HEALTH, SAFETY AND ENVIRONMENT SPECIFICATION

Camps, Offices, Laboratories, Workshops and Industrial Safety

Specification
DOCUMENT ID
- SP 1256
REVISION
- 2.0
DATE
- 5/10/08

HSE SPECIFICATION

Setting Clear Requirements

Authorised for Issue by the HSE IC 5/10/08

Document Authorisation
Document Authority
Naaman Naamany
Ref. Ind: MSEM
Date: 5/10/08

Document Custodian
Hamad Khalfeen
Ref. Ind: MSE/1
Date: 5/10/08

Document Author
Hamad Khalfeen
Ref. Ind: MSE/1
Date: 5/10/08

The following is a brief summary of the four most recent revisions to this document. Details of all
revisions prior to these are held on file by the Document Custodian.
Version No.
Version 2.0
Version 1.0

Date
October
2008
July 2002

Author
Hamad Khalfeen
Ref. Ind: MSE/1
Hamad Khalfeen
Ref. Ind: CSM/11

Scope / Remarks
Criteria Added for Location.
Original issue. Supersedes HSE Standards
Manual - Chapter 6 and 7; Occupational Health
Management Guidelines 1996 (GN 18; IN 19)

User Notes:
The requirements of this document are mandatory. Non-compliance shall only be authorised by CSM
through STEP-OUT approval.
A controlled copy of the current version of this document is on PDO's EDMS. Before making reference
to this document, it is the user's responsibility to ensure that any hard copy, or electronic copy, is
current. For assistance, contact the Document Custodian.
This document is the property of Petroleum Development Oman, LLC. Neither the whole nor any part of
this document may be disclosed to others or reproduced, stored in a retrieval system, or transmitted in
any form by any means (electronic, mechanical, reprographic recording or otherwise) without prior
written consent of the owner.
Users are encouraged to participate in the ongoing improvement of this document by providing
constructive feedback.

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Contents
1.0

INTRODUCTION............................................................................1

1.1 PURPOSE...................................................................................................... 1
1.2 SCOPE.......................................................................................................... 1
1.3 DELIVERABLES................................................................................................ 1
1.3.1 Records............................................................................................... 1
1.3.2 Reports................................................................................................ 1
1.4 RESPONSIBILITIES............................................................................................1
1.5 PERFORMANCE MONITORING.............................................................................2
1.6 REVIEW AND IMPROVEMENT..............................................................................2
1.7 REPORTING FORMAT........................................................................................2
2.0
2.1
2.2
2.3
2.4
2.5
3.0

GENERAL PERFORMANCE REQUIREMENTS......................................3

LEGAL REQUIREMENTS.....................................................................................3
LOCATION, DESIGN AND CONSTRUCTION.............................................................4
ELECTRICAL SUPPLIES, INSTALLATIONS AND EQUIPMENT..........................................4
GENERAL HOUSEKEEPING.................................................................................5
MAINTENANCE................................................................................................ 6
WORKSHOPS...............................................................................7

3.1 WORKSHOP DESIGN AND CONSTRUCTION............................................................7

3.1.1 Layout of Workshops...........................................................................7
3.2 WORKSHOP WORK PRACTICES...........................................................................8
3.2.1 Workshop Discipline............................................................................8
3.2.2 Lifting Operations in Workshop Areas..................................................9
3.2.3 Fixed Workshop Equipment.................................................................9
4.0

CAMPS, OFFICES AND LABORATORIES.........................................10

4.1 DESIGN AND CONSTRUCTION..........................................................................10

4.1.1. Furnishings and Fittings.....................................................................10
4.2 LABORATORY HOUSEKEEPING...........................................................................10
4.3 LABORATORY WORK PRACTICES.......................................................................11
4.3.1 Control of Chemical Substances........................................................12
5.0

INDUSTRIAL SAFETY...................................................................13

5.1 BASIC EQUIPMENT SAFEGUARDS......................................................................13

5.2 HAND TOOLS............................................................................................... 13
5.2.1 General Regulations..........................................................................13
5.2.2 Hand tools Used at Machines.............................................................14
5.3 PORTABLE ELECTRICALLY POWERED TOOLS........................................................14
5.3.1 General Regulations..........................................................................14
5.3.2 Cartridge or Powder Actuated Tools...................................................14
5.3.3 Maintenance, Inspection and Testing.................................................14
5.3.4 Electrically Powered Portable Hand Saws..........................................15
5.3.5 Pneumatic Tools.................................................................................15
5.3.6 Grinders............................................................................................. 18
5.3.7 Extension Cords.................................................................................18
5.4 ABRASIVE BLASTING OPERATIONS....................................................................19
5.4.1 General.............................................................................................. 19
5.4.2 Personnel Safety................................................................................19
5.4.3 Blasting Equipment...........................................................................20
5.4.4 Abrasive blasting materials...............................................................21
5.4.5. Work Practices...................................................................................21
5.5 INDUSTRIAL GASES.......................................................................................21

