safe work habits

8/13/2019 Safe Work Habits

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SAFE WORK HABITS

HOUSE KEEPING

Maintain the working area clean and orderly. Trash is to be placed in proper container. Place salvageable material in separate container. Do not leave rags and oily clothes in lockers, tool boxes etc. Keep aisles, passageways, stairs, platforms and ladders clear of obstructions. lean up any oil or chemical spills immediately. Make provision to contain oil leaks until they can be stopped. Make provision to control anticipated spills prior to opening an e!uipment. Place all cleaning rags in proper containers. "t the end of the working day or upon completion of the #ob assignment, check for

the following $to avoid tripping ha%ard& ' "ll tools are removed. (xcess materials, if any, is removed. )f necessary, barricades are provided. Trash is removed to nearby container. *elding machines and other e!uipment are shut off. Keep floor clean and in good condition. "ll excavations must be ade!uately guarded or covered with hard plants. Manhole + cover should be replaced immediately or barricaded guarded.

HAND TOOLS

Do not use defective tools, use the right tool for the #ob. heck tools before use, to ascertain their proper function and suitability for the #ob. Powered hand tools are re!uired to have a grounding plug. Do not use hammers and sledges with -Mushroomed /oose heads, cracked or

weakened handles. 0it screw drivers and wrenches properly on screws or nuts. 1btain slide wrench, if necessary. Do not hammer on wrenches. 2eturn damaged tools to tool room.

LADDERS

3ever climb on make4shift devices. 5se a ladder.


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)nspect ladders before use. 2eport cracked, split or damaged side rails and loose or missing rungs after tagging

the ladders as unsafe for use. /adders shall be properly secured to prevent slippage. *hen it is practical, ladders

should be secured at the top with chains ropes. Do not stand on the top three rungs or steps of a ladder6 obtain a longer ladder. Place the ladder in such a way that work can be done without leaning out more than

78 inches beyond the side rails. 2eturn the ladder to its proper place after use. "lways climb and descend facing the ladder with both hands free to assist in

climbing. 5se a tool pouch or belt sling for carrying tools etc. )n heavy or extensive work, ladders are not to be substituted for scaffolds. 1ne person shall climb ladder at a time. Muddy slippery shoe should be cleaned before mounting ladder. *hen carrying a ladder, raise the front to prevent accident. Metal ladders are not to be used in close proximity to electrical lines etc. Do not place ladder in front of a door when the door is locked or ade!uately.

SCAFFOLDS

Patent tubular scaffolding shall be erected with base plates or runners and accordingto manufacturer9s instructions.

:caffolding shall have handrails, guardrails and the boards installed when working

level is higher than one section. Midrails, when re!uired $if the gap is more than 7; & are to be construction of tubular

materials. Toe plates shall run entirely around the perimeter of the working deck toprevent tools, bolts, etc. from falling.

"n access ladder shall be securely attached to the scaffold. " step off deck shall beinstalled at intervals not to exceed inches and not more than 78 inches beyondthe end section support. They shall be securely fastened to the end sections.

:caffold shall be securely fastened every 8? ft. $; metres& to pipe racks, vessels,furnace structure or some other rigid structure.

@racing against opposite walls is an acceptable alternate to prevent tripping withinvessels, furnaces or tanks.

*here casters are used to permit moving the scaffold, they shall be locked beforethe scaffold is used. Mobile scaffolds are not to be moved with personnel onplatform.

0ree4standing scaffolds shall not be higher than A times the minimum basedimension i.e. the width.


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Metal scaffold materials, floats, etc. shall not be used where there is danger ofelectrical shock.

BARRICADES AND RAILINGS

@arricades must be erected to restrict mobile and personnel traffic into areas thatcould present a potential ha%ard because of escaping gas, oil, steam, catalysts,chemicals, etc.

(xcavations and open manholes must be covered, barricaded or roped off. overed excavations and manholes must be able to support anticipated loads and

must not cause tripping or any other ha%ard. *arning light must be provided for excavations or manholes left open overnight,

even though the excavation or manhole is barricaded or roped off. $31T( ' (lectricallights must be in good operating condition. " safe work permit must be issued if they

are used in a process or tank farm area. 2eflectors should also be considered&. @arricades or rope and kick plates will be used to guard areas before deck plating isremoved.

Temporary handrails must be installed in above grade structures before permanenthand rails are removed. They must remain in position except when immediate workre!uires removal.

