13 environment clauses-facilitiespetrochemicals

Buildings Practice Facilities Plants/PetrochemicalsChapter 13

Environment Clauses For Plant IndustryEnvironmental clauses for plant

Industrial city on construction contracts1 Environmental guidelines & environmental protection criteria (EG&EPC) for plant industrial city,

national environmental protection law and environment and natural reserves standards shall be complied with by contractor and its subcontractors operating within boundaries of plant.

2 Contractor shall comply with all applicable rules and regulations pertinent all relevant agencies having jurisdiction, which now exist or which may come into effect during course of work, relating to environmental protection and management.

3 Contractor warrants that it shall use its best endeavours to protect and to take care of all environmental and natural resources in order to prevent environmental pollution of whatever kind, resulting directly or indirectly from work performed under contract.

4 Notwithstanding any provisions contained within contract, contractor shall assume all liabilities for environmental and human health damage of whatever kind, arising directly or indirectly from work, shall indemnify company/client, hold them harmless from and against any and all losses, claims, demands, costs, proceedings, damages, charges and expenses, howsoever arising therefrom, whether or not, caused by negligence, in whole or in part.

5 Without relieving contractor of any of its obligations detailed herein or as imposed by any relevant agency, authority or any other body having jurisdiction, company/client may take part to any degree it deems necessary, in control, removal and remedy of any pollution or contamination, which is responsibility of contractor, under foregoing provisions or which is due to whatever act or omission, directly or indirectly, of contractor’s misconduct.

6 Contractor shall reimburse company/client for cost thereof, provided always that amount of all such cost may be deducted by company/client from whatever money due or becoming due to contractor.

7 Contractor shall furnish following documents for approval of company/client at least four (4) weeks prior to commencement of work at construction site.a Waste management planb Environnemental management planc Spill contingency plan

1 Contractor shall provide company/client with material safety data sheets (MSDS) for all chemicals/materials (where applicable) it shall use or supply prior to shipment.

2 Contractor shall dispose of all waste including, but not limited to packaging, discarded material, unspent and serviced material in an environmentally, acceptable and approved manner.

3 Contractor shall take immediate corrective action(s) to remedy one and all occurrence(s) of environmental pollution and report such incident(s) per environmental incident reporting requirement for plant.

4 Company/Client is entitled to impose such penalty as specified within environmental guidelines & environmental protection criteria for plant industrial city (plant), should contractor fail to take appropriate corrective action (s) or to report such incident.

5 In case of an environmental incident, company/client may take action to investigate incident, assess its impact and/or take necessary corrective action/to recover cost involved by such action from contractor.

6 Contractor shall complete and submit an environmental discharge form (in accordance with relevant exhibit) to company/client prior to commencement of demobilisation.

7 Demobilisation may only, commence upon authorization /approval of this form by company/client.

Preventive Measures Health, Safety, Environmental & Security

Standard Procedures/Hazard Control1 This procedure is applicable to all projects construction site activities.

of 75 2012 Int. P Eng Suraj Singh


Environment Clauses For Plant IndustryPurpose 1 Objective is to establish a procedure for systematically, identifying all hazards/risks associated with a

task or job and to implement appropriate control measures.

Preventive Maintenance 1 It is of utmost significance for such an industrial project, which must be kept in full considerations,

while conceptualizing whole scheme. 2 There should be a session of brain storming to find out causes & solutions for meeting every hazard

that may crop in, during operational life of project. 3 Every risk must be analysed, for involved miscalculation may lead to intensive fire breakout

resulting in losses of billions of dollars as well as, severe human loss. 4 There are nowadays several methods given in industrial safety as well as, loss prevention methods

for disaster management to prevent such mishaps. 5 Present scope of this book does not allow that literature to be elaborated, but informatively included. 6 Let us divide whole plant industrial area into various zones depending on defined & expected risks. 7 Process area, non process areas, explosive zone, secured zone, administrative zone, environment

unsafe zone etc.

Process areas1 Process area can be confined to real operative equipment trains zone, which is a pure chemical

product engineering portion, comprising of all vessels involving oil & its storage. 2 This is only major potential source, leading plant to major fire as well as, explosion hazards. 3 All equipments must be made fireproof to maximum extent possible. 4 Buildings contained in such zone must be made blast resistant. 5 All arrangements pertinent fire suppression must be provided. 6 Proper arrangements must be made for all personnel to use safety devices of all kinds depending of

nature of hazard, so that all users wear preventive dressing/equipment.

Hot & Cold Works 1 Hot as well as cold works areas are defined explicitly for purpose of preventive adaptation as well as,

for issuing permits to work within & without plant for engineering construction works in future. 2 Safe procedure must be defined elaborately for such activities. 3 No work should be allowed without granting of such work permits. 4 Lost gases or other products or bye products have potential to spread into environment air

consequently, transferring fire possibility, a detailed study of which consideration should be conducted to find a resolution to chart out suppression measures.

Non process areas1 Non process areas should be located distant enough say anything far up to 700 m from real trains, so

as adverse effects are not relocated to this zone, which requires only, blast resilience structures. 2 Accordingly, fire suppression & blast control provisions should be applied to constructions as well

as, precautionary measures be defined for action by personnel. 3 Circulatory areas should be defined in between process & non process areas that cannot be definitely

delineated, but shall carry piping, traffic, roads & many other components pertaining plant. 4 Accordingly, provisions should be charted out/provided for disaster management. 5 Most important aspect is control from fire everywhere, for defining which, regular mockups should

be conducted on site. 6 Assembly points should be clearly defined at various locations that shall allow, following fire alarm

to assemble & await further directions from fire wardens. 7 Immediate medical attendants & ambulance service should be provided.



Environment Clauses For Plant Industry8 Piping routes must be defined within declared corridors, equipped with proper fire protection &

guards. 9 No unauthorized person should be allowed movement within defined corridors.

Storage area1 Storage area particularly, of oil raw material must be provided full protection from firing &

explosion viewpoint. 2 This is actually a very high potential source of fire, which can cause heavy losses to industry as well

as, to humans.3 In case of fire disaster, adequate effective arrangements must be made available fully functional all

times to vacate personnel as soon as, possible from assembly points & further escorted off plant to safer locations.

4 All classes of fire suppression arrangement must be kept fully functional at relevant hazard locations, clearly defined to personnel involved & competent fire fighting team made available/mobilised.

5 Regular training & mock ups drills must be conducted to keep involved humans alert to meet an unforeseen as far as, all adverse effects during an occurrence of earthquake are concerned,

Fire ProtectionIntroduction 1 Contractor shall design fire protection system based on this specification. 2 Fire protection installations shall include all required systems and equipment for adequate protection

of process and utilities areas. 3 Design and engineering of firefighting systems shall consider plant layout, isolation philosophy,

inventories & critical equipment.

Fire Hazard Analysis study 1 Design of firefighting systems shall consider effectiveness of individual agents.

2 Water fire extinguishing, exposure protection and cooling, fire intensity control, ignition prevention and prevention of vapor cloud formation.

3 Foam securing and extinguishing of spill fires in plant.

4 CO2 gas fire extinguishing by means of oxygen reduction inside enclosures.

5 Dry chemical powder control and extinguishing small flammable liquid spill fires and gas flash fires.

6 Inert gases ‘Inergen’ is one product recognised as environmentally, safe to be used for Halon.

7 It is composed of naturally occurring gases nitrogen, argon and CO2.

8 Inergen may be used, where an electrically, nonconductive medium is required.

9 Inergen systems are designed and installed complying NFPA-2001.

10 IG-541 is name of Inergen in NFPA 2001.

11 Use of Inergen is subject to ‘room integrity overpressure testing’.

12 In manned areas, a qualified pre alarm status must be in place.

13 Fire proofing, layout, isolation with bunding and catchment shall also, be considered.

Codes and Standards 1 It shall be contractor's responsibility to be knowledgeable about requirements pertaining relevant

international codes and standards.



Environment Clauses For Plant Industry2 Following latest edition codes and standards to full extent specified herein, which shall be used as a

minimum & those codes not included herein shall also, constitute provisions applicable to this contract, therefore, contractor should search self to find all relevant missing codes a National fire protection association (NFPA) b NFPA 10 Portable fire extinguishers c NFPA 11 Low-expansion foam d NFPA 11C Mobile foam apparatus e NFPA 12 Carbon dioxide extinguishing system f NFPA 13 Installation of sprinkler system g NFPA 15 Water spray fixed systems h NFPA 20 Installation of centrifugal fire pumps i NFPA 24 Private fire mains j NFPA 30 Flammable and combustible liquids code k NFPA 70 National electric code l NFPA 72 National fire alarm code m NFPA 850 Electric generating plants n NFPA 2001 Clean agent fire extinguishing system

Reference Documents 1 Project specifications, architectural design basis, fireproofing, electrical design guidelines, power,

control and earthling cables, technical specifications for piping systems, general piping process and utility design, layout and drawing, design and installation of glass fibre reinforced epoxy and polyester piping, combustion gas turbines, painting, galvanising, fire and gas detection system, system cables, CCTV philosophy, building management systems, preservation and export packing, safety equipment specification, criticality rating calculation method, shop inspection and test requirements , health, safety and environmental philosophy, project drawings:

2 Fire protection general plant, fire water diesel pump

Document Precedence 1 Contractor shall notify company of an apparent conflict between this specification, related

datasheets, codes and standards and all other specifications noted herein. 2 Resolution/s and/or interpretation precedence shall be obtained from company in writing before

proceeding with design/manufacture. 3 In case of conflict, order of precedence shall be as indicated below: a Datasheet(s), narrative specification, project specifications and standards, industry codes and standards,

specification deviation/concession control

4 Contractor only, through concession request format shall seek technical deviations to this specification and its attachments.

5 Concession requests require company's review/approval prior to proposed technical changes being implemented.

6 Technical changes implemented prior to company approval shall be subject to rejection.

Quality Assurance and Quality Control 1 Quality management system shall comply with applicable requirement of ISO 9001.

2 Purpose of description herein is to determine factory inspection and testing requirements for fire protection equipment, fire detection equipment, gas detection equipment and alarm system equipment including control panels that should be listed within project specifications.

3 Level of shop inspection and test requirements is defined.



Environment Clauses For Plant Industry

Description Fire protection and extinguishing system shall include (but not be limited to): 1 Water supply and distribution system, including pumps, mains, hydrants, monitors, hose boxes, hose

reel stations and fire point shelters. 2 Water spraying systems for process equipment. 3 An automatic CO2 fire suppression system inside gas turbine enclosures. 4 Fire, smoke and gas detection with alarm systems in process areas. 5 Automatic fire suppression systems protecting vital equipment inside buildings. 6 Portable extinguishers (dry chemical powder, carbon dioxide and water) and other movables. 7 General building protection (manual call points, hose reels and portable fire extinguishers)8 Fire training facility

Basis of Fire Protection 1 Basic objectives for fire protection is to either limit or prevent escalation of a fire, avoiding risk to

life and minimizing material damage, until source of hazard has been isolated or consumed. 2 Fire protection shall mainly be provided by automatically and manually, operated fixed installed

systems in conjunction with portable and mobile firefighting equipment.

Requirements 1 Fire prevention and protection measures shall be considered during all stages of plant design. 2 Process and equipment design shall be assumed as following good engineering practices, such as

sufficient spacing of equipment, incorporation of emergency shutdown system, relieving system, drainage systems and other special safety considerations for individual process requirements.

3 Equipment arrangement and distances between fire hazardous equipment shall be set, so that in event of a fire, possibilities for escalation are minimized

4 However, within an operational complex, it is not always feasible to achieve complete separation of equipment.

5 Consequently, additional precautionary measures for fire protection shall be evaluated and submitted for company approval.

6 This applies particularly, to those areas, where a chimney effect may occur. 7 For example, a minor fire at a pump may affect overhead equipment causing fire to rapidly develop. 8 Also, updraft associated with air cooled heat exchangers may cause fire to spread.9 Design of firefighting system shall be based on assumption that no firefighting equipment and no

manpower for fighting fires, from outside plant shall be available in case of a fire. 10 A fire within plant shall be controlled or extinguished by plant fire brigade, using plant fire engines

and plant firefighting equipment and devices. 11 Philosophy for designing fire protection facilities is to utilize automatic systems and mobile

equipment, which require a minimum number of firefighters. 12 Access shall be provided for firefighting particularly, for equipment handling flammable liquefied

gases or flammable products at or above auto ignition temperature and seal/luboil units of rotating equipment.

13 Some equipment shall be protected with water spray systems to remain in operation, until fire brigade arrives to determine appropriate method of extinguishing attack.

14 Quantity of water required for fire protection shall be based on consideration that it is required to control and possibly extinguish one major fire situation at a time under following conditions: a Operation of deluge systems in zone on fire (or at least 1 monitor), b Operation of deluge systems of 2 adjacent zones if (or at least 2 monitors) and 2 hydrants (or 2

monitors).



Environment Clauses For Plant Industry15 Note: for large complex units, quantity of water required for fire protection shall be based on fire

hazard analysis study and QRA, which should determine “worst case scenario”. 16 Detection systems shall be installed in all relevant areas (process units and buildings) to detect fire,

smoke and gas. 17 Detection systems shall, where required activate fire protection systems or raise an alarm for action

to be taken. 18 Manual call point systems of 'break glass' type shall also, be installed throughout plant in selected

positions to raise an alarm. 19 Indication panels shall be provided in control room and fire station to enable operators to take

appropriate action and to indicate if a fire protection system has been activated. 20 Audible alarms and beacons shall be installed in process units, which would automatically, actuate

on leakage of gas or on outbreak of a fire. 21 Cables for ESD solenoid valves shall be fireproofed and preferably, laid in separate trays. 22 Passive fire protection shall be installed, wherever needed on steel supports, towers, vessels, heaters

and other process equipment, when subjected to severe temperature generated by a liquid hydrocarbon or gas fire.

23 Positive pressure shall be maintained in substations and a fire protection clean agent system installed to protect equipment against damage due to fire.

24 Television cameras with monitoring systems shall be installed to overlook general plant areas, enabling operators to take appropriate action when fire, smoke or gas is detected.

25 Around hydrocarbon production facilities, zones or spaces shall be defined, in which a gas cloud with gas concentration likely to be above lower flammability limit (LFL) be present, when a major gas or vapor leakage occurs.

26 Such zones are called restricted zones. 27 Restricted zones concept shall be used to define preventive ignition measures to be taken into

account for items of equipment located inside a restricted zone, e.g. shutting down specified electrical equipment in explosive atmospheres.

28 Hose boxes and fire points containing portable firefighting equipment shall be located at strategic points adjacent to hazardous areas.

29 Portable fire extinguishers shall be available in those locations, where rapid intervention with a relatively small fire extinguisher may prevent a small fire from escalating.

30 Required portable equipment and its location shall be indicated in fire hazard analysis, which must be performed as part of detailed design to address each potential fire hazard.

31 This analysis should consider following aspects namely type of combustibles, fire load of hazard, flash points, ignition sources, temperature of combustibles, combustible liquids, flammable liquids, exposure to adjacent combustion, chemicals involved, detection, alarm, automatic control and monitoring systems process area

32 An early detection of a developing fire and an early warning to operational and firefighting personnel, form an important aspect in basic concept of fire protection.

Fire and gas detection system 1 Fire and gas detection systems shall be designed complying with design specification. 2 Systems shall be used to provide monitoring and control of plant. 3 Fire and gas detectors are part of fire and gas system. 4 System shall incorporate data acquisition and printer facilities. 5 System shall consist of, but not be limited to fully intelligent system cabinets and their associated

field interface cabinets, located within IES (instrument equipment shelters) and various buildings. 6 Each system cabinet shall incorporate a display matrix for areas it covers. 7 A maintenance console shall provide diagnostic facilities for system.



Environment Clauses For Plant IndustryAlarm and maintenance printers1 There shall be a separate fire & gas network connecting fire and gas alarm system respecting all buildings and

plant.

2 Necessary fire alarm signals shall be repeated on DCS through serial interface and displayed on control room DCS consoles.

3 All fire alarm systems shall have local panels with display matrix in respective buildings.

4 Alarm lights and audible alarms shall be provided in plant for various systems.

5 Lights shall have different colors for different types of alarms.

6 These lights shall be located in same general areas as detectors.

7 Alarm colors (lights) provided in plant area shall be same on matrix panel and CRT graphics and should be treated as follows:

a Blue for flammable gas detectors b Red for fire detectors and manual call points c Orange for toxic gas detectors

8 Maintenance shall be considered for detector location. 9 Detectors for areas, such as compressor shelters should be accessible from crane platforms. 10 Ladders may be used.