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5.5.1 Industrial Compressed Gas Cylinders................................................21

5.5.2 Transport of Compressed Gas Cylinders............................................21
5.5.3 Storage of Cylinders..........................................................................21
5.5.4 Use of Cylinders.................................................................................21
5.6 GAS WELDING AND CUTTING..........................................................................21
5.6.1 General Safety Requirements............................................................21
5.6.2 Regulators.........................................................................................21
5.6.3 Hoses and Torches.............................................................................21
5.7 ARC WELDING.............................................................................................. 21
5.7.1 General.............................................................................................. 21
5.8 BATTERY CHARGING AND STORAGE..................................................................21
5.9 TANKS AND VESSELS.....................................................................................21
5.9.1 Opening and Entry of Tanks and Vessels...........................................21
5.9.2 Hot Work on Contaminated Tanks/Vessels.........................................21

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1.0Introduction
1.1

Purpose
This Specification describes PDO's requirements for managing occupational
health and safety risks associated with workshops, offices, camps,
laboratories and other construction or maintenance related industrial
activities.

1.2

Scope
This Specification applies to all camps, offices, laboratories, buildings and
other premises belonging to or occupied by PDO, Contractors or SubContractors authorised to work on behalf of PDO.
This Specification does not address:

1.3

Manual handling (refer to SP 1231 Occupational Health)

Ergonomics in the office environment and VDUs (refer to SP 1231
Occupational Health)
Public Health risks (refer to SP 1232 Public Health)
Fire Protection (refer SP 1075 Fire and Explosion Risk Management).

Deliverables

1.3.1

Records
Records shall be maintained to document the implementation of this
Specification (refer to CP 122 HSE Management System Manual, Part 2
Chapter 6).

1.3.2

Reports
PDO staf: Any non-compliance with this Specification shall be notified,
investigated and reported per the Non Compliance Report Form in CP 122
HSE Management System Manual, Part 2 Chapter 6.
Contractors: Any non-compliances with this Specification shall be reported
to the Contract Holder.

1.4

Responsibilities
Asset Managers
Asset Managers are responsible for ensuring that the activities they control
are managed in accordance with the requirements of this Specification.
In the event that circumstances prevent compliance with this Specification,
Asset Managers shall seek the advice and if necessary, a step-out
approval from the Document Authority. This approval requires recording
subject areas, which do not conform as a non-compliance (refer to the Non
Compliance Report Form CP 122 HSE Management System Manual, Part 2
Chapter 6).

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Corporate Functional Discipline Heads

Corporate Functional Discipline Heads are responsible for ensuring that the
requirements of this Specification are reflected in the documents for which
they are responsible.
Contract Holders
Contract Holders are responsible for communicating this Specification to
Contractors, and for ensuring that the requirements of this Specification
are adhered to within the scope of their contracts.
In the event that circumstances prevent compliance with this Specification,
Asset Managers shall seek the advice and if necessary, a step-out
approval from the Document Authority. This approval requires recording
subject areas, which do not conform as a non-compliance (refer to the Non
Compliance Report Form CP 122 HSE
Contractors are responsible for ensuring that activities undertaken within
the scope of their contracts are managed in accordance with the
requirements of this Specification.
1.5

Performance Monitoring
Compliance with this Specification shall be monitored through workplace
supervision, and periodic site inspection.

1.6

Review and Improvement

Any user of this document who encounters a mistake or confusing entry is
requested to immediately notify CSM using the User Feedback Form
provided in CP 122 HSE Management System Manual, Part 2 Chapter 3.
This Specification shall be reviewed every 4 years. However changes to
the current version may be made in less than four years as the need arises
depending upon the issue of new and relevant environmental legislation
and/or major organisational changes in PDO.

1.7

Reporting Format
PDO Staf: There are no routine reporting requirements against this
Specification.
Contractors: There are no routine reporting requirements against this
Specification.