@arricades must be installed on stairways before step plates are removed. @arricades that routinely block vehicular traffic into process areas must not be

removed until permission has been obtained from the supervisor.

@arricades must be erected to isolate areas before the demolition or dismantling ofan e!uipment begins.

Marked barricades must be installed at locations where radioactive e!uipment exist.They must comply with "tomic (nergy ommission regulations.

@arricades must be erected at locations where exposed electrical breakers, starters,transformers and open contacts exist.

Bates or chains are installed at all accesses from ladders to platforms. 5ser9s shouldproperly attach these when working on the platform.

WORKING O ERHEAD

"lways use :afety belt when working overhead. *hen working overhead, take precautions to protect personnel below you. 2ope off or barricade the area below. 3either drop or throw material, tools or supplies when working above the ground

level.


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@oth hands should be free while climbing monkey ladders. /oose material, tools and other ob#ects must not be left in places where they can be

knocked, blown or vibrated off4balance, and fall.

CO!PRESSED GAS C"LINDERS

Bases compressed, or li!uified under pressure are supplied in strong metal cylinders forvarious uses. These cylinders are constructed and maintained in accordance with gascylinder specifications and regulations. :erious accidents may result from their misuse,abuse or mishandling.

*orkers assigned to handle such cylinders need to be trained and work only undersupervision.The following rules should be observed to control ha%ards in the handling of compressedgas cylinders ' Do not remove or change numbers or marks stamped on cylinders. Do not change the colour and collar bands of the cylinder which is intended for

indicating the gas contained in it.

0or the transportation of cylinders motor trucks, hand carts or special transportersshould be used. ylinders may be rolled on the bottom edge but never dragged. Protect cylinders from cuts or abrasions on the surface of the metal. 5nder no circumstances should a magnet be used for lifting gas cylinders. *here a cylinder must be handled by a crane or derrick, use a cradle or similar

device and take extreme care that they are not dropped. Do not use slings. 3either drop cylinders nor permit them to strike with each other. Do not use cylinders, whether full or empty, as rollers, support or for any purpose

other than to contain gas. Do not tamper with safety devices in valves of cylinders. *hen empty cylinders are to be returned to the supplier, mark them (MPTC. lose

the valves and replace the valve protection caps. "lways consider gas cylinders as full and handle them with due care. "ccidents

have resulted when cylinder under partial pressure were thought to be empty.

S#or$n% C&'$n(ers Bas cylinders should be stored in a safe, dry well4ventilated place prepared and

reserved for the purpose. ylinders whether charged or empty should not be stored in the same area where

inflammable substances, such as oil and volatile li!uids etc. are stored.


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ylinders should not be stored near elevators, gangways or other places where theycan be knocked down or damaged.

ylinders of oxygen, when stored indoors should not be in close proximity tocylinders containing inflammable gases.

"cetylene and li!uified fuel gas cylinders should be stored and used with the valveend up and should not be allowed to lie hori%ontal.

ylinders should not be stored near sources of heat radiation or fire ha%ards. " direct flame or electric arc should never be permitted to come into contact with any

part of a compressed gas cylinders. 0illed and empty cylinder should be stored in separate areas. 0ire protection facilities should be provided in the cylinders storage area.

Us$n% C&'$n(ers

*hen cylinders are taken into use, care must be taken to see that valves andregulators with correct threads are employed. The use of adapters should besupervised by Maintenance or Production Manager.

5nder no circumstances should oil or grease be used on the thread of valves oradapters of gas cylinders.

5se only the special fitting spanners or keys supplied for the purpose of openingcylinder valves. 3ever use a pipe wrench or a loose key otherwise the spindle maybend, become round, and get damaged.

Do not use a cylinder of compressed gas without reducing the pressure through aregulator attached to the cylinder valve except where cylinders are attached to amanifold in which case the regulator will be attached to the manifold header.

@efore making connection to the cylinder valve outlet, except in the case of ahydrogen cylinder, - rack 1pen the discharge valve for an instant to ensure that thepassage is clear of dust or dirt. Do not - rack 1pen hydrogen cylinder valves.$:udden opening is called cracking9&. "lways point the valve end opening awayfrom the body and not towards anyone else.

5se regulators, pressure gauges and other connections only with the gases forwhich they are designed and intended. Do not attempt to repair or alter thecylinders, its valves or other attachments. This work should be done only by themanufacturer.

5nless the cylinder valve has first been closed tightly, do not attempt to stop leakbetween the cylinder and the regulator by tightening the union #oint.