Flammable gas detection Flammable gas detection in open areas 1 A flammable gas detection system shall be furnished. 2 Signal from flammable gas detectors shall be sent to instrument equipment shelters (IES) and then to

control room (CR). 3 CR shall send a signal to a panel in fire station. 4 Flammable gas detectors shall alarm at multiple points. 5 First alarm shall sound at about 10 % of lower flammability limit (LFL). 6 Sensor system shall be designed to alarm again at 25% of LFL. 7 When 10 % LFL is reached, each detector shall give:

a An individual visual alarm (blue flashing light) on concerned matrix panel, showing location of gas detection and system buzzer shall actuate.

b Signal shall be sent via data highway to fire and gas detection system in fire station and control room, wherefrom, it shall initiate an audible and visual alarm in control room, fire station & maintenance workstation

1 When 25 % LFL is reached, it shall be added with following requirements: a A common audible alarm and a common visual alarm (blue flashing light) in concerned process

plant area. b An audible and visual alarm in control room, fire station, maintenance workstation & concerned

area operator shelter 1 Flammable gas detectors for hydrocarbon gases shall be located on two criteria General area coverage detectors shall be as follows: 1 Between process units, handling flammable gases/liquids and process units, having open flames. 2 Around process units handling high pressure flammable gases (greater than 20 barg).3 Specific locations based on past industry experience. 4 Detectors shall be provided in following locations:

a On gas compressor seals and b On seals for pumps, which handle flammable liquids, inside entrance to ventilation intakes and

on manifolds and hydrocarbon valves to be defined by company



Environment Clauses For Plant Industry1 Type of flammable gas detectors shall be such, that concentrate of flammable gas should be

measured and displayed in range of 0 to 100 % lower flammability limit (LFL).

Flammable gas detection in buildings Buildings are divided in 2 categories as follows: Process buildings: 1 Instrument equipment shelter (IES)) 2 Electrical substation (SS) 3 Operator maintenance shelter (ZM) 4 Sulphur weigh station building (WS) 5 Sulphur weigh station truck driver building (J2) 6 Process chemical shed (PCS) 7 Compressor shelter (CPS) 8 Smoke room (SM) 9 Fire point shelter (FPS) 10 Analyser shelter

Non process buildings: 1 Laboratory 2 Storage building 3 Chemical store 4 Cooled chemical store 5 Maintenance building 6 Fire station 7 Gate Houses

Process buildings (except analyser shelter) 1 Three flammable gas detectors shall be provided at air intake of HVAC system (if so required). 2 A hydrogen (H2) gas detector shall be provided in battery rooms of substations and IES, where seal

batteries are used. 3 When 10 % of LFL for flammable gas detector or H2 detector is reached, each detector shall give:

a An individual visual alarm (blue flashing light) on concerned matrix panel, showing location of gas detection.

b An audible and visual alarm (blue flashing light) at entrance and in concerned building. c An audible and visual alarm in control room. d An audible and visual alarm in fire station. e An audible and visual alarm in maintenance workstation

When 2 out of 3 HC detectors or 1 out of 1 H2 detector reach 25% LFL, following actions shall be added: a An audible and visual alarm in control room b An audible and visual alarm in fire station. c An audible and visual alarm in maintenance workstation d An audible and visual alarm in concerned area operator shelter e Ventilation system shall be stopped and dampers closed, except for H2 detection in battery room. f Cutoff power supply of operator maintenance shelter (for flammable gas detection at air intake of

operator maintenance shelter) g Each H2 detector located inside a battery room shall cutoff battery feeder.




Analyser shelter 1 Two flammable gas detectors shall be provided at each air intake of HVAC system. 2 One flammable gas detector shall be installed inside analyser. 3 When one detector reaches 10% LFL, it shall give:

a A general audible alarm in IES associated with concerned plant area. b An individual visual alarm (blue flashing light) on concerned matrix panel, showing location of

gas detection. c A visual alarm in analyser shelter. d An audible and visual alarm in control room. e An audible and visual alarm in fire station. f An audible and visual alarm in maintenance workstation g Shutdown of sockets located inside analyzer shelter.

4 When 25 % of LFL is reached by one detector, following actions shall be added: a A general audible alarm in IES associated with concerned plant area. b An individual visual alarm (blue flashing light) on concerned matrix panel, showing location of

gas detection. c A visual alarm in analyser shelter. d An audible and visual alarm in control room. e An audible and visual alarm in fire station. f An audible and visual alarm in maintenance workstation g Shutdown of sockets located inside analyzer shelter.

5 If 2 out of 2 detectors reach 25% LFL, following action shall be added: a Ventilation system shall be stopped and dampers closed. b An audible and visual alarm (blue flashing light) in concerned process area c An audible and visual alarm (blue flashing light) in concerned process area operator shelter

Non process buildings 1 Two flammable gas detectors shall be provided at air intake of new HVAC system (if so required)

depending on detection philosophy. 2 When one detector reaches 10 % of LFL, it shall give:

a An individual visual alarm on concerned control or matrix panel, showing location of gas detection and system buzzer shall be activated.

b An audible and visual (blue flashing light) alarm (if so required) at entrance and in concerned building.

c An audible and visual alarm in control room. d An audible and visual alarm in fire station. e An audible and visual alarm in maintenance workstation

1 When 2 out of 2 detectors reach 25% LFL, following actions shall be added: a An indication in control room. b An indication in fire station. c An audible and visual alarm in maintenance workstation d Ventilation system shall be stopped and dampers closed

Flammable gas detection for packages 1 Three flammable gas detectors shall be located at each air duct inlet of package. 2 For flammable gas detection (distribution and installation) for packages refer to ‘Instruments

furnished with packages’

When 10% LFL is reached, each detector shall give:



Environment Clauses For Plant Industry1 A general audible alarm in IES and substations associated with concerned plant area. 2 An individual visual alarm (blue flashing light) on concerned matrix panel. 3 Signal shall be sent via data highway to fire and gas detection system in fire station and control room

to initiate: 4 An audible and visual alarm in control room, 5 An audible and visual alarm in fire station. 6 An audible and visual alarm in maintenance workstation

When 25% LFL is reached, it shall be added: 1 An audible and visual alarm in control room, 2 An audible and visual alarm in fire station. 3 An audible and visual alarm in maintenance workstation

When two out of two detectors reach 25% LFL, following actions shall be added: 1 A common audible alarm and a common visual alarm (blue flashing light) in concerned process plant

area. 2 Shutdown of machine. 3 Close ventilation dampers and shutdown ventilation fans 4 Isolate power supply to all equipment not suitable for zone 1

Toxic gas detection 1 A toxic gas detection system shall be furnished. 2 Signal from detectors shall be sent to IES and then to CR. 3 CR shall send a signal to a panel in fire station.

H2S gas detection in open areas 1 H2S detectors shall be located on two criteria: 2 General coverage detectors shall be as follows:

Between flares 1 Inside area handling substantial quantities of H2S and containing operating personnel 2 Specific location detectors shall be as follows: 3 On seals of gas compressors handling H2S4 On seals of pumps handling fluids containing H2S. 5 On areas of control valves handling gases that have a significant percentage of H2S. 6 On sulphur sumps

a Concentrations of H2S gas shall be measured and displayed over selectable range of 0-50 ppm. b First alarm point shall be set at 10 parts per million (ppm volume) H2S. c Second alarm shall be set at 20 ppm.

Fire Protection Design Basis 1 When 10 ppm is reached, each detector shall give:

a A general audible alarm in IES associated with plant area concerned and operator shelter b An individual visual alarm (orange flashing light) on concerned matrix panel showing location of

gas detection. c Signal shall be sent via data highway to fire and gas detection system in fire station, control room

and maintenance workstation, which shall initiate: d A common audible alarm and a common visual alarm (orange flashing light) in concerned

process plant area. e An audible and visual alarm in control room,



Environment Clauses For Plant Industryf An audible and visual alarm in fire station. g An audible and visual alarm in maintenance workstation

1 When 20 ppm is reached, following alarms shall be added: a A common audible alarm and a common visual alarm (orange flashing light) in concerned

process plant area. b An audible and visual alarm in control room, c An audible and visual alarm in fire station. d An audible and visual alarm in maintenance workstation

H2S Gas Detection In buildings Process buildings (except analyser shelter) 1 Two H2S detectors shall be provided at air intake of HVAC system (if so required). 2 When 10 ppm of H2S is reached, each detector shall give:

a A general audible alarm in IES associated with concerned building. b An individual visual alarm (orange flashing light) on concerned matrix panel showing location of

gas detection. c An audible and visual alarm (orange flashing light) at entrance to building and in concerned

building. d An audible and visual alarm in control room. e An audible and visual alarm in fire station. f An audible and visual alarm in maintenance workstation

3 When 1 out of 2 detectors reach 20 ppm, following actions shall be added: a An audible and visual alarm in control room. b An audible and visual alarm in fire station. c An audible and visual alarm in maintenance workstation d Ventilation system shall be stopped and dampers closed.

Analyser shelter 1 One H2S detector shall be provided at each air intake of HVAC system. 2 In units containing H2S, one H2S detector shall be provided inside analyser shelter. 3 When one detector reaches 10 ppm, it shall give:

a A general audible alarm in IES associated with concerned plant area. b An individual visual alarm (orange flashing light) on concerned matrix panel, showing location

of gas detection. c A visual alarm (orange flashing light) in analyser shelter. d An audible and visual alarm (orange flashing light) in concerned process area. e An audible and visual alarm in control room. f An audible and visual alarm in fire station. g An audible and visual alarm in maintenance workstation

4 When one detector reaches 20 ppm, following actions shall be added: a An audible and visual alarm in control room. b An audible and visual alarm in fire station. c An audible and visual alarm in maintenance workstation d An audible and visual alarm (orange flashing light) in concerned process area. e If concerned detector is located at HVAC air intake, ventilation system shall be stopped and

dampers closed.

Non process buildings 1 Two H2S detectors shall be provided at air intake of new HVAC system (if so required) depending

on detection philosophy.



Environment Clauses For Plant Industry2 When one detector reaches 10 ppm, it shall give:

a An individual visual alarm on concerned control or matrix panel, showing location of gas detection.

b An audible and visual (orange flashing light) alarm (if so required) at entrance to building and in concerned building

c An audible and visual alarm in control room. d An audible and visual alarm in fire station. e An audible and visual alarm in maintenance workstation

3 When 1 out of 2 detectors reach 20 ppm, following actions shall be added a An individual visual alarm on concerned control or matrix panel showing location of gas

detection. b An audible and visual (orange flashing light) alarm (if so required) at entrance to building and in

concerned building c An audible and visual alarm in control room. d An audible and visual alarm in fire station. e An audible and visual alarm in maintenance workstation f Ventilation system shall be stopped and dampers closed.

SO2 detection 1 SO2 detectors shall be used in sulphur handling units as fire detectors:2 SO2 is a product of sulphur combustion. 3 When 3 ppm is reached, each detector shall give:

a A general audible alarm in IES associated with concerned plant area. b An individual visual alarm (red flashing light) on concerned matrix panel, showing location of

gas detection. c An audible and visual alarm in control room d An audible and visual alarm in maintenance workstation e An audible and visual alarm in fire station. f A common audible alarm and a common visual alarm (red flashing light) in sulphur handling

units. 4 Concentration of SO2 gas shall be measured and displayed over selectable range of 0-20 ppm. 5 SO2 detectors shall be provided in sulphur handling units for liquid sulphur pumps, sulphur sump,

sulphur plant incinerators, reaction furnaces.

Cl2 Detection 1 Cl2 Detectors shall be provided to chlorine packages and connected to fire & gas system.

Closed circuit television monitoring systems 1 A closed circuit television system shall be supplied. 2 Closed circuit television and monitoring system shall be in accordance with manual call/egress gate

points 3 A system of manual call points and egress gate points for initiating a fire alarm shall be provided as

part of plant fire protection system. 4 Manual call points connected to fire and gas system shall be clearly recognized, provided with signs

and located as follows: a Along roads in plant area at intervals not exceeding 50 m, preferable at or near lampposts, inside

plant and positioned: b At exit doors of IES c Along logical escape routes d At each exit door of electrical substation



Environment Clauses For Plant Industrye At each exit door of operator shelter f Near sulphur loading bay. g Also, manual call points shall be located at emergency exit point from process areas (usually

normal entrance and exit). 5 Egress gate points (box containing key for plant fence door) shall be located as follows:

a At each egress gate inside plant b When there is a double fence for plant and for sulphur truck road, at each egress gate outside

plant and at each egress gate for sulphur truck road. 6 When operated, manual call points and egress gate points shall give:

a A general audible alarm in building or IES associated with concerned plant area. b A general audible and visible (red flashing light) alarm in concerned process plant area. c An individual visible alarm (red flashing light) on matrix panel.

7 Operation of manual call points and egress gate points shall be sent via data highway to fire and gas detection system in fire station and control room, it shall initiate: a An audible and visual alarm in Control Room, b An audible and visual alarm in fire station. c An audible and visual alarm in maintenance workstation

Fire detection 1 Fire detection in open area 2 Fusible plug detectors shall be installed on equipment protected by a fixed deluge system.3 These shall activate concerned deluge system. 4 Pressure drop in fusible loop shall be detected by one low pressure switch (PSL) and firewater flow

rate in deluge pipe shall be detected by one high pressure switch (PSH).

PSL shall give: 1 A visual alarm (red flashing light) on matrix panel 2 An Air low pressure alarm in control room 3 An audible and visual alarm in fire station 4 An audible and visual alarm in maintenance workstation 5 An audible and visual alarm in concerned process area

PSH shall give: 1 A general audible alarm in concerned IES. 2 A visual alarm (red flashing light) on matrix panel. 3 A high water pressure alarm in control room 4 An audible and visual alarm in fire station. 5 An audible and visual alarm in maintenance workstation 6 A common audible alarm and a common visual alarm (red flashing light) in concerned process plant

area. 7 A pressure transmitter shall be added on deluge system fusible loops. 8 In case of low air pressure in fusible loop, this transmitter shall send a signal to plant DCS.

Fire detection in buildings 1 Optical smoke detectors and heat detectors rate of rise type shall be used & not fixed temperature

type. 2 Rate of rise means a temperature increase at sensor about 9°C or more per minute, that activates rate

of rise feature, which closes contacts in sensor to transmit alarm condition to fire alarm control panel. 3 When rate of rise element alone has been activated, sensor is self restoring, while in case of fixed

temperature element, detector requires replacement



Environment Clauses For Plant Industry4 When executive action is expected, voting is required based on two separated loops with a maximum

of 6 detectors per loop, in case system is not addressable. 5 If executive action is not required, only one loop shall be installed with a maximum of 6 detectors

per loop, in case system is not addressable. 6 Heat detectors shall be installed in offices, smoking areas, HVAC rooms of IES, substations, battery

rooms of IES and operator shelters. 7 Smoke detectors ionization type shall be installed in building corridors, WCs, UPS rooms of IES,

control room of IES, battery rooms, switchgear room of electrical substation, power generation enclosures and diesel driven engines enclosures.

Fire detection by one detector on one loop shall give: 1 A visual alarm (red flashing light) on matrix panel in IES associated with concerned building with

system buzzer. 2 A general audible alarm in IES associated 3 An audible and visual alarm (red flashing light) at entrance to building and in concerned building 4 An audible and visual alarm in control room 5 An audible and visual alarm in fire station. 6 An audible and visual alarm in maintenance workstation

Fire detection by two detectors on two separate loops shall give following additional actions: 1 A general audible alarm in IES associated 2 An audible and visual alarm (red flashing light) at entrance to building and in concerned building 3 An audible and visual alarm in control room 4 An audible and visual alarm in fire station. 5 An audible and visual alarm in maintenance workstation 6 Stop ventilation system and close fire dampers of concerned building 7 Release after an adjustable ‘time delay’ automatic extinguishing system allocated to concerned loops

(when applicable). 8 Where there is an executive action, 2 detectors shall be installed per 50 m² (per BS 7273) on separate

loops. 9 When installed for alarm only, one detector per 50 m² with a maximum of 6 detectors per loop shall

be provided. 10 Smoke and heat detectors in enclosed rooms shall be looped separately i.e. to include all smoke

detectors in ceiling void to be in separate loops and all smoke detectors in floor void to be in another separate loops i.e. not to club detectors at ceiling void and detectors from floor void in same loop.

11 A remote indicator shall be provided for each detector installed in ceiling and floor.

Fire detection for packages 1 For flammable gas detection (distribution and installation) for packages refer to “Instruments

furnished with packages” 2 At least two rates of rise heat detectors shall be optimally, located in each enclosure compartment of

packages. 3 When some detector is activated, following alarm shall be initiated: 4 A general audible alarm in IES associated with concerned plant area. 5 Signal shall be sent via data highway to fire and gas detection system in fire station and control

room, which shall initiate: a An audible and visual alarm in fire station. b An audible and visual alarm in maintenance workstation

8 When two detectors are activated, following alarms and actions shall in addition be activated: a A common audible alarm and a common visual alarm (red flashing light) in concerned plant area,



Environment Clauses For Plant Industryb An audible and visual alarm in control room c An audible and visual alarm in fire station d An audible and visual alarm in maintenance workstation e Shutdown and electrical isolation of machine, f Stop fuel supply (when applicable) Shutdown of ventilation system and closure of fire dampers

(when applicable) g Release after an adjustable time delay of CO2 extinguishing system (30 seconds).

Fire detection in Non process buildings 1 Fire detection philosophy is fitted to installation. 2 On each building, fire control panel shall be provided. 3 If necessary, fire detectors shall be relocated or recovered. 4 One detector obtains executive action or one loop (no voting by two separated loops). 5 Fire detection by one detector or one loop shall give:

a An individual visual alarm on concerned control or matrix panel associated with concerned building

b An audible and visual (red flashing light) alarm (if so required) at entrance and in concerned building.

c An audible and visual alarm in main control room d An audible and visual alarm in fire station e An audible and visual alarm in maintenance workstation f Ventilation HVAC system shall be stopped and dampers closed.