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2.0General Performance Requirements

2.1

Legal Requirements
Legal requirements for industrial safety in Oman are established in Chapter
7 of Sultans Decree No. 34 1973 Oman Labour Law. Legal requirements
stipulate:

Every employer must advise workers about workplace hazards, and the
preventive measures to be employed.

Every employer must take the necessary precautions to protect

workers from injury to their health and safety by making sure that:
Adequate safety and hygienic conditions prevail in all places of
work
Machinery, pieces of equipment and tackle are installed and
maintained in the safest possible way
Places of work are clean and comply with conditions of health and
comfort.

A worker must:
Not carry out an action which is forbidden by workplace instructions
and is bad practice or causes damage.
Not shortcut the means provided for protection of the workers
health and safety, or the health and safety of fellow workers.
Use protective methods and undertake to regard them with care,
and carry out instructions laid down for the workers protection
and the prevention of injury.

Inspectors appointed by the Ministry have the power to examine the

worker-related records of an establishment and to enter places of work.
Inspectors also have the authority to question whoever they wish and to
publish reports on the results of their investigations. On the basis of the
reports produced by the inspectors, the Ministry will issue a written
warning to an employer who infringes the regulations, stating the nature of
the offence and the time limit set for it to be discontinued.
If there is danger to the health or safety of workers, and the employer
refrains from carrying out the instructions of the Ministry, the Ministry may
order the premises to be closed down partially or completely, or to stop
one or more pieces of equipment working.
Any employer contravening the health and safety regulations stipulated
above is liable to a fine not exceeding OR 5 for every worker employed.
The punishment will be doubled if the offence is repeated. Any employer
who refuses entry to inspectors, or provides false statements to inspectors
is liable to a fine not exceeding OR 100 or one month imprisonment. The
penalty will double if the offence is repeated.

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2.2

Location, Design and Construction

The location of new camps, offices, laboratories and workshops shall be
carefully selected to ensure that risks to workers are controlled to a level
that is as low as reasonably practicable. The selection criteria shall
include:
The
location
of
camps/accommodation
areas
and
workshops/offices/industrial areas with regard to existing hazardous
facilities;
The impact of the camps and industrial areas on existing roads in the
area, with any recommendations for road improvements, and preferred
routes/access points to minimize road traffic risk;
The transportation arrangements for workers to/from camps or
accommodation areas, and between those areas and the worksites.
All camps, offices, workshops and laboratories shall be designed and
constructed in accordance with the following documents:
PDO-ERD-17-01:
PDO-ERD-17-02:
PDO-ERD-17-04:
SP 1127:

Civil and Building Construction Specification

Building Services Construction Specifications
Civil and Building Design Criteria Manual
Layout and Spacing of Plant Equipment and Facilities

Temporary transportable units such as portacabins shall meet

requirements of PDO-ERD-92-02 Transportable Accommodation Units.
2.3

Electrical Supplies, Installations and Equipment

All electrical supplies to camps, offices, laboratories, workshops and
installations within these, shall be in accordance with the following
documents:
SP 1099:
Electrical Installation Practice
SP 1104:
Electrical Safety Rules
Temporary electrical supplies shall meet the requirements of SP 1111
Temporary Electrical Supplies for Construction and Maintenance Work. All
electrical supplies shall be in accordance with SP 1110 Electrical Supplies
in Mobile Camps.
Extension cords shall not be used for any permanently installed
equipment. Whenever utilised, electric power extension cords shall be in
accordance with this Specification and with SP 1111 Temporary Electrical
Supplies for Construction and Maintenance Work.
Electrical installations shall comply also with the following:
All electrical equipment shall be connected to the voltage for which it is
designed.
Plug adapters shall not be used in any industrial installation. All
equipment shall be fitted with the correct plug to fit in its
corresponding socket.

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Sockets shall be available in all industrial work sites.

Multiple
appliances or power tools shall not be plugged into a single socket via a
multi-outlet adapter.