*hen any leak occurs in a compressed gas cylinder containing flammable gases or1xygen, the cylinder should be taken out of use immediately and handled asfollows '4

lose the valve and take the cylinder outdoors, well away from any source of ignitionand discharge it slowly.


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Post warning notices prohibiting smoking or other sources of ignition. Tag the cylinder and notify the supplier. )n case of leakage from the toxic gas cylinders, use emergency kit to arrest leaks.

5se up the gas or neutralise the gas. Keep oxygen cylinders and fittings away from oil and grease and do not handle them

with oily hands, gloves or clothing. 3ever use 1xygen as a substitute for compressed air or to dust clothing. 3ever bring cylinders into tanks or unventilated rooms etc. Do not fill cylinders except with the consent of the owner and then only in

accordance with the gas cylinder specifications and regulations. *henever an accident occurs in connection with the use of gas cylinders involving

loss of life or serious in#ury to persons or property, intimation shall be given to hiefontroller of (xplosives in addition to the notification of accident as re!uired by

0actories "ct and the 2ules thereunder.

BLINDING

0or carrying out repairs, cleaning inspection or testing of e!uipment safety, first isolate itfrom other refinery e!uipment. )solation provided by closing block valves is usually notsufficient. 0or this reason, the more positive isolation of the system by the use of blindsis re!uired. There will be cases in which exceptions are necessary. "ctually, in somecases, it may be more ha%ardous to install blinds than to perform work of short duration.:uch exceptions are to be reviewed by the mechanical and operating supervisorsconcerned. )f the #ob is other than routine or involves special ha%ards, approval shall be

obtained from the Eead of Production or Eead of 0ire and :afety Division. )t shall be theresponsibility of the 1peration Department :upervisors involved to prepare necessaryblind lists, to clearly indicate the location of each blind and to inform the MaintenanceDepartment :upervisor of any ha%ard involved and the precautions to be taken. )f achemical ha%ard exists, the work order or work list shall so indicate. Detailed blindingprocedures shall be followed. )t is impractical to always install and remove blinds onlyafter the e!uipment has been steamed and washed. The practice of installing blindswith hydrocarbons or other refinery products in the lines will be continued. Eowever,each installation in an uncleaned line or vessel shall be regarded as an individual caseand the 1perations Maintenance and :afety Division supervisors involved shall review

the #ob and develop a safe procedure before the #ob is started. )f the pressure of thee!uipment is slightly above atmospheric pressure, the 1perations Department $ P3M&must approve the installation procedure. *hen e!uipment contains hydrocarbons slightpositive pressure should be maintained to prevent pulling in9 air.

:ome lines and e!uipment carry highly toxic concentrations of hydrogen sulfide. Thepossibility of toxic gas backing through purge and vent connections or connecting lines


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into e!uipment that is normally free of toxic gases should not be overlooked. 1therhighly toxic, volatile compounds may be encountered on specific units.

)t should also be realised that the installation of clamps to stop leaks involves many ofthe same ha%ards as does the installation of blinds in unpurged lines and e!uipment.

Safe Pra)#$)es for Ins#a''a#$on of B'$n(s

Genera'These practices are set out as a guide and are not intended as a substitute for carefulobservation and consideration of specific conditions, nor for good #udgement in carryingout the work. :pecific instructions and procedures for each refinery shall govern, in casethere be a conflict with these general practices.

@efore opening any flanged #oint for the installation of a blind, the following should be

observed.

"scertain from the designated operating personnel that the e!uipment or piping isproperly prepared and released for blinding.

Determine what product or material has been contained in the e!uipment or piping. )fthis material is ha%ardous, obtain and wear the appropriate protective clothing ore!uipment.

heck to be certain that lines and e!uipment have been depressurised and drained. @e

certain that drain valves are open and clear by inserting a wire through the valve andinto the pipe or e!uipment.

*hen opening any flanged #oint for the installation of blinds, the following should beobserved '

*ear protective clothing and e!uipment as dictated by the circumstances. "lways wearappropriate eye protection.

2emove flange bolts leaving a minimum of two bolts6 then loosen these last two bolts,

without completely removing the nuts. :pread the flanges to install the blind. "lwaysopen flange on the side away from the workman so that any sudden release will bedirected away from personnel.

0langes should be left open for a minimum length of time, consistent with the safeinstallation of the slip blind.


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engine shall be separated from the tank or the load, as the case may be, by a fireresisting shield which shall fully cover the tank or the load.