Basis For a Fire Protection Water System 1 Firewater shall be readily available at all appropriate locations at required pressure and designed

flow. 2 Firewater should not be used for any other purpose whatsoever.

Fire water rate Fire water rate design criteria 1 Quantity of water required for fire protection shall be calculated based upon criteria of section Firewater ring main system 1 Firewater ring mains of required capacity shall be installed to surround all processing units, loading

facilities, warehouses, workshops and utilities. 2 Normally, these units shall also, be bound by service roads. 3 Large areas shall be subdivided into smaller sections, each enclosed by firewater mains equipped

with hydrants and block valves. 4 Minimum size of fire water main pipe shall be provided 8”(200 mm) 5 Firewater mains shall be provided with full bore valve flushing connections, so that all sections and

dead ends can be properly flushed out. 6 Flushing connections shall be sized for a fluid velocity in relevant piping of not less than 80% of

velocity under normal design conditions, but not less than 2 m/s. 7 Firewater mains shall be installed underground in order to provide a safe and secure system. 8 Depth of cover shall not be less than 1.1 m. 9 A pressure transmitter shall be installed on main header every 500m connected to plant fire alarm

system. 10 Firewater mains network pipe sizes shall be calculated using an approved computer program. 11 Complete calculation shall be based on design rates at a minimum pressure of 7 barg at takeoff

points of each appropriate section and calculations made to prove that pressure drop is acceptable with a blocked section of piping in network.



Environment Clauses For Plant Industry12 Firewater ring main pressure shall be maintained, such that under fire conditions, a pressure 7 barg

should exists at most remote location under corresponding design flow conditions, while maximum allowable velocity in system could be 3.5 m/s.

Firewater mains - installation and material selection 1 Piping materials shall conform to design specification. 2 At each main tee, number of isolation valves shall be number of branches minus one. 3 Block valves shall be incorporated in ring main system, so that sections can be isolated for

maintenance etc. 4 These sections shall be selected, so that number of consumers is not more than 6. 5 Valves shall be butterfly/gate valves with position indicators. 6 Firewater ring main systems shall be equipped with hydrants, monitors, hose reel stations and deluge

valves.

Hydrants 1 Firewater mains shall be provided with permanent hydrants, located in strategic positions around

utilities units/areas. 2 In process areas, hydrants shall be provided with a top mounted water monitor. 3 Each hydrant shall have an isolation valve in addition to hydrant valve. 4 Hydrants shall be per ones with 4 x 2 1/2 outlets. 5 Takeoff points shall be on side of header. 6 Hydrants connected to buried lines, do not require bottom drains. 7 Spacing between hydrants shall not exceed following:

a Around utility areas 70 m (3 length of hose) b Around process unit, 50 m (2 length of hose)

8 Hydrants shall be readily accessible from roads and located in such a way that possible damage by road traffic be minimized, provided with a guard post and concrete drainage area.

9 Location shall not be less than 1.5 m from edge of road shoulder and at least 12 m from road crossings, sharp road curves and buildings or other structures.

Monitors 1 Firewater mains shall be provided with permanent monitors spaced note more than 50 m around

processing units. 2 Monitors to be installed on firewater hydrants shall be located at least 15m away from protected

equipment to ensure accessibility in case of a fire. 3 Rotation, elevation and nozzle adjustment shall be done manually without gears. 4 When monitors are in use, it shall be possible to leave monitor unattended operating safely.

Monitors shall comply with following requirements: 1 Upstream of mounting flange, each monitor shall be provided with a butterfly valve accessible from

grade. 2 Monitor shall have a capacity of at least 120m3/hr at 7 barg. 3 Larger capacity monitors require company approval. 4 Minimum/maximum operating pressure to be respectively 6/6 barg. 5 Water monitor shall have a 2-½ inch threaded end, allowing easy connection of an adjustable nozzle

of constant flow fog to jet stream type. 6 Monitors shall meet such design that hydraulic forces (jet reaction), considering pressure surges,

when opening upstream block (butterfly) valve are balanced. 7 Monitor shall be able to rotate 360 degrees by means of a turret, lockable in all positions. 8 Elevation setting shall vary from 15 degrees below to 85 degrees above horizontal i.e. a total 100

degrees.



Environment Clauses For Plant Industry9 Rotation and elevation movement lever should be operable, setting and locking shall be easy. 10 Moving parts shall be fully protected/enclosed against sand and salt spray. 11 Monitors and nozzles shall be made of materials and coatings suitable for use with seawater in

outdoor weather conditions. 12 Monitor shall be tested and certified by an independent authority to be approved by contractor. 13 Manufacturer shall provide a copy of certified test report. 14 As a minimum, test report shall include following data:

a Foot print (width x depth) i.e. area, where 80% of total water flow hits horizontal plane through raised face of mounting flange for jet and 30 degrees fog (both at 30 degrees elevation),

b Throwing distance (trajectory) measured from nozzle exit to center of foot print, c Pressure at monitor inlet flange,d Flow rate, diameter of used hose connection, wind speed and direction, e Angle between wind direction and water trajectory.

Firewater supply 1 Firewater supply storage shall be a volume equal to 12 hours consumption at maximum main pump

flow rate. 2 Well water being saline shall serve an emergency source only. 3 Complete fire water main system must be flushed with fresh water, after being used for emergency

purpose.

Firewater pumping facilities 1 Firewater shall be provided by pumps of horizontal split case centrifugal type (number of pumps

shall be in line/according worst case scenario). 2 Firewater pumps are installed in a location considered to be safe from effects of fire, clouds of

combustible vapour and from collision or crash damage by vehicles. 3 Firewater pumps shall be electric driven with one diesel driven (backup). 4 Pumps as well as, drives shall comply with requirements of NFPA20 and applicable design

specifications. 5 Power of drives for both main and standby units shall be so rated, that it is possible to start pumps

against an open discharge with pressure in firewater ring main system under non fire conditions, normally at 2 to 3 barg.

6 When pressure in firewater ring main system drops below minimum required static normally, approximately 2.7 barg, first firewater pump shall attempt to start.

7 Thereafter, at 30 seconds intervals, next designated available pump shall also, attempt to start if system pressure is less than 10 barg.

8 Contractor shall define startup logic. 9 Automatic starting facilities shall be configured to allow system testing including simulation of

alarm activation, while standby system remains operational. 10 Manual starting each pump unit shall be possible at pump, at control room and at fire station. 11 Manual stopping each pump unit shall only, be possible at pump station. 12 Operation of main firewater pumps shall actuate an alarm in control room and fire station panels

indicating system pressure. 13 System shall be protected from surge and hammering. 14 Hydraulic studies of system shall be performed to ensure that water hammer does not result in at all

expected operating conditions. 15 Hydraulic calculations shall be performed using approved software to verify that firewater pumps

capacity (flow rate and pressure) is satisfactory to achieve required flow rate in each area at 7 bars g minimum. (This shall apply for both electrical and diesel driven pumps)

16 Response time for starting firewater pumps and for feeding plant area shall be measured on site for



Environment Clauses For Plant Industryadjustment if necessary.

17 A ring main surge analysis shall be performed. 18 Diesel engines of firewater pump shall meet requirements of NFPA 20 and applicable design

specifications.

Following additional requirements shall also apply: 1 Capacity of diesel storage tank shall be provided, such that engine can operate on full power for at

least 12 hours. 2 Tank shall be installed at a safe distance from engine with bottom at least 0.2 m above suction valve

of diesel injection pump or as specified by pump vendor. 3 Tank shall be provided with a sump, an expansion dome, a level gauge and a low level alarm, which

should sound, when level of diesel has reached ‘2 hour diesel’ remaining level. 4 Tank shall be provided with one connection for refilling directly, from diesel distribution network. 5 A clutch shall not be installed between diesel engine and pump. 6 Discharge line from pump shall be fitted with a check valve, a test valve, a pressure gauge and a

block valve with a locking device. 7 Test line arrangement shall allow testing of either pump, while spare pump remains available for

service. 8 Test valves shall have a common return line with a flow metering unit. 9 Each pump shall be connected separately to a common manifold. 10 Pump discharge manifold shall be connected to firewater ring main system by a separate pipeline,

with a block valve of same size as ring main. 11 Firewater ring main pressure shall be maintained such that under fire conditions, a pressure of 7 barg

exists at most remote location, while under corresponding design flow conditions, maximum allowable velocity in system being 3.5 m/s.

12 Batteries for diesel pump and fire pump controllers shall be located in normally air conditioned areas.

Deluge systems Hose reels 1 Hose reel stations for process units shall be designed 2 Hose reels for buildings shall be designed as hose reel stations, but without associated foam station

as for process units.

Foam Compound Storage 1 Foam compound storage is necessary. 2 Contractor has to determine suitable quantities and mode of storage.

Portable and Mobile Fire Fighting Equipment 1 Portable and mobile equipment in accordance with requirements shall be available at first line of

attack and for backing up fixed fire protection systems.

Hose boxes 1 Hose boxes shall be installed at every other hydrant or monitor. 2 Each box shall contain 4 fire hoses and 2 water branch pipes.

Fire/Safety point shelters 1 A weatherproof fire point shelter shall be located near each process and utility unit at nonhazardous

area duly equipped with following: a 8 fire hoses in weatherproof cabinet.



Environment Clauses For Plant Industryb 2 x 75 kg ABC wheeled dry chemical powder fire extinguishers. c Spray/jet nozzles. d 1 Foam making branch pipe complete with pickup tubes and probes. e 5 Jerry cans each contains 25 liters foam (Fluoro protein foam FP 70 - AFFF type may be

considered as an alternative). f 2 breathing apparatus sets 30 min in weatherproof boxes. g 1 Stretcher. h 1 First aid box at chemical handling areas, fire point shelters shall also, be equipped with

chemical resistance gears (boots, gloves, face shields and coveralls)

Fire extinguishers 1 Extinguishers shall be positioned within process units and along walkways, such that travel distance

between extinguisher and possible fire hazard should be limited to 15 meters for process units and 30 meters for other areas.

2 For compressor handling flammable gas, one extinguisher should be provided within 5 meters of equipment at each floor level.

3 In buildings, fire extinguishers should be installed in concealed type cabinet combined with hose reel.

4 Dry chemical powder cartridge type, suitable for types A, B and C fires shall be provided in process unit, utilities unit and near transformers.

5 Such extinguishers should be provided at pumps, compressor handling flammable products and at vessels with a liquid hold up more than 1 m3.

6 Such extinguishers should also, be provided on high level walkways. 7 Units should also, be provided in buildings. 8 Wheeled ABC dry chemical powder extinguisher should be located in fire point shelters only. 9 CO2 extinguishers should be used for electric and/or electronic equipment fires, such as switchgear

houses, substations, instrument equipment shelters, analyzer buildings and laboratory. 10 CO2 extinguishers should be installed close to electrical and/or electronic equipment with travel

distance 6 m maximum. 11 Wheeled carbon dioxide extinguishers shall be supplied for substations and boiler areas. 12 For offices, no water extinguishers should be provided, but only 9 kg dry powder and 5 kg CO2

extinguishers. 13 Water hose reels each containing 11/2”diameter fire hose of maximum length 31 m shall also, be

installed duly connected to fire water system.

Fire fighting steam 1 If necessary, utility connections from low pressure steam system shall be provided for steam lances

with 15 m long electrically earthen hoses. 2 Steam lances should be used to smother small fires caused by leakage from equipment handling

flammable products on or above auto ignition temperature

First aid boxes 1 One first aid box shall be installed in each operator shelter, fire point shelter, electrical substation and

IES building. 2 Substations shall be provided with suitable first aid boxes.

Breathing apparatus 1 Breathing apparatus sets shall be located in fluids containing H2S process, utility areas, operator

shelters, IES, analyzer rooms and SCADA shelter, fire point shelters.2 Breathing apparatus sets shall be kept inside weatherproof boxes (one per one).



Environment Clauses For Plant Industry3 Additional BA (10%) shall be provided in fire station as back up. 4 A breathing air supply for maintenance shall also, be provided

Fire blankets 1 Wall mounted fire blankets shall be provided and installed within process and utility units at strategic

locations.

Firefighting vehicles 1 Firefighting vehicles and ambulance shall be provided for new plants per requirements.

Safety Showers and Eyewashes 1 Safety showers and/or eyewashes shall be provided in chemical handling areas

Fire Training Facility 1 Fire training facility shall be located with a safety distance of 100 meters from all units. 2 A branch from firewater network shall run to fire training facility. 3 This branch shall be fitted with 2 hydrants and 2 hydrants with top mounted monitors.

Fireproofing 1 Main objective of fireproofing steel structures is to prevent escalation of fires to an unacceptable

level, providing a temporary protection, until full firefighting capabilities can be deployed. 2 Judicious application of fireproofing shall delay an eventual collapse of steel structures and allow it

to occur gradually, depicting visible signs that provide time for isolation pertinent affected equipment as well as, for operating and firefighting personnel to evacuate safely.

3 For specific information as to requirements for fireproofing, refer to relevant project FEED

Fire Station 1 Fire station shall be designed per requirements. 2 Note: For large processing complexes, addition of satellite or new fire stations shall be considered

(based on minimum response time to farthest point from main fire station).

Fire protection requirements per area Gas turbines, Emergency generators and compressors enclosures 1 An automatic CO2 fire suppression system shall be installed to protect inside of gas turbine, 2 Emergency generators and flammable gas compressor enclosures for protection against hazardous

gas mixtures and fires. 3 Inerting enclosure by reduction of oxygen shall suppress and extinguish fire.4 Automatic CO2 shall meet requirements of NFPA 850 and NFPA 12. 5 All equipment shall be UL and/or FM approved or vendor national approval. 6 CO2 bottles shall be equipped with pressure indicators and with weighing indicator connected to fire

and gas system. 7 Each system shall comprise a dedicated fire and gas detection and protection system with extensive

requirements with respect to detection, visible/audible alarms, logic, delay of agent release, area ventilation etc.

8 Dedicated fire and gas system shall meet requirements of NFPA 850, 70 and 72. 9 Gas turbines and compressor sets, installed in open air shall be protected by a fixed water spray

system.

General process areas Fixed installed fire protection and firefighting systems monitors



Environment Clauses For Plant Industry1 Fixed installed manually adjustable and operated water monitors shall be positioned at strategic

points around hazardous areas. For specification of monitors 1 Water spray systems or deluge systems, 2 Open automatic water spray systems shall be installed for protection of following equipment: 3 All pumps handling products close to or above their auto ignition temperature. 4 Pumps handling C4 and lighter products. 5 Note: pump and a width of 1.5 m around pump shall be covered by water spray. 6 Water rate directly over pump shall be approximately, 40 dm3/min/m2 and on area around pump 20

dm3/min/m2. 7 All compressors handling C4 and lighter products, which are not installed in enclosures and cannot

be covered by fixed installed, manually adjustable and operated water monitors, water rate shall be 40 dm3/min/m2 of ground surface.

8 All vessels, columns and exchangers normally, holding a liquid volume of C4 and lighter products of more than 5 m3, water rate shall be 10.2 dm3/min/m2 of equipment surface.

9 Vertical vessels and columns shall be fully sprayed up to a height of approximately 15 m above potential source of fire, excluding skirt.

10 For equipment installed in congested areas, where escalation could occur, a spray system shall be provided at potential source of fire generally, pumps with additional protection to cover a resultant spill fire and facing surface areas of adjacent equipment applying water rates as given above.

11 Items of equipment containing flammable products, which are installed in locations, where a chimney effect occurs in event of a fire or pumps handling flammable products located underneath air cooled heat exchangers or critical flanged connections, water rate shall be 20 dm3/min/m2 of ground surface for pumps and of equipment surface for other items.

12 Each deluge system shall be fed from two different separated headers and provided with drainage facilities.

13 Deluge valves shall be located at least 15 m away from protected equipment, protected against radiant heat by a suitable protection wall and against collision by crash barriers painted in fluorescent red and white paint.

14 Each automatic deluge valve system shall be provided with an air reservoir as a backup in case of instrument air failure, which shall be mounted on a skid.

15 Deluge systems spray nozzles shall have blow off plastic caps. 16 Flushing facility for deluge valve systems shall be provided to prevent salt deposits accumulation

and to prevent system piping corrosion. 17 Deluge system shall initiate local fire alarm. 18 Deluge system activation shall also, give alarms as well as, indication at both main control room, fire

station and automatically, start main pump. 19 Each deluge valve shall be provided with strainer and bypass connections.

Hose reel station 1 Hose reel stations shall be provided in process units. 2 Two stations shall be positioned within 23 meters (walking distance) from all points within

production facilities area. 3 Hose reel stations shall be equipped with 31 meter of 1-1/2”, 19 mm internal bore, 500 # non

collapsible rubber hose and adjustable flow, combination straight stream fog type (all brass) nozzles. 4 Reels shall allow hose to be put into service without unwinding reel. 5 Manifolding including an eductor shall be provided at each station to permit use of water only, or to

allow introduction of foam from a 115 liters stainless steel foam tank.6 Hose reel stations shall be protected inside weatherproof closed cabinets.