Electrically powered equipment shall be switched off and disconnected

from the electrical supply prior to any cleaning or adjustment by nonspecialised personnel. Portable electrical tools shall comply with the
requirements of this Specification.
All faults such as cracked plugs, frayed or damaged leads or faulty wall
sockets shall be reported immediately and the equipment shall not be used
until repaired. All repairs shall be performed by competent, trained
persons. Fuses and MCB's shall be replaced with correctly rated units.
All electrical equipment shall be maintained in accordance with the
manufacturer's instructions. Temporary electrical installations shall be
installed by competent personnel and inspected as a minimum every
month.
2.4

General Housekeeping
Good housekeeping shall be considered one of the primary defences
against accidents, injuries and health problems in the workplace and
therefore is the responsibility of all personnel.
All camps, offices, laboratories and workshops shall be maintained clear of
debris, waste and other rubbish, which shall be disposed of in accordance
with the manufacturer's instructions and SP 1009 Waste Management. All
buildings shall be kept cleaned, and wastebaskets regularly emptied. All
floor coverings shall be regularly inspected and any loose or damaged
items replaced or re-secured immediately.
Loose carpets are not
recommended in offices as they represent a trip hazard.
All

furniture shall be regularly inspected for:

broken or loose legs, castors, wheels
damaged or cracked perspex or glass work surfaces
non-functioning or ill-fitting drawers or doors.

Any damaged items shall be repaired or replaced immediately.

Cabinets and shelving shall be loaded from the bottom shelf upwards, and
heavy items placed as low as practical. At no time shall heavy or sharp
objects be stored above eye level. Cupboards and filing cabinets shall not
have items indiscriminately stored on top of them.
All emergency walkways, passages and exits, fire doors, break glass alarm
points, fire fighting equipment, first aid and other emergency stations shall
be kept clean, unobstructed and in good working order.
All workplaces shall be maintained clear of debris, waste and other
rubbish.
Stockpiles of raw materials shall not be allowed to accumulate in the
workplace. All workshops shall be provided with segregated storage areas

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for incoming raw materials or equipment for repair, and outgoing finalised
products or repaired equipment.
Adequate storage facilities shall be provided for all tools and equipment
used in any workshop and a system of control implemented such that only
those tools or pieces of equipment required for the task being performed
are deployed.
All liquid spills, especially oily or greasy liquids, shall be immediately
cleaned up by absorption in inert sand or other suitable materials. If rags
are used to mop up spills of flammable materials, they shall immediately
be removed to a safe place and stored in closed containers for safe
disposal.
2.5

Maintenance
All camps, offices, laboratories and workshops shall undergo regular
preventive maintenance. Such preventive maintenance shall be planned
and recorded. The preventive maintenance program shall include:

SP 1256

Safety routes and exits, lighting, ventilation and sanitary facilities.

Floor and workbench surfaces shall be repaired as required.
Walls, ceilings and fixtures shall be painted on a regular basis to
maintain the standards of illumination required.
Electrical installations, specifically the integrity of insulation and
earthing provisions Compressed air, industrial gas and water
installations
All fixed equipment and machine tools, hand tools, etc.

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3.0Workshops
3.1

Workshop Design and Construction

In addition to the general requirements, the following requirements shall
apply to the design and construction of workshops:

3.1.1

All workbenches and working surfaces shall be fit for purpose,

constructed of suitable fire-resistant materials and to a sound design,
such that the work may be accomplished safely and without undue
strain to the worker.
Where wet processes are carried out, or where machinery is liable to
eject quantities of fluid, adequate containment, in the form of channels,
bunds or curbs, and drainage shall be provided. Drainage of industrial
effluent shall be in accordance with SP 1006 Aqueous Effluents.
Adequate provision shall be made for the collection, temporary storage,
and disposal of solid scrap and waste material from all workplaces.
Segregation and disposal of such scrap materials shall be made in
accordance with SP 1009 Waste Management.
Adequate toilets and washrooms shall be provided in all workshops.
These shall meet the requirements of SP 1232 Public Health. Where
necessary, special cleansers shall be provided to discourage workers
from using unsuitable industrial solvents for skin cleansing. Sewage
disposal shall be in accordance with SP 1006 Aqueous Effluents.
Adequate supplies of drinking water shall be provided in all workshops
in accordance with SP 1232 Public Health.
Workshop lighting shall comply with SP 1231 Occupational Health.

Layout of Workshops
Workshops shall be laid out as follows:

Clear areas shall be defined for each activity performed in the

workshop. Activities shall be segregated such that each activity does
not interfere or cause hazards to others present.
Hazardous activities such as welding, cutting, grinding, grit blasting,
painting etc., shall be segregated from other activities, normally in
dedicated booths.
All hazardous materials shall be securely stored in dedicated areas,
separated from work areas and, where necessary, from other hazards.
Transit walkways shall be clearly defined in all workshops, as shall all
work areas, specifically those requiring limits on access due to the
nature of activity performed.
All emergency systems: escape routes; fire alarms and fire fighting
equipment; first aid equipment; etc., shall be indicated by clearly
visible signs. Such signs shall conform to the requirements of ERD 8901 "Signs and Signboards".
Wherever possible, work areas, storage areas, walkways, hazardous
areas and escape routes shall be indicated by means of colour coding.
Colour coding shall follow the ISO Recommendation R 408, as detailed
in Table 1 below.