The fuel tanks of every such vehicle, if installed behind the cab of the vehicle, shallbe '4 :o designed, constructed and installed as to present no unusual ha%ard andshall be arranged so as to permit drainage without removal from their mountings.

Protected against blows by stout steel guards and provided with a lock in the fillingcaps.

)n every engine running on petroleum class ", a !uick action cut off valve shall befitted to the fuel feed pipe in an easily accessible position which shall be clearlymarked.

E'e)#r$)a' Ins#a''a#$ons

)n cases where electric light or instrument or any other electrically operated e!uipment isemployed on any vehicle $including a trailer& used in the road transportation of petroleumother than petroleum class '

The pressure of the electric circuit shall not exceed 8A volts 6

(lectrical wiring shall '

be heavily insulated and be ade!uate for maximum loads to be carried6 be provided with suitable over current protection in the form of fuses or automatic

circuit breakers and installed so as to be protected from physical damage andcontact with possible product spill either by location or by being encased in metalconduit or other oil resistant protective covering6 and

have all #unction boxes sealed. The generator battery, switches, fuses and circuit breakers shall be carried in the cab

of the vehicle or in the engine compartment and the battery shall be in an easilyaccessible position with a heavy duty switch close by to cut off the battery6

Benerators, motors and switches there of which are not installed within the enginecompartment shall be of the approved flame4proof type, provided that where suchgenerators or motors or switches there of are installed in an enclosed space,ade!uate provision shall be made for air circulation to prevent overheating and

possible accumulation of inflammable vapours. Two nos. portable fire extinguishers suitable for extinguishing petroleum fire shall be

carried in an easily accessible position and away from the discharge on every vehicletransporting petroleum by road.

Gehicles to be constantly attended + (very vehicle which is engaged in the transport of petroleum by road shall be

constantly attended to by at least one person who shall be familiar with the rules in


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this part. Provided that such a vehicle, if its tanks or compartments are empty butnot free from petroleum vapour, may be left unattended in places previouslyapproved for the purpose in writing by the hief ontroller of (xplosives.

(very vehicle in which more than ? kilolitres of petroleum, other than petroleum class

, is being transported by road, or which, while transporting petroleum, other thanpetroleum class , by road, is being trailed by another vehicle shall, so long as it is inmotion, be attended to by the driver and at least one more person, both of whomshall be familiar with the rules in this part.

The engine of a tank truck shall be turned off and brakes set before loading orunloading begins. *ooden blocks may also be used.

1ther safety precautions as per petroleum rules must also be observed while loadingand unloading

PILING AND LOADING OF !ATERIAL

:tack material so that it will not shift or fall. Material must not be stored where it will obstruct walkways, roadways, stairs,

ladders, fire e!uipment, exits etc. aution should be observed when storing material near hot lines, heaters or

electrical e!uipment. /oad material on all vehicles carefully so that it will not shift or fall. :ecure it as

necessary.

WORKING SAFET" + !AINTENANCE CRAFTS

E'e)#r$)a'

@ecause of the special nature of electrical work, employees working on electricale!uipment must be particularly cautious and alert at all times and recognise theseriousness of conse!uences which might result from a mishap. There are manyunexpected and unusual happenings that can lead to accidents in electrical work.2egard all electrical e!uipment as potentially dangerous. Gery special care shouldbe exercised when working above ground.

"ll voltage shall be handled properly and safely. )t must be realised that relativelylow voltages can cause serious in#ury. "void working on live e!uipment as far as practicable. )n case it is necessary to take

up some work on line installation of A7? volts or higher voltage lines e!uipment,)ndian (lectricity 2ules should be followed with the approval of the appropriateauthority.


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"de!uate protective e!uipment must be used when working on live circuits, specialattention should be given to rubber gloves, to be sure that they are in good condition.

1nly non4conductive ladders and safety hats shall be used by electrical workers. )nsulation on electrical wires can not be depended upon to give protection from

shock. Treat all electrical e!uipment designed for A7? volts and above as though these were

live, even though it is known or believed to be dead or de4energised. Keep the area around an electrical e!uipment as dry as possible to minimi%e the

possibility of shock. 1btain dry boards to stand on, if necessary. "s far as practicable, work shall not be performed on electrical e!uipment having

moving parts in operation. :hut off power before removing guards from motor4driven e!uipment. *hen it is necessary to work on an electrical circuit or any other electrical

e!uipment, dismantle or remove machinery driven by electrical motors, the proper

switches shall be opened, tagged and locked. 1nly the man who completes thework is to remove the tag and lock, after verifying that work is completed and covers,guards etc. are replaced. )f this man is not available, the tag may be removed by hissupervisor.