Portable fire fighting equipment Steam lances 1 Low pressure steam lances with associated utility connections shall be located proximate to pumps,

compressors handling flammable products at/above auto ignition temperatures and in sulphur recovery units.

Buildings 1 Fire protection systems shall be installed in buildings. 2 Protection of a building is based on fighting fire from both inside and from outside building. 3 Firewater shall be available close to and inside some buildings. 4 Type of fire protection systems applied depends on location, equipment to be protected and

particular fire hazard. 5 Equipment replacement and its replacement value shall also, be considered, when making an

assessment for design of fire protection systems. 6 Protection and detection shall be normally, provided in areas as defined below. 7 Protection for specific buildings shall also, be provided. 8 Where relevant, all doors to enclosed spaces shall be provided with an instruction plate, which

clearly indicates, what type of extinguishing agents are installed in particular space.

Fire protection for building areas 9 Instrument equipment shelter (IES) and electrical substations (SS)

a CO2 fire extinguishers shall be provided. 10 IES except HVAC & SS except HVAC.

a An automatic Inergen fire suppression system shall be installed for protection against fires.b Inerting enclosures shall suppress and extinguish fire. c Automatic system shall meet requirements of NFPA 2001. d All equipment shall be UL and/or FM approved or vendor national approval. e Inergen bottles shall be equipped with pressure indicators. f All Inergen system shall be activated directly from approved control panel PLC and shall not be

interfaced with separate control box. g Where chances of failures are more important, Inergen activation signal from PLC shall be wired

in duplex to reduce malfunction (i.e. one pair from each PLC). h Inergen release to different rooms in IESs shall be distinguished i.e. Inergen gas shall be released

only, in room where fire is detected and not to whole IESs. i Manual mechanical activation of Inergen cylinders shall be provided in case of automatic

activation fails. j At Inergen release, pressure calculations shall not exceed limits to avoid door damage and floor

tiles flying. k Calculations shall be integrated with HVAC ventilation system design i.e. integrity test shall be

carried out and provided to company for review. l Door switches shall be designed to inhibit overriding each other/s i.e. action from one switch

(manual or auto) shall not be changed from any other switch. m Systems and procedures shall be established to de energize system, when area is occupied. n Lockout system shall be provided to all suppressant systems. o HVAC control panels shall be protected by automatic release CO2 system. p Manual call points shall be provided at each exit door.

Operator shelter 1 No hose reels shall be installed.



Environment Clauses For Plant Industry2 Only 9 kg dry powder portable extinguishers shall be installed.

Chemical shed 1 Fire protection shall consist of 9 kg dry chemical powder fire extinguishers and hose reel with 31 m

hose connected to fire water supply.

Hydrocarbon type fireThere are two common types of fire that may occur in a hydrocarbon processing complex: 1 First is a pool fire, which occurs, when a flammable liquid leaks from a vessel or pipeline to form

a fluid reservoir following ignition2 Second and potentially, more dangerous type is a jet fire, which can happen following rupture of

a pressurised vessel and/or gas line. a A hydrocarbon pool fire generates temperatures of more than 1000 Celsius within ten minutes of

ignition with heat fluxes of around 150kW/m2. b A jet fire exhibits same temperature rise, but heat flux could be double that of pool fire.

Three distinct types of passive fire protection products are normally, used on hydrocarbon processing complexes1 Cementitious products generally, based on Portland cement plus lightweight aggregates.2 Cementitious materials protect steel in two ways.

a Firstly, they contain trapped moisture, which in a fire situation boil and keep steel temperature around 100 Celsius, until all water has disappeared.

b Product then acts secondly, as an insulator.1 Intumescent coatings generally, epoxy based spray or hand applied.

a In event of a fire, such coatings intumesce (i.e. coatings swell to many times original thickness) to form a tough insulating char.

1 Blanket systems made from manmade fibres, which use insulation as primary fire protection mechanism. a Blankets are used primarily for cable tray and valve protection.

Protection against hydrocarbon fires within an onshore petrochemical complex 1 In order to protect structures against hydrocarbon fires in an onshore petrochemical complex, steel

(such as in pipe racks and vessel skirts) is fire proofed, with passive fire protection products that have been fire tested to appropriate standard.

2 Hydrocarbon standards/tests include BS476, Part 20, 1987 appendix D, Underwriter’s laboratory 1709 and Norwegian petroleum directorate 'H' class test.

3 Products used for onshore protection are applied at thicknesses that prevent collapse of steel for a certain time period.

4 This specification describes minimum fireproofing requirements for protection against a hydrocarbon type fire, which is defined in UL 1709.

5 Protection is necessary for vessel skirts and other steel support structures, where respective sudden collapse due to fire would seriously endanger personnel, lead to release of large quantities of flammable products and/or toxic materials, lead to consequences beyond property limit (including environmental damage) or endanger major equipment.

6 In special cases, fireproofing is required for critical control and electric cables. 7 Fire exposure resistance time shall be of 2 hours, when exposed to a hydrocarbon fire as defined in

UL 1709 or in BS 476 Part 20, Appendix D. 8 Extent of fireproofing shall be shown on construction drawings. 9 Fireproofing details shall be in accordance with standard drawings. 10 Standard fireproofing material is lightweight ‘vermiculite concrete’ for steel structures and

‘intumscent mastic’ for critical control and electric cables.




Definitions Fireproofing Zones 1 Only specific structures and equipment, located within a fire proofing zone (FPZ) shall be

fireproofed. 2 A FPZ shall only, be applied to a plant or system, with a maximum operating inventory of more than

5 metric tons of flammable product. 3 In this context, a ‘system’ is defined as smallest volume of piping and equipment (including vessels)

that can be ‘blocked in’, when fire breaks. 4 Such zones shall be identified early, in detailed engineering project phase 5 For liquid pool fires, FPZ is a volume, within which, a cylinder having been located within a radius

of 9 m from potential source of leakage (PSL) and a height of 9 m above hazard level (HL). 6 For liquid or vapour torch fires, FPZ is a volume, with a special radius of sphere to be 9 m. 7 Sphere/bullet storage shell (up to their connecting flanges and nozzles) containing liquefied gases

should be considered as fire potential equipment.

Structures Supporting Equipment 1 Steel structures located within a FPZ shall be fireproofed, when supported equipment contains a total

of more than 2 metric tons of flammable product or has a total mass (including contents) of more than 10 metric tons or contains toxic material or sudden failure is likely to cause danger to personnel.

2 Steel structures within a FPZ supporting air coolers should be fireproofed if air cooler contains a total of more than 1 metric ton of flammable product or total mass of air cooler/s supported by structure, exceeds 2.5 metric tons including contents.

3 Steel columns, beams and other members within FPZ, designed for purpose of reducing effective buckling length of columns should be fireproofed.

4 When resistance to mechanical damage is required towards bottom of a column, fireproofing shall be made of reinforced concrete erected from grade level up to a minimum 1.8 m height.

5 Stairways, walkways and platforms designed mainly for live loads and top surfaces of beams, supporting floor plates, gratings or equipment are normally, not fireproofed.

6 In early stages of design features, which should be considered include: a Comparison of cost and construction time for prefabricated concrete structures versus steel

structures and fireproofing. b Fire protection policy and plant availability. c Minimizing need for bracing in a framework, where fireproofing is required. d Weight of fireproofing. e Increased overall dimensions of fireproofed members. f Prefabrication

7 Measures to protect supporting steel structures from torch fires generating, thermal radiation level of 350 KW/m² are in descending order of preference: a A judicious location and orientation of PSL’s relative to supporting steel structures in order to

avoid impact of accidentally, released product jets/in case of ignition of resultant jet flame on structure.

b Application of fire shielding either near PSL or near surfaces to be protected to deflect jet or jet flame and thus avoid impact.

c If neither of above is possible or practical, application of fireproofing as specified.

Steel Pipe Supports 1 Individual pipe supports and steel structures supporting overhead piping located in an FPZ shall be

fireproofed if one or more of following apply: 2 Pipe is a flare line or an emergency depressurizing vent line.



Environment Clauses For Plant Industry3 Pipe contains toxic material. 4 Pipe is connected to equipment, which would be severely, damaged by additional nozzle loading in

event of loss of pipe support. 5 Pipe runs beneath an air cooler, whose steel support structure is fireproofed (including horizontal

members). 6 Pipe carries firefighting water and/or other utilities, which would reduce firefighting capability in

event of loss of support. 7 Pipe is an instrument airline or hydraulic control line, whose loss would interfere with ability to shut

down plant. 8 Spring hangers shall be fireproofed, with suitable easily removable covers, such as PYTEC fire

protection system or equivalent. 9 Columns of pipe racks and pipe supports shall be fireproofed from HL up to 0.3 m below lowest

horizontal member of structure. 10 Diagonal bracing for resisting only, lateral forces shall not be fireproofed.

Vessels and Exchangers 1 Outside skirts of vertical vessels located within an FPZ shall be fireproofed if vessel contains a total

of more than 2 metric tons of flammable product, total mass (including contents) being more than 10 metric tons or it contains toxic material.

2 Inside of skirts shall be fireproofed if diameter is 1.2 meter and above. 3 Inside and outside fireproofing of vessel skirts shall be provided in accordance with reference

standard drawing

Supports for insulation and fireproofing 1 Saddles supporting horizontal vessels and exchangers shall not be fireproofed. 2 If there are flanged pipe connections within circumference of skirt of vertical vessels, fireproofing

shall be applied to inside of skirt as well.

ESD Valves 1 Actuators of ESD valves, when match ‘emergency shutdown philosophy’, protection flow chart shall

be fireproofed using flexible covers. 2 Flexible covers shall be installed directly on actuator casing with uniform thickness. 3 Fire protection shall protect actuators at least 30 minutes assuming a continuous total exposure to fire

with a flame temperature of 1100 °C. 4 Critical control and power cabling serving safeguarding systems shall be installed and fire protected

against direct radiation and flame impingement.

Codes and Standards 1 Following latest codes and standards to extent specified herein shall apply. 2 Alternate standards and codes meeting requirements of referenced standards and codes may be used

with approval of company. a American welding society publication (AWS) b AWS D1.1 Structural welding code c Underwriter’s laboratories inc. (UL) d UL 1709 fire resistance rapid temperature rise e Occupational safety and health administration (OSHA) f Code of federal regulations, title 29 g British standards h BS 476 Part 20 : 1987 New Appendix D : hydrocarbon curve torch fire i Decision flow chart for fireproofing of structures supporting equipment




General 1 Standard fireproofing material is lightweight vermiculite concrete. 2 Alternative proprietary system with proven track record may be used. 3 Extent of fireproofing shall be included within scope as indicated on design drawings. 4 Required thickness of fireproofing material shall be calculated according to criteria Hp/A & from

data derived from fireproofing manufacturer’s datasheets.

Materials 1 Light weight vermiculite concrete shall be used as fireproofing material. 2 Proprietary cementitious fireproofing system should incorporate a water repellent and/or seal coat

layer to protect material from staining and/or ingress of detrimental substances. 3 Minimum required curing period shall be 7 days.

Material Performances 1 Two hour protection based on testing according to UL 1709, hydrocarbon curve or according to BS

476 (Part20) Appendix D. 2 Shore hardness requirement shall be at least 40.

Installation 1 All application procedures and materials used shall be provided in strict accordance to

manufacturer’s published manuals. 2 All deviations from established methods shall be submitted for approval & review before application

on site.

General Considerations for Application of Materials Surface preparation 1 Steel work surfaces, which are to be fireproofed with lightweight vermiculite concrete shall be

prepared and painted in accordance with specification for painting. 2 Where alternative fire proofing materials are proposed, specification for surface preparation and

painting shall be considered as integral part of fire protection, which details should be submitted for approval.

Fireproofing supports and mesh reinforcement 1 Applicator in accordance with manufacturer’s recommendations shall submit for approval detailed

procedure pertinent fireproofing installation to contractor, prior to commencing work. 2 Mesh reinforcement shall be plastified/galvanized or be stainless steel type to ensure durability of

fire protection against environmental corrosion.

Top coat 1 Seal coat or/ paint system for application to external surfaces of fireproofing materials must be

recommended by manufacturers for approval by contractor/company.

Accidental damage 1 Those columns/steel members that have been applied with, fire proofing of light weight vermiculite

concrete, located within 1.5 m of an access way, usable by vehicles and maintenance equipment should be protected from damage.

2 Type of protection proposed shall be submitted for approval.

Sealing



Environment Clauses For Plant Industry1 At all locations, where steelwork emerges from fireproofing, interface shall be sealed.

Application methods on steel profile Depending on sizes of steel profile: 1 For steel profile up to 200 mm between wings/flanges 'solid fill’ method shall be used. 2 For steel profile above 200 mm between flanges ‘follow member size profile’ method shall be used,

which means that protection should be applied in surrounding of member. 3 Boxed configuration should not be allowed.

Inspection and testing 1 Inspection and testing shall be carried out in accordance with site QA/QC procedures, provided by

fireproofing material manufacturer. 2 Applicator shall ensure that all work is inspected at all stages, for quality control in respect of

reinforcement strength, coverage, thickness, finish uniformity and application. 3 Applicator shall ensure that all materials meet service conditions and design requirements. 4 Acceptance of applied thickness shall be based upon random measurements, but in no case shall be

less than minimum stated within fireproofing manufacturer’s application specification and project document.

Repair 1 Repair of damaged or defective areas shall be accomplished in same manner as original coating, as

specified in project specifications &manufacturer’s instructions. 2 Repair materials and procedures shall be approved by contractor/company prior to commencing

repair work. 3 Surface finishing of repaired material shall be identical to finish of adjacent original approved

application.

DefinitionsDefinitions regarding certain terms1 Safety means safety, health & environment disciplines to support project activities2 Company means an organization carrying out or prosecuting project/contractually, is defined

engineer/client3 Contractor means organization that has won project from client4 Subcontractor means an organization that has won part of a project work from contractor

organization5 Client means an organization entitled company in contractual terms that has entrusted project to

organization of contractor6 Personnel means all personnel involved on project site activities including all parties7 Responsibility means job & contract responsibility8 Training means training imparted for specific safety topic on job/on project site9 Management means organization/s top, middle & lower management10 Safety manager means a person with job title safety manager deployed by certain organization11 Project manager means a person as such, with PM title deployed by contractor & approved by

engineer/client12 Engineer means a person appointed by client or client company, for an overall project responsibility

Project Engineer/Employer/owner- ENGINEERSafety Task Analysis Risk Reduction Talk (STARRT) 1 A process that utilises employees/personnel to identify and resolve environmental, safety and health

hazards, associated with a task prior to its being performed (Attachment).



Environment Clauses For Plant IndustryJob Hazard Analysis (JHA) 1 Identifies key job steps, tools, equipment, potential environmental, safety and health hazards, hazard

control practices, required personal protection equipment (PPE) for larger, more complex and usually repetitive jobs.

2 It is prepared by a team normally consisting of a representative from environmental, safety and health department, employee supervisors and field engineering representative

Task/Activity 1 A specific activity or subpart of a job (i.e. installing a pipe hanger, building a concrete form or

installing electrical power to a fabrication area).Hazard Control Sheets 1 A series of risk assessment sheets used for assisting line supervision in developing STARRT/JHA

process.2 Responsibilities in general respecting certain contract positions3 Project Manager responsible for overall obligations, to provide schedule, all resources, direction,

engineering resolutions.4 Site Manager responsible for overall site prosecution management over works & subcontractors.5 Site Safety Officer responsible for overall safety management on site & report to Project

Manager/Site Manager/Corporate Safety Manager6 Construction Manager responsible to arrange all safety related resources & provide site team all

requirements 7 Project Site Engineer responsible to carry out safety issues within section8 Site Safety Inspector/Engineer responsible to supervise safety measures on site & control safety

issues, should bring to site line management to adopt correct measures.9 Site Foremen responsible for compliance of safety measures as standards or as directed10 An individual working on site responsible to maintain safety measures, in case missing, should bring

to site team attentionResponsibilitiesSite Manager 1 Ensure that this procedure is being applied for control of all activities through EPC contractor

supervision and subcontractor managementHealth, Safety and Environment Supervisor/Manager1 Is responsible for development of this procedure and monitoring complianceSite Manager – (Civil or other discipline Contractor)1 Shall ensure that sufficient resources are provided to implement this procedure and that procedure is

understood as well as, applied in conformities.Site Superintendents/Supervision & Subcontractor1 Shall be thoroughly, familiar with this procedure on their individual responsibilities regarding

implementation and enforcement.2 Shall carry out regular inspections (daily) within their work areas to ensure that requirements under

this procedure are being followed.

Instructions1 Guidelines for STARRT2 Subcontractor Supervision shall ensure employees involvement with STARRT process by:3 Ensuring that all employees under control are trained in STARRT process4 Establishing a system to follow up with all crews to verify STARRT process is being correctly

implement5 Requiring employees to participate with an individual STARRT review prior to start of each shift for

each new task



Environment Clauses For Plant Industry6 Supervisors shall discuss hazards relating to project/facility with employees to compile information

necessary to complete STARRT card 7 Upon completion of STARRT card, supervisors shall review requirements of card with employees

performing work and supervisor sign card.8 Card shall be translated into common workers language and displayed for review within

immediate work area.9 STARRT cards are to be returned to supervisor and forwarded to Contractor’s Safety Supervisor’s

office as appropriate at end of each shift or completion of work activity. Supervisor is responsible for ensuring that cards are properly completed, signed and returned.