In addition to Table 1, contrast colours and/or wording or symbols may be

added to improve visibility, as detailed in Table 2 below.
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Yellow and black diagonal striping shall be used to indicate hazards or

sources of particular danger (e.g., moving machinery, load lay down
areas, areas requiring entry permits).
Safety colours may be applied directly to surfaces to indicate their
condition. Thus emergency walkways or escape routes should, in
general, be painted green, while the flooring of a welding shop, or
other permanent restricted access or hazardous area should be painted
either yellow, or yellow with black stripes, depending on the level or
type of hazard present. Safety colours should not, however, be
overused, and normal workplace floors should be a neutral colour such
as grey.
Personal Protective Equipment shall be available in all workshops, and
shall meet the requirements of SP 1234 Personal Protective Equipment.

Table 1: Colour Coding

COLOUR
Red

MEANING
Stop;
harmful
activity, Prohibition

Yellow

Caution Danger

Green

Safety

Blue

Information
Mandatory action

EXAMPLE OF USE
Stop
signals,
Emergency
shutdowns Identification of Fire
fighting Equipment
Indication
of
Hazards
(Fire,
explosion, radiation, chemical,
trip
etc.);
Identification
of
thresholds, dangerous passages,
obstacles
Escape routes, refuges, first aid
eye baths, deluge showers.
Mandatory information signs,
such
as:
Wear
personal
protective equipment

Table 2: Contrast Colours

3.2
3.2.1

SP 1256

SAFETY COLOUR

CONTRAST COLOUR

Red
Yellow
Green
Blue

White
Black
White
White

SYMBOLS
WORDING
Black
Black
White
White

OR

Workshop Work Practices

Workshop Discipline

Smoking shall not be permitted in any workshop or industrial area,

except in designated smoking zones.

Eating food shall be restricted to designated areas and work breaks.

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3.2.2

Horseplay of any kind shall be prohibited in the workplace.

Lifting Operations in Workshop Areas

Personnel working under or in the vicinity of an active overhead crane
inside the workshop or workshop area shall wear safety helmets.
Lifting operations shall be conducted in accordance with SP 1257 Safety
Standards for Scaffolding, Working at Heights or Over Water, Lifting
Operations and Earthworks.

3.2.3

Fixed Workshop Equipment

General
Fixed workshop equipment, such as compressors, lathes, grinders, drills
and hydraulic presses present specific hazards. All such equipment shall
be installed in such a way that these hazards are minimised. As a
minimum, temporary or permanent screens should be in place, particularly
next to lathes, grinders and drilling machines to protect personnel working
nearby.

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4.0Camps, Offices and Laboratories

4.1

Design and Construction

In addition to the general requirements for design and construction,
laboratories shall comply with:
DEP-34.17.10.31 Laboratories (appropriate to the chemicals being handled
and work performed )

4.1.1. Furnishings and Fittings

Glass doors and full-length windows shall be fitted with reflective warning
strips close to eye height.
Where the height of storage shelving requires their use, steps or ladders
shall be provided. Shelving and flooring shall be of adequate design and
strength to carry the intended loads.
Storage cupboards for stationery and other flammable materials shall be
metallic and, when not in a dedicated storage room, fitted with doors.
4.2

Laboratory Housekeeping
In addition to the general requirements for housekeeping, particular care
shall be taken in laboratories to ensure that:

Quantities of chemicals likely to react adversely shall not be disposed

of together.
All chemicals to be disposed of shall be placed in clearly labelled
containers with a description of the contents and international hazard
sign.
Waste shall be suitably segregated to minimise hazards to disposal
personnel. Particular attention shall be given to separating all broken
glassware and other sharp objects from regular waste. The proper
disposal of waste shall be the responsibility of designated laboratory
staff.