"s an additional precaution, fuses where provided, must also be pulled out. 3ever bridge a fuse or use a fuse which is higher than the capacity for the circuits. 0uses should be replaced with fuses of the same capacity as removed. 0inger rings, bracelets and metal wrist watch bands are not desirable when working

with electrical e!uipment. Do not operate any oil immersed switch with the oil pan in the lowered position,

unless all load has been disconnected. )n opening disconnects, shield the eyes from a possible flash. )n opening

disconnects of any kind, wear rubber gloves. 5se a disconnecting pole on highvoltage.

@e sure that the circuit breaker is open before attempting to remove draw out typecircuit breakers from their enclosures.

"fter repairs, replace cover plates on lighting and power cabinets or other electricalenclosures.

:afety belts shall be a part of lineman9s e!uipment and used whenever the lineman

is supported by climbing hooks. /ineman shall check their safety belts before eachuse.

*hen serving a lineman, the groundman shall stand at one side of the pole, and notat the foot.

onsider a line hot unless it is grounded. $ground all phases of the line&. Bround and short4circuit any line as close to the work as possible. Brounds should be clamped to pole ground wires or an overhead ground wire.


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Eandle telephone or signal wires with care since those may come in contact withhigh voltage wires and become dangerously charged.

@efore removing all wires, support shaky poles with pikes or other means. )t is best not to use arm guys, braces or fixtures as handholds while climbing the

pole. These might pull loose. )n working on hot lines of A7? volts or over, two men shall always work the pole

together except when changing fuses. 1ne man must keep himself in the clear andin a position to aid his pole mate if necessary.

Personnel working on elevated hot circuits from the insulated baskets of an aerialplatform truck should make certain that loose materials being handled do not-Bround the machine.

Temporary installations shall conform to generally accepted safety practices. )t isparticularly important that all electrical installations be properly grounded, sufficientclearance be provided over railroads and roadways and proper type of e!uipment be

installed in gaseous areas. :uitable barricades shall be installed around exposed temporary high voltage

electrical e!uipment, such as field transformers. @arricades or markers shall be provided for unattended open underground conduit

manways. *atch carefully for flammable material seepage into manholes. Takenecessary precautions to prevent being overcome by vapours of ignition of thematerial.

)nspect all electrical extensions before placing in service. "void wrapping cordsaround any part of the body.

Bround all electrical power tools, before using electrical extension lights or portable

tool cables, examine them for defects. "lways follow the re!uirements of )ndian (lectricity 2ules.INSTRU!ENTATION

Permission must be obtained from the competent authority before working onoperating e!uipment. 2efinery instrumentation directly affects the safety ofe!uipment and personnel. @e absolutely certain that you understand the various

#obs assigned to you so that these can be properly executed. Take every precaution to assure that line pressure is off before opening a line.

"ssume the line to be under pressure even after steps have been taken to relievethe pressure, particularly on ha%ardous materials, steam or hot oil lines. onsiderthe possibility of carry over of ha%ardous materials into metering e!uipment.

"void excessive spillage or spraying of li!uid while draining or venting meter pots.heck the nearby area to ensure that there is no hot work being performed, or there

are no other sources which could ignite flammable material. Make certain that the thermowell is not loosened while removing thermometers from

thermowells.


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To prevent skin or eye contact, use protective e!uipment when cleaning li!uid levelgauge glasses with steam and or chemicals. Make sure that steam hoses aresecure before opening steam line valves.

autiously remove pressure gauges from lines. @leed entrapped material betweenthe gauge and block valve before completely removing the gauge.

*hen putting pressure gauges into service, open the line valve slowly and stand toone side of the gauge glass face. )mmediate surge of high pressure can rupture thebourdon tube and cause the glass face to be blown off from the gauge. 5se onlygauges e!uipped with blow out devices.

To be sure that no trapped material is left in the valve body under pressure, openand close the control valve with the drain valve in open position prior to removing thecontrol valve from the line.

*hen drilling to vent gauge floats, run water continuously over drilled surface. Thisprevents the ignition of vented flammable materials.

Mercury is toxic in both li!uid and vapour phases. 1bserve the following precautions' *ash hands thoroughly after handling mercury. lean up spills promptly and maintain ade!uate ventilation of areas where mercury is

handled.

"lways use non4conducting ladders, scaffolds when working at a place whereelectrical shock ha%ard exists.