10 STARRT cards should be reviewed for proper usage/completion by Health, Safety and Environmental Supervisor and recorded on file in contractor’s HS&E Office.

Guidelines for Job Hazard Analysis (JHA)1 JHA may be included as part of a work plan/work package. 2 Requirements of JHA may be incorporated into hazardous work permits (HWP) as well as,

project/facility specific HSE plans as appropriate.3 A JHA of specific jobs or operations is required for, but not limited to followings only:

a High risk jobsb New jobs or tasks that present unspecified or unknown hazardsc Jobs or tasks involving new equipment, machinery or proceduresd Major job categories that shall be repeated frequentlye Jobs or tasks that have historically experienced a repeated or significant rate of accidents,

injuries, exposures or near missesf Jobs involving environmental remedy of hazardous waste.g Jobs or tasks that in professional judgment of responsible HSE Representative require a formal

JHA.h Jobs or tasks are broken down into a series of successive steps or activities. i Required or anticipated tools and equipment for each step or activity are to be included. j All potential hazards within each step or activity are identified.

Include following hazard categories in JHA:1 Chemical exposures2 Oxygen deficiency3 Exposures to ionizing and non ionizing radiation4 Electrical hazards5 Physical hazards6 Fire and explosion7 Temperature extremes8 Excessive noise9 Biological hazards

Input1 Input should be solicited from multi disciplinary professional staff for hazard evaluation. 2 This input should include safety, industrial hygiene, health physics, and engineering personnel.3 After all known suspected or potential hazards have been identified and accident experiences

reviewed, a plan must be developed giving solutions to eliminate further/or control hazards.4 Elimination or control of hazard should be implemented first by engineering methods then by

administrative methods and at last, by proper use of Personal Protection Equipment (PPE).

Guidelines for Using Hazard Control Sheets



Environment Clauses For Plant Industry1 Hazard Control Sheet applicable to a work activity shall be used as a reference on developing a

STARRT card or a specific Job Hazard Analysis.2 In circumstances, where a STARRT card or JHA are not deemed necessary then Hazard Control

sheet may be used as a guideline for conducting a task team talk by supervision to respective employees.

References1 BS HSE proceduresAttachments1 STARRT Card2 Job Hazard Analysis and Control Program Sheets

AttachmentSafety Task Analysis Risk Reduction Talk

(STARRT) CARDSUPERVISOR:

DATE:

JOB DESCRIPTION:

PRIMARY HAZARDS RISKS:

LOCATION:

ELECTRICAL Y N NALOCKED & TAGGEDTRY & TESTDISCONNECTEDEXCAVATIONSHORED/ BATTEREDLADDER PROVIDEDDAILY INSPECTIONENTRY PERMITHAZARDS (BODY)FALL POTENTIALPINCH POINTSELECTRICAL SHOCKHOUSEKEEPINGSLIP TRIP



Environment Clauses For Plant IndustryFLYING PARTICLESTHERMAL BURNSMANUAL LIFTINGSHARP OBJECTPERMITSHOT WORKCONFINED SPACEBREAKING PROCESSEXCAVATIONCRITICAL LIFT PLANPERSONNEL BASKETEMERGENCY EQUIPMENTFIRE EXTINGUISHERSAFETY SHOWEREYEWASHPERMIT DISPLAYEDALL CONDITIONS METEVACUATIONASSEMBLY AREAHAZARDS (ENVIRONMENTAL)AIRBORNE PARTICLESVAPOURSHOT/COLD SURFACESHOT/COLD MATERIALSNOISEHEAT STRESSPROPER EQUIPMENTMAN LIFTPERSONAL BASKETFORKLIFTJLG LIFTCRANECHAINFALLHAND TOOLSPOWERED TOOLSGOOD CONDITIONSOPERATOR CERTIFICATE



Environment Clauses For Plant IndustryPROPER RIGGINGCURRENT INSPECTIONTRUCKS, TRACTORS etcOVERHEAD WORK OR FLOOR OPENINGFIXED BARRICADES(TAPE) DANGER(TAPE) CAUTIONBARRIERSSIGNSHOLE COVER/CLEATHANDRAILS/TOEBOARDPROCESS EQUIPMENTVALVES LOCKEDTAGS HUNGBLINDS INSTALLED AND TAGGEDPROOFEDSTANDBY PERSONCONFINED SPACEFIRE WATCHSANDBLAST PERSONTRAFFIC WATCHWELDINGSHIELDSFIRE BLANKETFIRE EXTINGUISHERCYLINDERS SECUREDCOMBUSTIBLESMOVED SPARKSSPARKS CONTAINEDHAZARDS (CHEMICAL)MSDS’S REVIEWEDCHEMICAL BURNSKIN/EYE IRRITANTINHALATIONPERSONAL PROTECTIVE EQUIPMENT



Environment Clauses For Plant IndustryWORK GLOVESCHEMICAL GLOVESANTI VIBRATION GLOVESWET SUITSFOOT GUARDSRUBBER BOOTSMONO GOGGLESFACE SHIELDFRESH AIREAR PROTECTIONSAFETY HARNESSBURNING GOGGLESHARD HATSAFETY GLASSESRESPIRATOROTHERS

PRINT EMPLOYEE NAME EMPLOYEE SIGNATURE

1. 2.

3. 4.

5. 6.

7. 8.

9. 10.

11.12.

13.14.

15.16.

17.18.




19.20.

Supervisor Name (print) Supervisors signature______________________________ _______________________________

ATTACHMENT JOB HAZARD ANALYSIS (JHA) and Control Program Sheets




JOB HAZARD ANALYSIS

Description: Location: Page of

KEY JOB STEPS POTENTIAL INJURY OR HEALTH EFFECT

TOOLS OR EQUIPMENT USED ENGINEERING SAFE PRACTICES, EQUIPMENT,

PPE ETC.

Responsible Supervisor: Safety & Health Representative:Date: Date:


ATTACHMENT Hazard Analysis and Control Programme Sheets

001 Civil Works Excavation002 Civil Works Concreting and Shuttering003 General Transportation of Gas Cylinders004 General Gas Cutting005 General Grinding006 General Welding007 General Diesel Engines008 Mechanical Installation Radiography009 Mechanical/Commissioning Pressure Testing010 Electrical Installation Cable Drum Handling011 Electrical Installation Cable Pulling012 Electrical Installation Cable Laying/Cable Termination013 General Material Handling014 General Handling of Steel015 General Handling of Timber016 Civil Works Concrete Pours017 Civil Works Steel Fixing018 Civil Works Backfilling of Excavations019 Mechanical Installation Transportation/Lifting of Heavy Equipment020 Temporary Works Erection of Scaffolding021 Temporary Works Provision & Maintenance of Safe Scaffolding022 Temporary Works Dismantling of Scaffolding

023 General Use of Hazardous Substances024 Civil Works Erection of Fencing025 Civil Works Fabrication of Gates026 Civil Works Erection of Gates027 General Removal of Waste Material028 Mechanical Erection of Steel Work029 Mechanical Installation of pipeline and Valve Fittings030 Electrical Electrical Work031 Civil Works Rock Drilling032 Civil Works Rock Blasting033 Site Preparation Earthworks034 General Site Transport

HAZARD ANALYSIS AND CONTROL PROGRAMMECIVIL WORKSREF No:- A - 001.......................................

ACTIVITYEXCAVATION

HAZARDSa) Cables/pipelines buried underground.b) Existing Structures/Buildings.c) Existing pipes being struck or cracking at joints.d) Vehicles/Plant driving into excavation.e) Personnel falling into excavation.f) Collapse of excavation.g) Accumulation of Gas/Water.

CONTROL MEASURES1. Cable detection instrument/tool to be used prior to excavating in order to determine cable routes. No direct excavation by mechanical

equipment should be conducted in that case.2. Services record drawings to be used to determine existing cable/pipeline route.3. Trial hand digging/excavation to be undertaken in order to verify cable/pipeline route.4. Detailed study to be undertaken, if excavation work is to be carried out adjacent to existing and/or temporary foundations/buildings. 5. Temporary shoring or supporting of structures in order to prevent collapse to be approved and completed prior to commencement of

excavation.6. Pipe work/Cables exposed by excavation to be supported.7. Stops/Barriers to be provided, where necessary at excavation edges in order to prevent vehicles driving into them.8. Banks men to be provided, whenever vehicles are working adjacent to excavations.9. Guardrails to be erected around excavations, where risk of falling being 1.2 to 2 meters or more.10. Excavations deeper than 1.2 meter to be adequately opened benched or supported.11. Certain soils do not allow benching, which excavations should be protected by supports.12. Continuous dewatering is required, when soil is susceptible to subsistence by water.13. A survey of area to be carried out to assess risks to, whatever adjacent structures and/or utilities that may exist. Operators to be

briefed on certain identified potential hazards.14. Prior to commencement of excavation, it has to be structurally studied or analyzed whether or not, proposed excavation would result

in subsidence of adjacent structures. In such a situation, excavation cannot be commenced with, until that portion is well protected against such risk.

15. Adequate access arrangements should be made for all concerned to ingress & egress from trench or pit safely. Benches or ramps may be constructed if soil properties so permit & required land area is available.


ACTIVITYCONCRETING AND SHUTTERING

HAZARDS

a) Unsafe means of access onto shuttering.b) Manual and mechanical handling.c) Handling and use of cement/concrete.d) Use of hand tools/power tools.

CONTROL MEASURES1) Access for personnel to carry out work on shuttering to be planned. Working platform required to be temporarily erected for columns &

beams. 2) Access platforms to be erected for whole area for access. Stepped ladders to be erected when, higher level works are carried out. 3) Ladders shall not be allowed in such cases. 4) No nails should be allowed to be dropped here & there. All nails should be removed from site in every case. Nail can punch into feet of

workers.5) Safe means of access to be provided at all times in order to prevent risk of falls from height.6) Suitable and sufficient crane hoisting to be provided in order to alleviate manual handling of shuttering and associated components. 7) Manual handling procedure to be developed and implemented. For manual handling, assembly of forms should be done on site location

rather than in carpentry shop or yard.8) Mechanical handling of assembled or fabricated sides to be controlled by experienced slingers.9) Where necessary, Banks men consideration for guiding crane operator /high wind conditions and associated risks to be recognized.10) Personnel to be provided with appropriate PPE during work involving cement/concrete - gloves, rubber safety footwear, RPE, hearing

protection, eye protection etc. Training to be given on hazards associated with work with cement/concrete.11) Hand and power tools to be properly maintained. Defective tools shall not be used. Generally, electric saws & electric drills are used on

forms, which must be protected during work. Industrial sockets should be used for protection.12) Dangerous moving parts of machinery to be guarded.13) Proper handling of vibrators should be instructed.14) Carpenters must be available on examination of loosening props/supports.15) Pouring concrete is a continuous operation, which makes it necessary to arrange cold liquids for consumption to prevent dehydration

during hot hours as well as, rest pause intervals. During cold weather, tea or coffee should be allowed to be served.16) Rest pauses must be planned for workers in stages or groups.NOTE: Wash out area for concrete trucks to be identified to prevent build up of waste concrete.

HAZARD ANALYSIS AND CONTROL PROGRAMMEGENERAL

REF No:- A - 003.......................................

ACTIVITYTRANSPORTATION OF GAS CYLINDERS

HAZARDSa) Fire/Explosion during transportation.b) Manual handling and health risk.

CONTROL MEASURES1) Cylinders to be supported during transportation in order to prevent them from falling over.2) Cylinders to be segregated by type in order to prevent fire/explosion risk.3) Valve caps to be fitted to all gas cylinders during transportation.4) Loading/Off Loading of cylinders to be carried out by competent person utilizing correct slinging techniques.5) Cylinders being offloaded from a vehicle should not be dropped to ground and shall not be rolled. Only vertical position handling is

permissible. Horizontal handling may result in leakage though valves leading to hazards.6) While cylinders are transported by vehicle in city, an alert should be sounded en route about travel, so that others keep off vehicle

avoiding possible explosive danger.

HAZARD ANALYSIS AND CONTROL PROGRAMMEGENERALREF No:- A - 004.......................................

ACTIVITYGAS CUTTING

HAZARDSa) Cylinder explosion.b) Damage to eyes.c) Fire.d) Explosion risk - Live plant.

CONTROL MEASURES1) Oxygen cylinders valves/fittings to be kept free from grease/oil.2) Flashback arrestors to be fitted to gas cylinders.

3) Gas hoses and gauges to be maintained in a safe condition and inspected daily. Defective hoses and gauges are to be replaced immediately.

4) Cylinders to be used in vertical position and secured against falling.5) Personnel carrying out gas cutting operations shall wear suitable eye protection.6) Suitable measures e.g. Provision of fire blankets/fire watchers, shall be used to prevent risk of fire during cutting operations.7) Prior to gas cutting operations in Live plant areas, gas checking shall be carried out and work would proceed in accordance with ‘permit

to work’ requirements.


ACTIVITYGRINDING

HAZARDSa) Damage to eyes/hearing/other body parts.b) Fire/Explosion.c) Wheel burst.

CONTROL MEASURES1) Grinders to be maintained in good condition and inspected prior to use.2) Guards to be fitted to grinders. Without guards, equipment shall not be used.3) Changing of abrasive wheels to be carried out by trained and authorized personnel using proper disc spanners.4) Personnel carrying out grinding work shall wear suitable eye and hearing protections.5) Grinding operations in Live plant areas shall be carried out in accordance with ‘permit to work’ requirements.6) Grinding operations shall be controlled in order to prevent risk of injury to other personnel from sparks/metal splinters. Immediate medical aid should be made available, in case of injury to hand or fingers.8) Housekeeping in areas at grinding operations to be maintained at high level. 9) No cable should lie on floors in working areas to avoid tripping hazards.

10) Grinder operator should concentrate on its working without disturbance by either use of mobile phone or talking to others.11) Precautions should be taken respectively for vertical use grinder as well as horizontal use grinder accordingly. Horizontal use grinders do

not require any guide on it. Vertical use grinder requires guide on it.12) Both types are required to carry out different activities. For example, vertical type is generally used for cutting while, horizontal type is

used particularly, for grinding uneven surfaces on floors, walls or ceilings. Accordingly, safety issues should be care about.

HAZARD ANALYSIS AND CONTROL PROGRAMMEGENERALREF No:- A - 006......................................

ACTIVITYWELDING

HAZARDSa) Damage to body parts.b) Fire/Explosion.c) Electrocution.d) Health impairment.

CONTROL MEASURES1) Welders shall be provided with and wear following personal protective equipment:-

Welding gloves Overalls Welding goggles with correct filter RPE (where identified) (Respiratory Protective Equipment)

2) Flammable materials shall be removed from areas, where welding is to be conducted.3) Fire extinguisher should be immediately made available in areas of welding operation.4) If as indicated in (2) is not practicable, other suitable precautions shall be taken to alleviate fire and explosion risk e.g. Provision of fire

blankets/fire watcher. Fire watcher should constantly surveillance welding activity & act instantly to extinguish fire using fire extinguishers. In case of fire spread, further action should promptly be resorted to.

5) Before welding operations are carried out, materials involved and their byproducts shall be identified, risks assessed and necessary control measures identified in order to prevent possible respiratory disease/systemic poisoning (e.g. cadmium, stainless steel, galvanized, lead coated materials).

6) Welding cables and cable joints shall be maintained in a good condition.

7) Welding returns should be firmly connected to metal on which, welding is applied. This requirement to be carried out by means of well constructed earth clamps only.

8) In order to prevent risk of Arc Eye injury to other personnel, suitable screens to be placed around welders working area.9) Damp, humid and wet conditions shall decide for voltage and type of transformer used.


ACTIVITYDIESEL ENGINES (Process Areas)

HAZARDSa) Engine exhaust firesb) Over speeding of engine in live plant areas.

CONTROL MEASURES1) Spark arrestors to be fitted to diesel engine exhausts.2) Chelwyn valves shall also, be fitted where needed

HAZARD ANALYSIS AND CONTROL PROGRAMMEMECHANICAL INSTALLATIONREF No:- A - 008.......................................

ACTIVITYRADIOGRAPHY

HAZARDSa) Exposure to radiation.

CONTROL MEASURES1) Site radiography shall only be carried out by competent and experienced radiographers2) Radiation testing kit or instrument shall be used by personnel involved on testing.3) Transport driver shall also, use radiation testing instrument.

4) Site radiography to be carried out in accordance with procedure for site radiography set out in EPC Contractor’s/EMPLOYER’s HSE Manual.

5) Local working rules shall be consulted/submitted by NDT contractor prior to work6) Area shall be barricaded by embankment on site for open performance. Embankment shall be higher to diminish radiations 7) Material storage pit say 1 to 1.5 m deep shall be constructed to avoid unauthorized access8) Emergency equipment e.g. local shielding, sand bags, tongs etc. to be provided on site.9) Warning signs/barriers/flashing lights/alarms etc. to be provided. Tri Folio warning sign shall show RPO address, telephone & location.10) Radiation meters to be calibrated and certification obtained11) Contractors, personnel located in adjacent working area and security staff to be notified in advance. 12) General notification respecting radiations to be circulated to all.

