No.:_____________________________________________
2. Crane Inspection Sticker valid: Yes: No: Date of
expiry:________________________________________________________________
3. Operator Saudi Aramco certified: Yes: No: 4. Description of
load:___________________________________________________
5. ·Type of crane to be used Stowed Erecte N/A (lbs/kg
______________________ d s)
·Boom length (total) Jib:    ______
_______________________ft/m _
·Jib length Extension:    ______
____________________________ _
__ft/m
Hookblock (Main): ______ _____ _____ ______
_
Aux. Boom Head: ______   ______
_
Headache Ball: ______   ______
_
Slings, Shackles, ______ ______ ______ ______
etc.: _
Others: _________________________ _______
_________
_________________________ _______
_________
Total (Gross Load
Weight): _______
 6. · Weight of load · Effective weight of jib _____ lbs/kgs (see
_______lbs/kgs jib chart)
· Effective weight of jib headache ball · Weight of load block _____ lbs/kgs
______ lbs/kgs
· Weight of hoist rope below boom · Weight of spreader bar _____ lbs/kgs
tip______ lbs/kgs
· Weight of other rigging
______ lbs/kgs
Total load weight _____ lbs/kgs
7. Hoisting clearance ________ft/m. 8. Lift quadrant zone ___________________ . 9. Operating radius
___________ft/m.
10. Crane capacity at operating radius __________ (Note: Do not make lift if total load is greater than crane
capacity shown in Item 10. Refer to GI 7.028 for appropriate derating based on type of lift.)
11. Crane capacity for jib configuration:____________ 12. Ground and site
conditions:______________________________________________
13. Wind speed:__________mph (Maximum 20 mph)
14. Work permit required: Yes No:
15. Load moment indicator: Yes: No: Type:_________________________________________
16. Sketch and supplementary information for crane lift is required to be attached to this plan. (Note: The
sketch of the crane should include the following rigging information: size of each component; safe working
load (SWL) capacity; length of slings; type of component; component diameter; weight of component and
sling angles).
Contractor:______________________ Date:__________________ Crane Operator:_______________________
Date:__________________________
Approved:_______________________ Date:__________________ Reviewed by:_____________________
Date:_____________________________
(Competent Person) (Saudi Aramco Site Representative)
Approved:_______________________ Date:__________________
(Heavy Haul/Rig Move Unit, Transportation Dept., Abqaiq)
Footnote: This form is to be filled out for the following lifts: 1. At all construction sites and operating plants;
2. Associated with offshore and marine sites and operations; 3. Within safety zones of power lines; 4.
Involving personnel platforms (as per GI 7.027, 7.028 and 7.030).
WIRE ROPE SLING INSPECTION LOG
Contractor:______________________________________ Location: __________________________

BI/JO Number: ___________________________________ Project Title: ______________________

Sling# Diameter Length SWL Date-In Date-Out- Inspector Signature

Service Service (Date)
CARTRIDGE/TOOL ISSUANCE CONTROL

Cartridge Quantity Received By

Dat Issue Return Return Return Tool Cert Name/ Issued By Remarks
e d ed ed ed Un- Issued No. Signatu
Used Unuse explod (Type/M re
d ed DL)
Warning: Above items can only be issued to workers with valid training certificate Storekeeper:
Safety Officer:
EMERGENCY REPORTING INSTRUCTIONS
TELEPHONE: XXX-XXXX (if busy see below)

I have an emergency to report:

I am calling from _____________________________________________________

My name is _________________________ My badge number is _______________

I see a _____________________________________at
________________________
(fire, gas leak, etc.) (north/south/east/west)

There are ___________(no.) of people hurt and requiring medical assistance.

DO NOT HANG UP. ENSURE THAT YOU HAVE A RESPONSE THEN IF

NECESSARY REPEAT THE ABOVE INFORMATION AND ANSWER
QUESTIONS.

1. If the number is busy or unavailable, try the following in the order

listed:

2. telephone xxx-zzzz

3. radio frequency xxx.xx

4. (other for the facility)

After the message has been given successfully, the reporting individual, if an
operator, should return immediately to the emergency site to do whatever he can
safely do to improve the emergency situation.
PROJECT MANAGEMENT AND CONTRACTOR'S SAFETY
COMPETITION SITE REGISTRATION FORM
To: Saudi Aramco Loss Prevention Department Date:
____________________________

Name Of Contractor: Contractor's Contractor's Phone

Address: Number:

Job Description: Job Number: Starting Date:

Estimated Completion
Date:
B.I. Number:
Peak Number Of
Employees:

Contractor Site Saudi Aramco Site Project Mgmt.

Representative: (PMT) Engineer: Department:

Telephone Number: Telephone Number: Org. Code:

Name Of Contractor's Contractor's Site Site Location:

Safety Representative: Phone Number:

Signed:____________________________________________________(C
ontractor's Representative)

Job Title:__________________________________________________

Company:__________________________________________________
Date:_______________________________________________________

Saudi Aramco Proponent

Department:__________________________________________________
__

This form is to be completed and sent to the local Saudi Aramco Loss
Prevention Office with a copy to the designated senior Project Engineer,
who is a member of the proponent Project Management Team (PMT).

Signed:________________________________________
Saudi Aramco Project Manager

February 1993 - A.1 Safety Competition Site Registration Form Page 650