@e familiar with and follow safety precautions listed for the electrical craft pertainingto your work.

"de!uate precautions should be taken while working on any instrument keeping inview the direction of wind and direction of flow.

INSULATION

*ear protective gloves while mixing and applying insulating cements. Do not throw pieces of insulation from high elevations where people below could be

hit by flying particles. @efore covering any e!uipment, be sure that all bolts are in place and tight and all

test holes are closed. Do not insulate over leaks. "void tying or pulling wires overhead. This might cause tools to slip and inure face

and hands. 5se care in cutting wire, the cut end may slip around and hit you in theface or eye.

@end all wire lacings and reinforcements to prevent in#ury from exposed ends.


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To avoid cuts on sharp edges and snags, use caution while cutting or handling sheetmetal. Bloves are recommended while performing sheet metal work6 however, donot wear gloves while feeding the sheet metal rolls.

"ttaching large pieces of sheet metal can be ha%ardous during strong winds,particularly at higher elevations. onsult your supervisor before starting such #obs.

*hen handling, cutting, installing or removing asbestos containing insulation, thefollowing safety precautions shall be followed '

2espirator $filter type& shall be worn. "sbestos cement mortar, coatings, grout and plaster shall be mixed in closed bags

or other containers. Dry sweeping of asbestos dust is not permitted and vacuum or wet cleaning method

shall be adopted. "sbestos waste and scrap shall be placed in sealed containers, labeled' -*arning '

ontains "sbestos .

)f visible clouds of asbestos dust result from the operation, inform your supervisor.Gisible clouds contain higher than permissible concentration and re!uire moreprotection for continued exposure than that provided by the dust mask typerespirator.

LABOUR

(mployees engaged in ordinary labour work must also be familiar with and observethe sections of this manual that apply to all employees. The following refer morespecially to labour work '

*hen using a pick maintain a safe distance from the men around you and weargoggles, whenever necessary.

)n group lifting, lowering and carrying of material, coordination is essential. /ift andlower at a given signal. *ork together. "ccidents occur when one man lifts orlowers a load before the others are ready.

(xcavated or other material shall not be placed closer than two feet to the edge ofany excavation which employees may be re!uired to enter $"lternate is effectivebarrier&.

To provide safe work conditions, all trenches and excavations should be properlybraced and shored where necessary. )n large excavations all sides must be slopedto safe angles not steeper than the angle of repose of particular soil.

"ccess ladders should be used in those trenches and excavations which are fourfeet or more in depth.

3ever enter a tank or vessel without authori%ation from the area in4charge and anentry permit.

"lways use the protective e!uipment provided for your safety. onsult yoursupervisor to be sure when such e!uipment should be used or worn.


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"ny tool that becomes defective should be returned promptly for replacement orrepairs.

3ever use compressed air in excess of 8 km cm8 for cleaning. 5se pressurereducing gun provided for this purpose.

Persons working at a height more than 8.? metres, must wear safety belts it platformwith necessary railing is not provided.

!ACHINING AND !ECHANICAL WORK

(mployees engaged in machining and mechanical work must be familiar with andobserve their sections of this manual that apply to all employees. The following refermore specifically to employees performing this type of work.

"lways wear goggles while operating lathes, drill presses or shapers. $2efer to thesection ' Personal protective e!uipment&.

3ever wear neckties, dangling sleeves or other loose clothing while operating orworking close to moving machinery. *hen using a drill press, the work should be securely clamped to the table, #ig or

chuck. "lways use a brush to remove cuttings from a machine. 3ever use your hands. *hen using compressed air for cleaning, the pressure reducing gun shall be used.

"ir pressure should not exceed 8 kg cm8. @e certain that you and other employeesare not struck by chips.

Do not stand in line with high speed wheels. Do not use emery wheels that are outof round. 0or side grinding, use only the special wheels provided for this work.

@efore using a grinding wheel, be sure that the guards are in place and that the toolrest is properly spaced. The guard shall be ad#usted so that clearance between thegrinding surface and the guard does not exceed > mm. learance between tool restand wheel shall not exceed < mm. Do not ad#ust while the wheel is moving.

3ever use files without handles. @efore making repairs to any pump, valve or any other piece of mechanical

e!uipment, be sure that the pressure has been released, fluid drained and linesdrained or properly isolated.

@efore starting work on an operating e!uipment, obtain permission from the shiftincharge and see that the e!uipment is properly isolated.