HAZARD ANALYSIS AND CONTROL PROGRAMMEMECHANICAL / COMMISSIONINGREF No:- A - 009.......................................

ACTIVITYPRESSURE TESTING

HAZARDSa) Bursting of blinds/pipes/fittings under pressure testing.

CONTROL MEASURES1) Pressure testing of piping shall only be carried out by competent and experienced personnel2) Pipe work under test and surrounding area to be barricaded / cordoned off and suitable warning signs displayed.3) Non testing related personnel shall be instructed not to enter areas, where pressure testing is being conducted.4) A written procedure for gradual pressurization to be developed.5) All fittings e.g. sight glasses, gauges, bursting discs likely to fail under test pressure to be removed.

HAZARD ANALYSIS AND CONTROL PROGRAMMEELECTRICAL INSTALLATIONREF No:- A - 010.......................................

ACTIVITYCABLE DRUMHANDLING

HAZARDSa) Cable drum fallingb) Trapping injuries.

CONTROL MEASURES1) Damaged cable drums not to be used.2) Vehicles to be located suitably with regard to site traffic and area for offloading to be barricaded off.3) Cable drums to be loaded/offloaded using slings of an adequate strength to sustain working load safely. This operation is to be carried out

by experienced and competent personnel.4) Cable jacks to be placed on even surfaces.5) Cable drums shall be located on cable jacks of suitable capacity and base designed for this purpose.6) Protruding nails on cable drums to be removed/bent over.7) Cable drums to be checked, when stored.

HAZARD ANALYSIS AND CONTROL PROGRAMMEELECTRICAL INSTALLATIONREF No:- A - 011......................................

ACTIVITYCABLE PULLING

HAZARDSa) Cable drum fallingb) Trapping injuries.c) Manual handling - back injuries.

CONTROL MEASURES1) Personnel to wear suitable gloves/footwear, when cable pulling is ongoing.2) Cable jacks to be of sufficient capacity and placed on an even surface.

3) Personnel shall be instructed in cable pulling techniques/methods including requirement for ensuring good manual handling methods as well, when so adopted.

4) Assessment of weight of cable to be pulled and numbers of persons required to be defined depending on cable weight calculated or assessed.

HAZARD ANALYSIS AND CONTROL PROGRAMMEELECTRICAL INSTALLATIONREF No:- A - 012.......................................

ACTIVITYCABLE LAYING / CABLE TERMINATION

HAZARDSa) Cable drum fallingb) Trapping injuries.c) Manual handling - back injuries.

CONTROL MEASURES1) Personnel to wear suitable gloves/footwear, when cable laying/terminating cables.2) Cable jacks to be of sufficient capacity and should be placed on an even surface.3) Warning signs to be positioned adjacent to cable laying/cable termination areas.4) Personnel shall be trained in cable laying/cable termination techniques including requirements for ensuring good manual handling methods

as well, when so adopted.5) Cable terminations shall be carried out by trained and competent personnel using suitable tools6) ‘Permit to work’ system to be followed to ensure that glands and terminals of cables are on electrically isolated panels.


ACTIVITY

MATERIAL HANDLINGHAZARDS

a) Manual handling - back injuriesCONTROL MEASURES

1) Whenever practicable, mechanical lifting aids e.g. cranes, forklift trucks etc. shall be used to alleviate requirement for manual handling. 2) Supervision shall assess weight, center of gravity etc. and determine number of persons required to carry out work safely.3) Personnel should be trained in safe manual handling techniques, which are many times too useful to save time & cost.4) Gloves, Safety footwear and goggles to be worn by personnel engaged in material handling.5) Good housekeeping measures shall be enforced in order to prevent slips, trips and falls during material handling.6) Material shall be stored in designated areas. Storing should be conducted systematically.7) Material that is required for finishing items should be separately stored to avoid damage by hard materials.8) Materials should be stored in such a manner that issues to site from stocks or stores should be conducted in a professional manner without

damages either to workers or to personnel.9) During manual handling single pieces, safety officer or foreman should instruct personnel to handle in such a way that least impact is

transferred to worker’s body.10) Cement bags should not be transported by putting on heads of personnel.11) Steel bars should not be carried by keeping on shoulders of workers en route to site locations from fabrication yard.


ACTIVITYHANDLING OF STEEL

HAZARDSa) Trapping injuries.b) Falling material.c) Manual handling.d) Slips, trips and falls.

CONTROL MEASURES1) Personnel to wear suitable gloves/footwear and goggles, when handling steel.2) Personnel to be trained in slinging and banks man techniques in order to ensure materials are lifted in a safe manner.3) Suitable equipment is to be used to lift steelwork.4) Steel shall be stored in a designated area on wooden skids/sleepers.5) Good housekeeping standards shall be maintained in steel lay down areas in order to prevent slips, trips and falls.6) Tug lines should be used, when lifting/traveling materials by cranes.7) Personnel not involved in any steel handling, operation to be kept clear off from area of work.


ACTIVITYHANDLING OF TIMBER

HAZARDSa) Trapping injuryb) Slip, Trip and Fallc) Hand injury

CONTROL MEASURES1) Personnel to wear suitable gloves/footwear, when handling timber products.2) Timber to be de nailed in order to prevent penetration into feet or other parts of body by overlooking by someone.3) Timber shall be stored in designated areas away from offices and other buildings.4) Good standards of housekeeping shall be maintained in order to prevent slips, trips and falls.5) Sawn wood chips and sawdust pools must be removed in a timely manner to prevent accumulation of fire hazard.6) Circular saws to be fitted with riving knives and guards.7) Push sticks to be used for cutting of timber by circular saws.8) Personnel shall be instructed on safe operation of mechanical equipment.9) Carpenter’s saw table should be well designed, so that carpenters while operating electric saw, do not feel tired or endangered.10) Industrial electrical fittings should be used for connection to electric saw.

11) Fabrication should be numbered accordingly after one job is complete, which should then be placed at one corner for shifting to site location.

12) All jobs so finished shall be placed within carpentry yard or shop or on site areas designated as such, so that no circulation of other site workers as well as, working carpenters, is obstructed & makes site untidy.

13) All pieces of sides so fabricated should be transferred to site using mechanical means to avoid injuries & also, to save working time. 14) Suggested not to crowd carpentry shop but, earliest installation of forms on site location is always better.

HAZARD ANALYSIS AND CONTROL PROGRAMMECIVILSREF No:- ...A - 016......................................

ACTIVITYCONCRETE POURS/Post Pours

HAZARDSa) Manual handling.b) Defective plant/equipment.c) Falling materials.

CONTROL MEASURES1) Personnel placing concrete shall wear suitable gloves/footwear and eye protection.2) Plant and equipment used during concrete placing to be operated by trained and authorized personnel under close supervision3) To an extent feasible, concrete should be procured from an approved concrete mixing pant & transported to site using transit mixer.4) All plant and equipment shall carry current certification and be maintained in a safe condition. Defective plant/equipment to be removed

from service and effective remedial actions taken. 5) Slinging and lifting operations to be carried out by trained personnel6) Unauthorized personnel must be prohibited from entering areas, where concrete placing activities are being undertaken.7) Access across re-bar fixing shall be maintained with timber boarding to provide a safe access and place of work.8) Concrete pump should be so stationed that its boom reaches to site location conveniently & concrete is poured to locations without causing

any impact or concrete pulling manually. Workers in crew should not stand below concrete pump boom discharge outlet.9) Provide cold drinks & refreshments to all crew workers for long hour concrete pours to prevent dehydration.10) Allow rest pauses intermittently to crew groups by replacing with other workers.

11) During night hours, hot tea should also, be allowed for upkeep of mood.12) While, applying power float & curing, tired crew members should not be deployed.13) Adequate lights should be provided at night hour operations both above & below suspended slab pours to ensure supports are intact.14) Requirement of traffic diversion should be conducted, if so required during day as well as, during night hours. 15) Transit mixers & concrete pumps may occupy road space temporarily for which official permission as well as, traffic diversion made with

signaling persons/flags men on duty throughout concrete operation remains ongoing.16) Specific area should be selected at off site locations with official approval for cleaning transit mixers after concrete has been delivered to

locations on site. 17) All such dumped concrete after it is dried should be removed to permanent dumping site keeping in view environment controls.18) Adequate curing arrangements should be made post pour using water hose up to required level by pumping or otherwise. Minimum manual

handling of water for curing using bucket etc. should be conducted. 19) When curing is conducted using curing compound, all precautions envisaged by compound manufacturer should be strictly adhered to.20) When using certain defects observed post concrete, whatever chemicals to be used for repairs shall be complied with manufacturer’s

instructions on applications method statements. Masks should be used, while applying chemicals.21) When certain repairs are required by concrete surface chipping, adequate precautions should be taken by protection of eyes. Masks should

be used while chipping or working in concrete areas that are still under water cement reactions.22) Should repairs be conducted in basements or areas, where no ventilations is available, adequate ventilation arrangements should be made

available by providing suitable fans or ducts to supply fresh air.23) Adequate lights should be provided in all such non ventilated areas. No loose cable or surface cables should be seen on floors.


ACTIVITYSTEEL FIXING

HAZARDSa) Falling materialb) Slip, Trip and Fallc) Manual Handling.d) Cut injuries.

CONTROL MEASURES1) Experienced and trained steel fixers shall be used with adequate supervision provided.2) Steel fixers should wear suitable gloves/footwear and eye protection.3) Re-Bar shall be lifted into work area using certificated lifting equipment and tackle.4) Re-Bar off cuts / binding wire requires to be removed in order to prevent slips, trips and falls.5) Steel fixers to use proper tools in order to assist in bar bending (type activities).6) Toolbox talks shall be conducted emphasizing hazards of bar bending (pinch points) and handling steel re-bar (sharp edges)7) Exposed vertical bars e.g. pile CAPs/columns/others that are left in a manner that exposes personnel to risk shall be covered or protected

by plastic caps temporarily or by some other means. 8) No unauthorized access shall be allowed to any such steel areas. Warning signs shall be installed indicating exposed steel bars.9) Adequate & suitable steel dies should be used properly fixed to bender’s desk or table or post. Preferably bending machine should be used.10) Though, manually bending is not preferred but, in case, quantity is smaller & immediate electric supply is not available as well as, keeping

abreast economy on item, it may be permitted.11) Similarly, cutting bars manually may be permitted but, electrical operated cutting machine is recommended for major rebar cutting for

major quantities. 12) During manual cutting, safety risks are highly significant for hazard consideration, which requires strict & close controls on safety.13) Cut waste & smaller bars should not be left around on site locations as well as, on site areas that converts site into untidy description state.

All such pieces should be stored for possible use as either spacer bars or for scrap disposal.14) In case, bars are required to be welded on site, all safety considerations about welding should be applied. 15) Placing & fixing steel bars are of much significance. Excessive heat/high temperature working environment is not recommended. 16) To an extent possible, steel bars should be assembled in shop & then raised or transported to location for a good functioning but, it is not

always possible.17) For steel placing & fixing on higher levels, adequate arrangements of scaffolding & well guarded working platforms must be made

available for workers to stand safe on such platforms. Stepped access must be provided to lead to such areas.18) Adequate arrangements should be made by using wooden planks on steel assembled meshes on horizontal placed steel for easy walking

during working, so that chances of falling from bare steel are avoided.19) Magnet should be used to remove all nails, steel wires from forms prior to commencement of concrete pours. Such nails & wires should

not be pulled out using arms.20) Strong convenient steel fabricates chairs should be placed as close as possible to allow good support to upper steel bars & smooth

movement to steel fixers & other personnel

HAZARD ANALYSIS AND CONTROL PROGRAMMECIVIL WORKREF No:- A - 018......................................

ACTIVITYBACKFILLING OF EXCAVATIONS

HAZARDSa) Collapse of excavation.b) Physical injury due to proximity of plant.

CONTROL MEASURES1) Only approved mechanical shovels/JCB shall be used to carry out this work.2) Plant used to backfill excavations should carry current certification and maintained in a safe condition.3) Plant shall be operated by trained and authorized personnel4) Banks men shall be deployed to control backfilling operation in order to prevent plant working too close to excavation pit or trench edge.5) Unauthorized personnel should be excluded from areas, where backfilling of excavations is moving.6) In case of mass fill using mechanical equipment, it is to be ensured that pressure imposed from heavy equipment may not damage certain

below ground services or also, not damage nearby structures. Simultaneously, to be studied that compaction in layer could be attained without compromising safety of equipment & personnel.

7) In case, by backfilling activity dusting on site results, water should be sprinkled

HAZARD ANALYSIS AND CONTROL PROGRAMMEMECHANICAL INSTALLATIONREF No:- A - 019.......................................

ACTIVITYTRANSPORTATION / LIFTING OF HEAVY EQUIPMENT

HAZARDSa) Defective equipment.b) Overloading of vehicles.

CONTROL MEASURES1) Plant/Equipment used shall be maintained in a good condition.2) Licensed and experienced operators shall be deployed /entrusted to carry out this activity.3) Loading of equipment to be carried out in accordance with company approval.4) Loading shall be closely supervised in attendance of trained banks men.5) Rigging /Crane studies shall be conducted, if so required to ensure lifting operation is carried out in a controlled and effective manner,

utilizing located /provided existing lifting points.6) Weight of raise able load shall be determined to ensure that overloading is prevented.7) Banks men shall wear reflecting vests or jackets or other means of personal identification.8) Arrangement to raise loads to be in such a manner that crane or lifting equipment is stationed nearest to structure. Simultaneously, angle of

boom shall also be ensured not to be maximum degree.9) It is suggested to select certain locations of equipment on site so that one station may serve many lifts. Such consideration saves

repositioning time of equipment.10) Prior to lift load or raise it to location, at low level, a test may be conducted that load remains well suspended. It is better if failure occurs

at low level rather than from higher levels. It is also, significant to note that a blind trust cannot be made even on, third party certification of fitness respecting equipment.

HAZARD ANALYSIS AND CONTROL PROGRAMMETEMPORARY WORKSREF No:- A - 020.......................................

ACTIVITYERECTION OF SCAFFOLDING

HAZARDSa) Scaffolders fall from height.b) Scaffolders / Other personnel injured by falling materials.

CONTROL MEASURES1) Scaffold erection to be undertaken by trained scaffolders working under competent supervision.2) Safe means of access/egress to be provided and maintained for scaffolders carrying out erection work.3) Suitable and sufficient material shall be available in order for scaffold to be erected properly.

4) Scaffolders to wear gloves, safety footwear, safety helmets and safety harnesses during scaffold erection activities.5) Scaffold components to be lifted using safe techniques. (Components should neither be thrown up to scaffolder nor to ground).6) Unauthorized personnel to be excluded from area, where scaffold erection is being carried out.7) Scaffolds and access ladders to be tagged as ‘Safe to use’ by a competent person on completion prior to use.8) It is suggested to procure, if not brand new, little older scaffolding material, so that it retains its original strength that cannot be 100%

assured when, old material is used. 9) When material is procured, its datasheet must be referred to in details to ensure what strength all members possess. Whatever load is

transferred to these members should be comparatively, lesser than specified.10) Ensure that all materials are classified & stored accordingly, so that tracing by personnel is an easy exercise. 11) When, design of scaffolding is available, that has to be followed on site & materials be laid accordingly in a systematic style. All

scaffolders require understand such significant information.


ACTIVITYPROVISION AND MAINTENANCE OF SAFE SCAFFOLDING

HAZARDSa) Collapse of scaffoldb) Personnel falling from scaffolding.

CONTROL MEASURES1) Detailed consideration shall be given to all scaffolding to ensure that it is properly planned and erected to meet working requirements,

designed to carry necessary loading and maintained in a sound condition (B.S. 5973 shall be followed as guidance).2) Scaffolding shall be provided with adequate ties/supports in order to prevent collapse.3) Scaffolding shall be inspected and tagged prior to use4) Regular inspections of scaffolding shall be conducted and recorded in order to ensure that structure is maintained in a safe condition.5) Personnel working from scaffolds shall be instructed not to interfere or alter an existing scaffold.6) Effective actions to be taken by supervision in order to ensure that scaffolding defects are rectified immediately e.g. guard rails replaced or

toe boards replaced etc.

7) Only authorized scaffolders shall be allowed to alter scaffolding in whatever way. Supervision shall liaise with scaffolders in order to ensure coordination of scaffolding fitness & its maintenance.

8) Incomplete scaffolding to be clearly identified and personnel should be prohibited from using such structures. Regular inspection of scaffolding to be conducted.


ACTIVITYDISMANTLING OF SCAFFOLDING

HAZARDSa) Fall off scaffold material, during dismantling.b) Fall off scaffolders/other personnel during dismantling.

CONTROL MEASURES1) Dismantling of scaffolding to be carried out by trained and competent scaffolders under supervision.2) An assessment by supervisor in charge of best method of dismantling scaffold shall be conducted to reduce overall risks, risk at falling

material and maintenance of stability of structure prior to dismantling.3) No ties or bracing shall be removed in advance of general dismantling.4) Working platforms shall be dusted and cleared of all materials and debris before dismantling commences.5) All possible access to dismantled sections of scaffolding should be barred and a warning sign displayed for displaying ‘not to use’

indication or instruction.6) Scaffold materials shall be lowered carefully. ‘Bombing’ of scaffold materials shall be strictly prohibited.7) Surplus boards and fittings shall be removed from platforms, as work progresses and at end of each day.8) Tubes and fittings shall be stacked at ground level, unless first lift has been designed to support extra loading.9) Unauthorized personnel shall be excluded from areas, where dismantling of scaffolding is ongoing.