@efore starting work on a chemical or hot oil e!uipment, keep proper protectivee!uipment on hand and available for use.

*hen operating a hydraulic press be sure that the guards are in place and allpersons in the immediate area are wearing goggles.

Do not remain on platforms or catwalks of gas engines while they are being started.


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1il spillage should be cleaned up promptly, and waste rags put in metal containersprovided for that purpose.

lothing, that has become saturated with any chemical or oil, should be changed atonce. )f any portion of the body is affected, it should be washed thoroughly withwater. " report must be made to your supervisor.

"lways keep aisles and passageways clear and free of oil and litter. *hen performing work on internal parts of an engine, be sure that the engine has

been properly tagged or locked out of service, and a work permit obtained beforeoperating a drill or doing other work likely to cause sparks.

)nspect the ceiling hoist thoroughly before lifting heavy loads. 3ever overload chainhoists or walk under suspended loads.

*hen pouring hot metal into a mould, always wear goggles and be sure that there isno moisture present.

"void heating e!uipment or containers which could have contained li!uid. "lways have ade!uate ventilation when doing metali%ing work.

PAINTING

(mployees engaged in painting must be familiar with an observe other sections ofthe manual that apply to all other employees. The following refers more specificallyto painting '

Buard against undue exposure to paint ingredients. 5nnecessary smearing of thehands and face should be avoided.

*hen painting with materials containing creosote, use protective creams provided toprevent skin irritation. Protective cream may also be used when doing spraypainting. This prevents direct skin contact and facilitates removal of the paint.

Precautionary measures to prevent fires shall be used when handling flammablematerials such as paint thinners and cleaning solvents. *hen not in use, all paintand solvent cans must be covered.

0lammable product tanks shall not be scaled, sand blasted or painted unlessauthority and safe work permit have been obtained from the department in4charge ofsuch tanks. :pecial written procedures must be observed when performing suchwork. onsult your supervisor.

Do not paint any electrical e!uipment such as switch board, panel, etc. without

approval from the supervisor4in4charge of electrical work. 3ever paint hot surfaces except with an approved type of paint and upon instructions

by the supervisor. Take ade!uate precautions to avoid falling when painting above ground level. *hen working on high places where proper platform is not provided, wear a safety

belt. *hen doing spray painting, always wear an approved type of respirator.


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"lways wear goggles when scraping or removing old paint. " respirator must be worn when painting or scraping near vents of tanks containing

toxic chemicals or poisonous gases. @efore a swinging scaffold is used, all parts must be thoroughly inspected. The

scaffold should be raised one foot off the ground and tested by applying a full load.

:pray painting in the shop is not permitted unless an exhaust and spray booth isavailable or alternately use cartridge respirators. "lways wear goggles when using paint and varnish remover. 3ever leave oil or paint soaked rags in your pockets. *hen sand blasting, always wear sand blast hood and use appropriate safety

e!uipment. Do not use compressed air in excess of 8 kg cm8 pressure for cleaning. 5se

pressure reducing gun provided for this purpose.


18/21

OPERATING SAFET"

Genera'1perating personnel shall be familiar with and follow all procedures for '

start4upnormal operationshutdownand emergencies.

These procedures shall be followed as closely as possible and all associated safetyprecautions shall be observed. Deviations from the posted procedures must beauthorised by the supervisor directly in4charge.

!o,$n% E-u$ /en#

@efore starting any e!uipment with moving parts ' @e sure that all safety guards are properly in place. @e certain that all personnel are clear of moving parts. heck start4up procedure. @efore shutting down any e!uipment with moving parts and turning over to

maintenance ' heck shut down procedure :hutdown the e!uipment. @e sure that prime mover is secured safely from the power source and check the

following (lectrical e!uipment must be shut4off at the switchbox and locked until the work is

completed. :team or fuel valves should be closed and locked or blinded until the work is done.

This is to be done if the work is not on the prime mover. )f the work is to be done on the prime mover, the fuel or steam must be blinded or

double4blocked with bleeder open and tagged or isolated by an atmospheric break.

L$%0#$n% 0ea#ers

heck your manual for specific instructions on the heater you are about to light. heck all burners individually to be certain that they are shut off. Dampers must be opened wide. Make a visible inspection for oil on the heater floor. heck gas lines for li!uid. Drain any li!uid that may be present. 1pen all purge lines and purge heater with steam for at least 7? minutes or until the

firebox is free of gas. heck with gas tester.