HAZARD ANALYSIS AND CONTROL PROGRAMMEGENERAL

REF No:- A - 023.......................................

ACTIVITYUSE OF HAZARDOUS SUBSTANCES

HAZARDSa) Health impairment.b) Fire/explosion.c) Environmental impact.

CONTROL MEASURES1) Assessments on hazards and risks to health by potentially harmful substances shall be conducted. These assessments shall detail control

measures that should be affected to reduce risks to health.2) Material safety data sheets MSDS, assessments of risk and necessary control measures to be adopted, prior to work being carried out.3) Personnel shall be instructed to take appropriate precautions to protect their health from impacts of hazards. Training to be conducted for

correct use and maintenance of personal protective equipment.4) Hazardous substances shall be stored in a safety required manner. Materials shall be segregated in accordance with good industrial

practice e.g. keeping oxidizing and reducing agents apart.5) Contingency arrangements should be adopted to prevent spillage of some hazardous substance to ground.

HAZARD ANALYSIS AND CONTROL PROGRAMMECIVIL WORKSREF No:- A - 024.....................................

ACTIVITYERECTION OF FENCING

HAZARDSa) Fall of material.b) Manual handling.c) Slip, trip and fall.

CONTROL MEASURES1) Erection of fencing to be carried out by personnel, who have been clearly briefed in proper method of work.

2) Good housekeeping standards shall be maintained during work.3) Suitable tools shall be used during stretching of mesh.4) Posts shall be lifted with mechanical assistance in order to alleviate manual handling.5) Personnel to wear gloves, safety footwear and safety helmets during work.6) Training shall be conducted on hazards associated with cement/concrete work.7) ‘Permit(s) to work’ shall be required, when working adjacent to overhead lines, underground utilities etc.

HAZARD ANALYSIS AND CONTROL PROGRAMMECIVIL WORKSREF No:- A - 025.......

ACTIVITYFABRICATION OF GATES

HAZARDSa) Falling materials.b) Fire and explosion.c) Damage to body parts.d) Electric shock.

CONTROL MEASURES1) Gate fabrication to be carried out by personnel, who have been familiar with requirement for safe working practices.2) Personnel to wear gloves, safety footwear and welding goggles with suitable filter during carrying out this work.3) Welding shall be carried out in dry conditions and in accordance with requirements of Hazard Analysis and Control Procedure respecting

welding control sheet.4) Gas cutting to be carried out in accordance with requirements of Hazard Analysis and Control procedure respecting gas cutting control

Sheet.5) Good standards of housekeeping shall be maintained in fabrication area.6) Fire extinguishers shall be provided.7) Oxy/Acetylene sets to be located in an adjacent location with valve keys fitted and secured upright and flash back arrestors fitted.

HAZARD ANALYSIS AND CONTROL PROGRAMME

CIVIL WORKSREF No:- A - 026................................

ACTIVITYERECTION OF GATES

HAZARDSa) Fall of gate.b) Damage to body parts.c) Manual handling.

CONTROL MEASURES1) Gate erection to be carried out by trained personnel under supervision.2) Personnel to wear gloves, safety footwear and safety helmets.3) Sharp edges on gates to be removed by grinding prior to erection.4) Lifting of gates into position shall be undertaken using suitable lifting tackle and equipment.

HAZARD ANALYSIS AND CONTROL PROGRAMMEGENERALREF No:- A - 027.......

ACTIVITYREMOVAL OF WASTE MATERIAL

HAZARDSa) Manual handlingb) Damage to body partsc) Occupational health problems

CONTROL MEASURES1) Personnel engaged in removal of waste material shall wear gloves, safety footwear and safety helmets.2) Light waste to be swept up and removed using a wheelbarrow.3) Heavier waste e.g. steel off cuts, drums etc. should be removed using mechanical plant e.g. fork lift truck, excavator etc.

4) Waste material shall be stored in designated areas in steel skips.5) Waste material classified as hazardous shall be removed by a service contractor duly classed as competent for such work task6) Hazard sheet in relevance to hazardous waste shall be followed for handling of some/whatsoever hazardous waste.

HAZARD ANALYSIS AND CONTROL PROGRAMMEMECHANICALREF No:- A - 028..................................

ACTIVITYERECTION OF STEELWORK

HAZARDSa) Falls from height.b) Structural stability.c) Manual handling.d) Falling materials.e) Trapping injuries.f) Slips, trips and falls.

CONTROL MEASURES1) Steel erection shall be carried out by trained and competent personnel working under supervision. Work may also, be conducted at night

during hot weather conditions.2) Method statements detailing proposed erection schemes shall be submitted for approval.3) These method statements shall identify hazardous site features and other aspects likely to impair safe erection. 4) Proposed methods for ensuring stability of framework and its components during erection, until completion shall also, require to be

addressed. 5) Initial framing shall be assembled on ground &then raised by cranes to locations for lineup, level & fastening etc.6) Steelwork shall be lifted into position using suitable certified lifting tackle/equipment. 7) Trained banks men/slingers shall be used to control lifting operations.8) Personnel should wear gloves, safety footwear and safety helmets. 9) Safety harnesses to be worn and attached to a secure anchor point, when erection work is being undertaken.10) Safe means of access onto steelwork to be provided and maintained. Man lift shall be utilized for raising personnel to carry out alignment

& fastening activities.11) Good housekeeping standards shall be maintained in areas, where equipment erection is being undertaken.12) Area of site affected by erection operations shall be designated as a restricted area:- barriers and notices to be erected to prohibit entry to

non erection personnel.13) Certain modification or changes on bolt holes or other steel members may be carried out on ground preferably. 14) If so required, such activities could be conducted on higher level at exact locations provided, all safety measures are made.

HAZARD ANALYSIS AND CONTROL PROGRAMMEMECHANICALREF No:- A - 029..........

ACTIVITYINSTALLATION OF PIPELINE AND VALVE FITTINGS

HAZARDSa) Manual handling.b) Trapping.c) Slip, trip and fall.

CONTROL MEASURES1) Installation shall be carried out by trained and competent personnel working under supervision2) Heavy fittings shall be lifted using suitable certificated lifting tackle/equipment and tug lines.3) Personnel should wear gloves, safety footwear and safety helmets.4) Suitable tools should be used to assist in installation of fittings.5) Good housekeeping standards shall be maintained in areas, where installation work is being undertaken.6) Pipelines shall only be installed on structures, which have been mechanically complete or are safe to work from.7) Rigging studies shall be prepared for spool pieces/valves etc. being placed inside structures of limited access.8) No pipes shall be placed & fixed on such framing that has not been tested & approved by competent inspection.

HAZARD ANALYSIS AND CONTROL PROGRAMMEELECTRICAL

REF No:- A - 030..........................

ACTIVITYELECTRICAL WORK

HAZARDSa) Fall from height.b) Electric shock.c) Fire and explosion.

CONTROL MEASURES1) Electrical work shall be carried out by trained and competent electricians. 2) These persons should have technical knowledge and experience to understand hazards, which may arise during work for which, necessary

precautions would be required to be resorted to.3) Work on live conductors or on electrical equipment, which have been made dead shall be carried out only, under an appropriate ‘permit to

work’ procedure.4) Safe means of access to be provided for electricians, required to work at height (e.g.) ladders, scaffold towers etc.5) Adequate means or equipment should be used to prevent fall of electricians from higher level of working.6) Insulated tools should be used in order to carry out electrical work.7) All such electrical works shall be conducted in hours of low temperatures. 8) Electrical works require installation of first fix, installation of second fix & relevant testing. Later, installation of final fix & relevant

testing is conducted. It follows pre-commission & commissioning. All safety precautions to comply with such activities.

HAZARD ANALYSIS AND CONTROL PROGRAMMECIVIL WORKSREF No:- A - 031.............................

ACTIVITYROCK DRILLING

HAZARDSa) Cables/pipelines buried underground.b) Existing structures/buildings.

c) Noise.CONTROL MEASURES

1) Cable detection tools to be used prior to rock drilling in order to determine presence of live cables.2) Services records drawings to be used to determine cable/pipeline routes.3) Trial hand digging/excavation to be conducted in order to verify existing live cable/pipeline routes.4) Temporary sharing or supporting of existing foundations/buildings to be carried out prior to commencement of rock drilling.5) Personnel carrying out drilling work shall wear safety helmets, gloves, safety footwear and hearing protection.6) Unauthorized personnel should not be allowed in areas, where rock drilling is being undertaken.

HAZARD ANALYSIS AND CONTROL PROGRAMMECIVIL WORKSREF No:- A - 032......

ACTIVITYROCK BLASTING

HAZARDSa) Use of explosives.b) Noise.

CONTROL MEASURES1) Only trained and experienced shot firers to be permitted to use explosives.2) Adequate planning based on area requirement shall be conducted for a safe operation.3) Before explosives are used, a written ‘system of work’ shall be prepared. 4) Personnel involved in blasting operation must be made aware of safe ‘systems of work’ prior to be followed. 5) Consideration shall include blast mats, audible alarms, site inspection and communications.6) Sentinels and visual warning signs shall be posted around area likely to be affected by blast.7) Effective actions shall be taken to ensure that danger area is clear of all personnel/animals immediately, before firing is commissioned.8) An audible means of giving warning alert that an explosion shot is about to fire and to sound all clear, to be provided.9) Police site personnel and other relevant parties/authorities shall be notified of shot firing times.10) Existing foundations/pipes in vicinities of rock blasting shall be protected by shoring.11) It has to be made sure that basting does not cause adverse impact on environment.

12) Should area be located in vicinity of residences & other accommodations, relative notification should be made for all residents, so that adequate precautions are made.

13) It has to be made sure that vibrations transferred to such buildings are to a minimum level & accelerations produced do not cause an impact on such structures.

14) Explosive shall be managed for use & storing in such a way that it complies with regulations.

HAZARD ANALYSIS AND CONTROL PROGRAMMESITE PREPARATIONREF No:- A - 033.....................

ACTIVITYEARTH WORKS

HAZARDSa) Movement of heavy mobile plantb) Dustc) Noise

CONTROL MEASURES1) Drivers, operators and banks men of mechanical plant and equipment shall be adequately trained, be competent and at least would be 18

years old. Only authorized drivers and operators shall be allowed to use plant and equipment.2) Drivers and operators to be trained, not only in correct operation of plant and equipment but also, in limitations of use and possible

involved hazards/risks, if equipment not used properly.3) Preventive maintenance program shall be established to ensure that all plant and equipment are systematically inspected, serviced, repaired

and maintained as necessary.4) Prior to earthworks commences, all overhead and buried electrical cables and other pipelines shall be identified for adopting precautions to

prevent damage to these services.5) Non required personnel shall be kept distant from area of operation and trained banks men should be provided, where necessary.6) Measures shall be taken to prevent dusty conditions from impairing visibility by use of water spray on roads and if practicable, one way

system for traffic to be followed.7) Site speed limits to be set and strictly enforced. All personnel shall drive defensively.8) Plant items should not be parked in such a location, so as to cause an obstruction to other plant or site activities or so close together as to

cause danger to working personnel in vicinity. A stacking system to be operated away from area of activity, if required.9) Plant shall be fitted with reversing alarms, where appropriate.10) Employees working in vicinity of earth moving operations should wear safety helmets, safety footwear and high visibility vests.11) Drivers should not remain on a vehicle being loaded, unless a suitable overhead protective canopy is provided. 12) Personnel should stand well clear of loading operations.13) Personnel shall be instructed to establish contact with driver prior to walking in path of a vehicle.14) Sleeping under or against vehicles is strictly prohibited.

HAZARD ANALYSIS AND CONTROL PROGRAMMEGENERALREF No:- A - 034........................

ACTIVITYSITE TRANSPORT

HAZARDSa) Vehicle/Pedestrian Interfaceb) Site Conditionsc) Contact with structures/overhead linesd) Vehicle Defectse) Falls into excavations

CONTROL MEASURES1) Site conditions shall be taken into account in selection of plant. Drivers to be fully trained in election of plant and be aware of limitations

of machines as well as, concerning safe operating procedures.2) Vehicles shall be maintained in an efficient condition/state, in efficient working order and in good working mode. Basic maintenance to be

carried out by driver/operator on a daily/weekly basis. Whatever defects found shall be repaired, before vehicle is put into service. Periodic servicing of vehicles to be carried out in accordance with manufacturer’s instruction.

3) Speed limits shall be established and clearly displayed for traveling on site haul roads.4) Personnel working adjacent to haul roads should wear high visibility jackets and suitable warnings to be displayed, so that all such

personnel are easily & clearly visible to operators/driver.5) Possibility of vehicles coming into contact with overhead structures or power lines shall be reduced by erecting height gauges of goad post

type, constructed from non conducting material, distinctively marked with red and white stripes or bunting.6) Drivers to be instructed not to leave vehicles while, vehicle’s engine running.7) Drivers to be instructed not to carry unauthorized passengers.8) Safe working procedures shall be planned in order to reduce possibility of personnel being struck by reversing vehicles. These may include

(i) avoiding need to reverse by providing a one way system of movement (ii) exclusion of pedestrians from areas, where vehicles have to reverse (iii) Provision of banks men (iv) Fitting of reversing alarms to vehicles

9) Vehicles shall be prevented from falling into excavations by (a) clearly marking haul roads and securely fencing off immediate excavation area (b) providing a banks man to guide vehicle and warn personnel in excavation to keep clear and (c) by providing a fixed stop e.g. timber baulk securely anchored well back from the edge.

10) Vehicles should not be overloaded and loads to be evenly distributed, secured and not projecting beyond 11) On Sides or back of vehicle, If some projection is unavoidable, load to be properly marked in order to ensure that projection is clearly

visible.12) Drivers should not remain in their vehicles, whilst vehicles are being loaded with loose materials.13) Loading and unloading of tipper trucks shall be attended by a competent banks man. Tipper trucks should not be allowed to move off, until

body has been lowered.14) Dumpers should not be allowed to travel with body in a raised position, unless inching forward to discharge its load.15) Connections between trailers and towing units shall be securely fixed using correct towing pin and trailer parking brakes applied before

disconnection from towing vehicle.

Scaffold Procedure 1 Purpose of this procedure is to provide guidelines for erection, modification, dismantling and storage of scaffolding that shall be

constructed / used on project.2 Implementation of these guidelines shall be essential to allow a means of safe access to work fronts using scaffolding that is assembled,

inspected and maintained in a safe and accident free environment. 3 Procedure shall provide guidance on how to manage ‘scaffold services’ to ensure that only, well designed, erected and maintained

scaffolds can provide safe means of access and a safe working area for end users. 4 Specify minimum acceptable safety codes and specifications. 5 Define parties involved in scaffolding works 6 Identify responsibilities of parties 7 Describe types of scaffold approved (including modular) and all limitations on its use 8 Outline minimum safe work practices to be applied during erection of scaffolds, including use of fall arrest equipment and tools, training

requirements and competencies/ skills (certified/experience) of scaffolding supervisors/workers.

9 Establish a procedure to control how scaffolds can be erected, modified and dismantled safely, including all safety checks. 10 Highlight need for proper use of this scaffold system to other workers by incorporating ‘how to use scaffold safely’ into ‘safety

inductions’ required before permission to enter site is granted 11 Require quality audits to be undertaken to ensure compliance with this procedure.

Scope 1 Following procedure shall cover all scaffolding erected, dismantled, modified and stored on project including any offsite or

subcontracted elements of project that require scaffolding to execute works. 2 Compliance with statutory regulations following international standards shall be applied for project: a BS EN 39:2001 - Loose steel tube for tube and coupler scaffolds prEN 74-1 - Couplers, spigots and base plates for use in false work and

scaffolds - Part I: Couplers for tubes – Requirements and test methods. b BS EN 12811-1:2003 - Scaffolds – Performance requirements and general design or equivalent approved codes of practice. c BS 2482:1981 - Specification for timber scaffold boards d EN 354:2002 - Personal protective equipment against falls from a height - Lanyards e EN 355:2002 - Personal protective equipment against falls from a height - Energy absorbers f EN 361:2002 - Personal protective equipment against falls from a height - Full body harness g EN 362:2004 - Personal protective equipment against falls from a height - Connectors h EN 364:1992 - Personal protective equipment against falls from a height - Test methods i EN 365:2004 - Personal protective equipment against falls from a height - General j Requirements for instructions for use and for marking k EN 795:1996 - Personal protective equipment against falls from height - Anchor devices l Requirements for testing prEN 12402-4 - Personal flotation devices Part 4, Class D (inland / close to shore. 100 N), safety requirements

prEN 1263-1 – Safety nets 1 Contractor shall obtain prior written approval in event alternative standards are proposed. 2 Request for a substitution shall include a comparison of proposed alternative standard(s) with British Standard/Euro Norm listed above,

highlighting any differences.

Definitions Scaffolding Representative 1 Employee of contractor certified and approved to supervise and inspect scaffolding works. Subcontractor 1 A party having a contract with contractor to carry out work required for realisation of project

Subcontractor Scaffolding Worker 1 Employee of a subcontractor, such as qualified scaffolders, scaffolding foremen and supervisors, who are certified and approved to carry

out scaffolding work Subcontractor Scaffolding Inspector 1 Employee of a subcontractor certified and approved to carry out inspection of scaffolding work 2 End User -Any party authorised to be on site that has cause to utilise scaffolding.

Responsibility 1 Contractor shall ensure that scaffolding provided by a subcontractor complies with safety and erection regulations for scaffolding. 2 Contractor shall be responsible for ensuring that scaffolding is only erected, modified or dismantled by or under direct supervision of a

competent and experienced scaffolding person. 3 No scaffolding should be modified by any person other than approved subcontractor’s scaffolding workers. 4 Contractor shall require that subcontractors engaged in scaffold works: a Provide all scaffolding workers with overalls, hardhats, leather gloves, safety glasses and safety boots as well as, ‘fall arrest’ safety

equipment. b In addition, ear defenders, dust masks and life vests shall also, be provided wherever necessary. c Train all scaffolders in use of ‘fall arrest’ equipment, so that scaffolders are tied off at all times. d Provide scaffold workers, supervisors and inspectors, who are qualified and whose qualification has been verified with trade tests. e Records of tests, qualification certificates, training and performance shall also, be maintained f Provide qualified scaffold workers, supervisors and inspectors, who are trained in proper use of fall arrest equipment and maintain

records of qualification certificates, training and performance. g Provide training for scaffold inspectors, supervision and labour from a competent electrical specialist on, when scaffolds must be earthed. h Contractor shall implement a scaffold inspection and control system to be common across project. i Contractor shall appoint sufficient number of suitably qualified and experienced scaffolding representatives to manage, supervise and

audit inspection system used by scaffold subcontractor staff and labour. j It is responsibility of subcontractor/contractor to provide sufficient suitably qualified scaffolding inspectors to conduct an inspection

signature prior to access to scaffold being given to relevant workforce. k Subcontractor shall also, be responsible for carrying out inspections including scaffold tube, boards, ladders and other materials within

contractors approved storage area to ensure no damaged tubes or boards reach site from storage area prior to erection. l Defective materials shall be destroyed and disposed off from site. m Ensure that inspectors, foremen and scaffolding supervisors immediately, report all breaches of safety or discipline regarding integrity of

scaffold by other discipline contractors to contractor’s scaffolding representative or their own safety representative.

n Contractor’s scaffolding representative shall be responsible for: o Coordination and communication across all scaffolding subcontractors 100% audit of special scaffolds p Auditing of scaffold inspection and control system for standard scaffolds q Auditing inspection of materials in storage areas r Providing safety training to end users on safe use of scaffolding onsite, including checking that inspection date be current and not beyond

1 week validity s Contractor shall include instructions on safe use of scaffolding on site induction given to all labour, staff and visitors, before site entry is

permitted. t This induction shall specifically, include prohibition of scaffold modification by any party other than qualified scaffolder, whose

obligation should be to immediately, report all scaffolding defects observed and authorisation to stop work being carried out using it and at an earliest, remove a green scaffold tag, when such defects are noticed.

Types of Scaffold Special Scaffolds A scaffold that falls within following categories shall be designated as nonstandard, special construction and as such, requires additional safety checks specified below.1 This includes requirement for contractor’s safety representative to carry out 100% audit of all special scaffolds, countersign tag and

logbook. Load Bearing Scaffold 1 Load bearing scaffold is one that is required to carry working load other than an evenly distributed load of 2.5kN/m2 or is subject to

point loading. 2 Examples may include scaffolds used as false work in supporting civil type structures, such as concrete floors or that used as means of

support for lifting equipment, such as chain blocks and winches. 3 This type of scaffold shall always be approved in advance by contractor’s representative and supported with drawings relevant load

calculations. 4 Erection of this type of scaffold cannot commence, until full approval has been granted5 It may not be utilized, until a full inspection by contractor’s representative is carried out, following installation assembly approved.

Engineered Scaffold 1 Scaffold structure in excess of 38m height shall be designed by a competent engineer and approved by contractor’s HSE Manager

Suspended Scaffolds

1 Bosun’s chairs and gondola type scaffolds are not covered by this specification.2 Permission for their use shall only, be given by contractor’s HSE Manager, following submission of detailed method statements specific

to particular proposed application.3 Use of Bosun’s chair shall be permitted only, in exceptional circumstances and with approval of company’s HSE manager. 4 Bosun’s chair is a devise used to suspend a person from a rope to perform work aloft

Cantilever Scaffold 1 Cantilever scaffold shall be erected from beams, which protrude beyond face of building or structure. 2 Contractor shall implement same approval and inspection requirements, as for load bearing scaffolds detailed above.Note: Supporting data provided for approval shall include details of proposed fixing method.

Hanging Scaffolds 1 Hanging scaffold shall be considered, when suspended from a point of support above intended final working platform. 2 Contractor shall implement same approval and inspection requirements, as for cantilever scaffolds, including details of proposed fixing

method.

Mobile Scaffolds 1 Mounted on castor wheels, consisting of four or more standards. 2 Wheels must be locked, when users are on scaffold. 3 When moving scaffold, no personnel should be allowed on it for any reason. 4 Maximum height/base ratio for a mobile scaffold shall be: a Indoors: 3.5:1 b Outdoors: 3:1 up to a maximum of 3 lifts or 6m.

Standard Scaffolds 1 Subcontractor/contractor may elect to use scaffold types rated as suitable for differing loads for routine construction activities in

accordance with categories listed below. 2 Where this approach is adopted, subcontractor/contractor shall specify, how different load capacities shall be readily and visually,

identified to ensure workers do not create safety hazards by wrongly, loading up scaffolds3 As a minimum this shall require identification on scaffold safety tag.

Heavy Duty

1 Scaffold erected for use of multiple disciplines, civil, mechanical, piping, electrical, with a maximum allowable weight of 2.5kN/m2

Light Duty 1 Main purpose of this type of scaffold is for painting, plastering, glazing and light electrical work and in some cases, inspection

requirements with a maximum allowable weight of 1.5kN/m2.

Safety during erection, modification and dismantling of scaffold 1 Below are basic principles that should be adopted as minimum requirement:

Use and care of fall arrest equipment 1 Fall arrest equipment shall consist of a full body harness with 1.75m double lanyards incorporating integral shock absorbers, one of

which to be tied off to a secure anchorage all times. 2 Each lanyard shall terminate with a 55mm opening scaffold hook for one handed operation, inspection of which equipment should be

carried out by a competent person at intervals recommended by manufacturer or at an absolute minimum of one (1) month.3 Records of these inspections should be kept and be made available for safety audits. 4 An approved person, specifically trained to carry out inspection of fall arrest equipment shall train all project scaffolding personnel ‘in

use, inspection and maintenance of fall arrest equipment’. 5 Records of this training shall be logged on relevant register. 6 Fall arrest equipment shall be worn all times and 100% tie off be required for all persons, when following situations occur: 1 Work is ongoing @ place 2m or greater above a working platform/grade. 2 Work moves at certain height above a significant hazard (e.g. uneven or rocky surface, water etc). 3 Work is located outside confines of a complete platform. 4 Work is moving from mobile working platforms. 5 When raising or lowering materials (a double guarded handrail provided). 6 Anchor points shall wherever possible, be provided above shoulder height. 7 Always clip on to ledgers supported with load bearing couplers, guardrails supported with load bearing couplers, transoms supported by

ledgers in lift above, fixed at both ends by single couplers 8 Never clip on to standards, ledgers supported with putlog or half couplers, ledgers or guardrails within a bay, where it has a joint,

guardrails supported with a putlog or half couplers, transoms below foot level, transoms, when under slung below ledgers.

Tools 1 Tool belts to be provided and worn at all times.

2 No adjustable, open ended or homemade wrenches to be used. 3 Only, correct socket type wrench shall be used, when tightening couplers, which should assist in reduction of hand and wrist injuries. 4 Apply correct torque on coupler to reduce risk of slippage and tools falling to ground level.

Barricade 1 During scaffolding works (erection, modification, dismantling), warning tape and signs shall be erected to prevent others entering work

area.

Working in a Marine Environment1 When working close to or over water, PPE requirements shall be reviewed. 2 A full job safety analysis shall be conducted and where appropriate, fall prevention equipment would be replaced by life vests for works

over water. 3 In addition, a suitable boat shall be readily accessible, equipped with at least one boat hook, one ring buoy and 20m of 10mm polyester

rope.

Confined Space Working 1 Work in confined space shall be carried out in accordance with confined space entry procedure required to be developed for project,

which typically requires use of a permit system for entry, low voltage power supply for lighting and provision of a trained watchman.

Requirements specific to scaffolding works 1 To prevent hazards from falling objects, protection by means of a physical barrier (e.g. scaffold boards) shall be provided inside and out,

above entry points to confined space areas, such as tanks and other equipment items. 2 Scaffolding erected inside equipment shall generally, be built up from floor. 3 Where it is proposed to construct a cantilever scaffold attached to a support ring or similar, attachment method shall be provided by a

purpose made clamp. 4 Attachment by adapting use of jacking devices, such as adjustable base plates shall not be permitted. 5 Contractor’s HSE manager shall review and approve any proposed method.

Protection from falling objects during demolition 1 Contractor shall ensure that all horizontally, stored or erected tubes are closed with a purpose made plastic end cap to prevent objects

being inserted into tubes (e.g. small tools, rubbish etc) that subsequently, falls out during demolition.

Regulations for scaffolding 1 Only metal scaffolding systems shall be used. 2 Scaffolding built with tubes and couplers shall comply in accordance with BS EN 39 and use galvanised steel tubes with a minimum

48.3mm outside diameter, wall thickness of 3.2mm and yield strength of 235N/mm2. 3 Couplers shall comply with prEN 74-1.4 Where proprietary quick assembly/modular scaffold systems are used, contractor shall provide full technical data and seek written prior

approval before use. 5 Modular scaffolds shall be subject to approval and installed in accordance with manufacturers written instructions.

Ladders 1 Use of rope, cable or homemade ladders shall not be permitted on project, unless specifically permitted by HSE manager. 2 Wooden ladders shall not be permitted 3 Metal/Aluminum ladders shall not be used near or in vicinity of electrical installations 4 Extendable ladders shall be permitted for access only, and shall be allowed no longer than 10.5m (extended). 5 Minimum overlap shall be allowed in accordance with manufacturer’s recommendations or 1m, whichever is greater. 6 No ladders are to be utilized as supports for working platforms. 7 One person only, shall be allowed on a ladder, always facing rungs, when ascending or descending. 8 No tools or objects are to be carried by user. 9 Inspection of ladders shall be carried out as required. 10 All defective ladders discovered in inspection shall be removed from site. 11 Ladders shall be installed on a firm base, erected with a 1:4 slope (1 horizontal to 4 vertical) with 1 meter or 5 rungs protruding above

landing platform and a sideways exit or entry provided to landing platform. 12 Safety bars or gates at landings shall be installed. 13 Ladders providing access to high working platforms shall have a landing platform every 5m. 14 Landings shall be 2000 x 1200mm as a minimum and not be utilised as storage places. 15 As minimum, ladders shall be secured at both top and bottom using clamps. 16 Where ladders are required to ensure stability, additional intermediate support points shall also, be secured with clamps. 17 Ladders should be installed at earliest possible phase of erection and removed as late as, possible to minimise need for scaffolders to

climb around structure 18 A minimum of 200mm clearance is required for vertical and horizontal area behind ladder rung.

Scaffold Planks 1 Scaffold planks providing working platform shall be slip resistant. 2 If timber boards are used, should be 38mm thick and comply with BS 2482. 3 It is recommended that cleats should be used to fix down boards with underside of boards, clamping to top of scaffold, wherever

possible. 4 If this is not feasible ensure fixing from top causes no tripping hazards. 5 Timber boards shall be adequately, supported by transoms and bearers, spaced at a distance of 1.2m to 1.5m required by loading of

scaffold. 6 Every board shall have three supports, unless its thickness or span is sufficient to prevent sagging under load. 7 Timber scaffold boards shall extend a minimum 50mm beyond putlog or transom, with a maximum permissible overhang 4 times board

thickness. 8 Prefabricated metal planks shall be installed in accordance with manufacturer’s instructions. 9 Boards should be butted together (on all scaffolds except circular structures), but when lapped boards are used, beveled pieces to

minimize risk of tripping should be fitted at laps. 10 Minimum width for platform shall be 600mm (3 boards)

Guard Rails and Toe Boards 1 A guard rail shall be provided at outer edge and ends of all scaffolds. 2 It shall be minimum 1m or more above working platform level. 3 A mid rail shall also, be provided located half way between top of toe board and guard rail. 4 Toe boards should also, be fitted on outer edges of scaffold structure. 5 Toe boards shall be provided minimum 150mm high, with a maximum gap 12mm between board and scaffold. 6 Guard rails, mid rails and toe boards shall also, provide distance between ledger of a working platform and an adjacent wall exceeds

225mm.

Foundations 1 All scaffolds must be constructed on an area that has been compacted 2 Regular scaffold inspections shall include a check for undermining of foundations by other subcontractors. 3 If certain undermining is apparent, inspector shall remove any personnel working on relevant scaffold then close down scaffold (by

means of scafftag system) and inform HSE representative. 4 No scaffold bases are to be constructed by means of temporary supports i.e. laying scaffold board over voids or trenches to support sole

plates should not be permitted. 5 Load at base of a standard of a high scaffold may exceed two (2) Ton. 6 A load of this magnitude may cause subsidence if not properly, distributed over a sufficient area. 7 When required, supporting earthwork shall be compacted to ensure a sound foundation.

Soleplates 1 Generally, a continuous timber soleplate of 200mm x 200mm x 38mm shall be considered satisfactory to distribute load from a base plate

to ground. 2 However, in some cases, in addition to ground compaction, it may be necessary to increase thickness and area of soleplate.

Earthing of scaffold 1 Scaffolding that carries lighting or small power circuits greater than 50V shall be bonded to protective carrier of circuit that it carries. 2 Below this voltage, no bonding is required and for circuits above it earthing shall be designed and installed by a competent person

(qualified electrician).

Scaffold inspection and control system 1 Contractor shall establish a system of control for scaffolds. 2 Proposed system shall be illustrated by producing typical flow schemes, showing how process is controlled from request stage through to

demolition. 3 Responsibilities of each party and methods of communication between/among them shall clearly be defined on flow schemes. 4 System shall include registration and inspection of new build scaffolds, subsequent recorded periodic inspections and use of a tagging

system with following features: 5 A register/logbook of scaffolds shall be established recording a scaffold request from an end user and a unique identification number for

scaffold to be built. 6 Upon completion, before scaffold is allowed to be used, scaffold shall be inspected by a qualified inspector with date and name of

inspector recorded. 7 Inspection is only, valid for seven calendar days. 8 Scaffold erected for longer than 1 week must be re inspected to revalidate inspection tag. 9 Scaffolds must also, be inspected after bad weather, which may affect scaffolds strength and stability. 10 Subsequent daily checks and inspections following modifications shall be recorded in register/logbook, concluding with a record of

dismantling date. 11 A standard checklist shall be developed by contractor and used/applicable for all inspections across site.

12 Checklist shall include a check of whether earthing of scaffold is required. 13 Status of a scaffold shall be indicated on site by using a tag attached to structure itself. 14 Tag consists of two elements, a holder and an insert. 15 Holder shall be placed on scaffold structure as soon as, possible after initial erection and as close as possible, to point of access or ladder

access. 16 Where a scaffold has more than one access, a tag shall be attached at all of entry points. 17 Scaffold tag has a hole in top, which must be placed over a tube in order to secure it. 18 Holders must not be affixed by any other means. 19 Scaffolds must not be used if they have a red “DO NOT USE SCAFFOLD” symbol on holder. 20 Scaffold tag insert is green in colour and when it is present, it signifies to potential users that it is safe to use. 21 When a scaffold has been inspected and passed, tags are to be signed by responsible safety inspector using a permanent ink pen. 22 Green insert contains more significant information than holder and is used to record details of statutory inspections, maximum allowable

loading. 23 While RED holder is in place, access to scaffold structure is prohibited to non scaffold personnel. 24 When a scaffold is to be structurally modified, scaffold crew assigned work shall remove green scaffold tag and barrier off area. 25 Tag shall therefore, only comprise red holder with “DO NOT USE SCAFFOLD” symbol and only scaffold personnel allowed on

scaffold. 26 Once modification is complete, scaffold should be re inspected by inspector prior to use and when accepted, GREEN tag would be

inserted into holder signifying it being safe for use. 27 If a scaffold requires a minor modification for a short period due to construction reasons, e.g. removal of handrail or board to allow pipe

installation, only scaffold personnel shall be permitted to make modification. 28 Contractor shall develop a detail procedure to control these type of modifications that cover following non exhaustive list of concerns: 29 Provision of ‘standby’ scaffold crew(s) to ensure minimal waiting time for workers requiring modifications. 30 Safe use of scaffold during work that created need for modification (i.e. use of fall arrest equipment by all scaffold users) 31 Re inspection and recertification of scaffold

13 environment clauses-facilitiespetrochemicals

Engineering