19/21

*ear protective face mask, goggles and gloves when admitting the igniter. 5se lighted torch or other method provided to ignite burners. Pilot, if provided, must be first lighted before any burner is ignited. "s an additional precaution, position yourself to avoid in#ury due to flashback when

looking into the heater. Do not look directly into heater until burner is ignited. "fter burner is ignited, ad#ust primary air opening $on premix gas burners&. )n case the burners go out, repeat procedure from step 8. 3ote ' )n case of a fire or a possibility of fire where it becomes necessary to shut off

the fuel to a heater, do it as remotely as possible.

DRAINS1 ENTS

*hen draining or venting process e!uipment or lines, an open valve shall never beleft unattended. )f a more urgent need for your services arises, shut off the valve

before leaving it. "ll valves open to atmosphere must be blinded or plugged if not in use. $:ample

valves and tank water draw4off valves are excluded&. The vent drain nipple not in use to be kept capped.

CO!BUSTION2DRI EN E3UIP!ENT

ombustion4driven e!uipment must not be driven without a proper work permit intoprocess unit battery limits, dike or restricted areas.

:pecified speed limits shall not be exceeded. Drive with caution and obey all stop and caution signs. Do not mount or dismount from moving vehicles. 3ot more than two passengers should ride with the drive in the cabin of truck. " dumpster container must not be used for transporting personnel. "ll e!uipment being towed must be safely hatched and secured. 5pon warning of gas or vapour leaks or a large li!uid hydrocarbon spill in the area,

shut off the engine, set the brakes and move to a safe place on foot.

PEDESTRIANS

*alk on the right side of refinery roads to see the approaching vehicles. "void taking short cuts through process units or dike areas. Do not walk through restricted areas without approval of the appropriate unit

supervisor or his delegate. 2oad Traffic 2ules


20/21

These rules apply to the use of roads within the refinery walls. These are in additionto the applicable Bovernment rules. These rules are not inclusive of any safetyinstructions especially applicable to different vehicles such as dumpers, mobilecranes tractors etc.

The vehicular traffic must keep to the lift of the road except when passing a bicycleor a parked vehicle, which should be passed on the right. There shall be no cuttingof corners.

The speed limit for all vehicles on main roads within the refinery is 8= km. Per hour. "ll drivers should use normal traffic signals.

There shall be no overtaking of one motor vehicle by another inside the refinery exceptin the following cases '

:low moving vehicles like crawler9s etc. can be overtaken. 0ire engines and ambulance vans may overtake vehicle when on emergency duty. The driver of the vehicle should check his vehicle everyday before using it and

ensure that the following are in good order to avoid any road accident. @reaks. Eeadlights 2ear and :toplights Tyres *indshield and wipers Eorns 2ear view mirror. 3o one shall drive a motor vehicle including the dumpers on the refinery roads

unless he has a license to drive that vehicle. " person designated by the supervisor must do the trial running of a motor vehicle to

test its brakes or steering mechanism on the refinery roads. " motor vehicle must be loaded only according to the re!uirements of the

Bovernment rules. The loading beyond the sides or the front of the vehicles orbeyond 7 meter at its back is strictly prohibited. "lso care should be taken not toload the vehicles up to a height which may entangle with overhead obstructions.

*here this not possible for any particular work, a responsible person from theconcerned section must accompany the vehicle until the material has beenunloaded.

Truck carrying lengthy materials hanging outside the tailboard of the truck shouldcarry read flags tied at the end of the material.


21/21

Persons must not attempt to board or alight from a motor vehicle in motion. TheDriver must make sure before starting his vehicle that not one is alighting orboarding.

Gehicle must be started, stopped or turned gently and not suddenly. 2oads must always be kept free of obstruction. During road repair work or any

excavation work along the roads, proper barricades and suitable caution noticesshould be displayed.

3o vehicles should be parked within nine meters of any corner or rail crossing orroad #unction or a fire hydrant.

Drivers must not leave their vehicles with engine running. The security personnel should report any violation of traffic rules by the employee of

the corporation to the Eead of Department under whom the employee is working. The traffic accidents must be reported to the :afety ell whether in#uries are

caused to personnel or not. 3ecessary action to deal with traffic collisions between

motor vehicles and fixed or moving ob#ects shall be taken up by the :afety ell.This :afety ell shall report the accident, 5nder 0actories "ct, if necessary.

"ll vehicles, including dumpers, bicycles and pedestrians should stop at everyunmanned railway crossing, watch out on either side and cross the rails only whenthere is not traffic on the rails.

safe work habits

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