Any spillage of liquid, especially of toxic, corrosive or otherwise hazardous

liquids, shall be immediately cleaned up in accordance with manufacturers
instructions, the SHOC Cards or the MSDS (refer to SP 1009 Waste
Management, Section 2.3). All staff shall be familiar with the procedures
for dealing with spillage in the laboratory. Any materials used to mop up
spills shall immediately be removed to a safe place and stored in closed
containers for safe disposal (refer to SP 1194 Chemical Management,
Section 5).
Adequate time shall be assigned in all laboratories to ensure that good
housekeeping is maintained. If deemed necessary, in addition to the
housekeeping efforts of laboratory workers, specialised cleaning personnel
may be required to maintain adequate levels of cleanliness. If such work is
carried out during normal working hours, provision shall be made to ensure
they neither interrupt the regular work patterns or distract the laboratory
workers, nor are put at risk by the laboratory processes. Likewise, if
cleaning activities are carried out outside normal working hours, this work

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shall be supervised by competent laboratory staff to ensure the cleaning

personnel are neither at risk from chemicals, nor cause damage to
equipment.
4.3

Laboratory Work Practices

All laboratory work shall be carried out by qualified and competent
personnel, working in accordance with written and approved work
procedures. The hazards of all chemicals used in the laboratory shall be
assessed and specific HSE training relevant to the hazards shall be
provided to all laboratory staff handling those chemicals.
Personal protective equipment (PPE) as specified in the above work
procedures and in SP 1234 Personal Protective Equipment shall be
available in the laboratory and worn by staff while performing laboratory
work. Each laboratory shall have eye wash baths and emergency showers
installed.
Personal protective equipment (PPE) as specified in the above work
procedures and in SP 1234 Personal Protective Equipment shall be
available in the laboratory and worn by staff while performing laboratory
work. Each laboratory shall have eye wash baths and emergency showers
installed.
No activity which involves gas, electricity, water or chemical reaction shall
be left unattended without the approval of the laboratory supervisor.
No person shall perform laboratory work alone unless appropriate safety
measures have been taken (e.g. use of dead mans alarm, direct contact
with other staff working outside the laboratory or a camera installed which
can be monitored by other staff working nearby).
Any operation which may result in the release of toxic or noxious fumes
shall be performed in a suitable fume cupboard. Ventilation and fume
extraction systems shall meet the requirements of DEP 34.17.10.31
Laboratories and be maintained in good condition.
The process of diluting acids or other reactive liquids shall be done by
adding the concentrated liquid to the required quantity of water, rather
than adding water to the concentrated reactive liquid.
Pipetting shall only be carried out using an aspirator bulb.
No food or drink shall be brought into, prepared, or consumed inside
laboratory work or storage areas. Designated areas where no chemicals
are present may be allocated for this purpose.
No unauthorised work or experiments shall be performed in laboratories.
Laboratory equipment which may be subjected to pressure or corrosive
substances shall be inspected and tested in accordance with
manufacturer's recommendations and shall meet the specified Certification
requirements.
The use, storage and handling of industrial gases in the laboratory shall
comply with the requirements of this Specification.

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4.3.1

Control of Chemical Substances

The use and disposal of chemicals within the laboratory shall comply with
SP 1194 Chemical Management and SP 1009 Waste Management.
Only the required quantity of chemical substances for the daily operations
shall be kept in the laboratory. Bulk chemicals shall be kept locked in
dedicated, fit-for-purpose stores.

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5.0Industrial Safety
5.1

Basic Equipment Safeguards

All moving parts of machinery, such as drive belts, gear wheels, etc., shall
have adequate guards in place at all times to prevent injury.
Adequate protection shall also be in place at the point of operation, i.e.
circular or band saw blades, grinding wheels, power presses, etc., to
prevent operator injury from both the equipment and debris such as metal
chips, sawdust etc. created in the work process.
Adequate support and guides shall be provided for work pieces, such that
they are secured and controlled when being cut, ground or otherwise
worked and cannot "kick back" to injure the operator.
Signs shall be provided in accordance with ERD-89-01 Signs and
Signboards, indicating the personal protective equipment (eye protectors,
ear protectors, work-gloves etc.) required for the safe operation of the
equipment.
The protective equipment itself shall be placed in a
convenient position close to the machine.
Powered workshop equipment shall be used only by trained operators.
Operators shall demonstrate their competence to their supervisor before
being allowed to work unsupervised.

5.2
5.2.1

SP 1256

Hand Tools
General Regulations

All hand tools shall be assigned to a responsible person. This may be

on an individual basis, or a single person may be assigned to control
the hand tools of a particular work area or shop.

The responsible person shall ensure that hand tools are maintained in
good condition. Regular six monthly inspections shall be made of all
hand tools and records of these inspections maintained. If any defects
are identified the tool shall be removed from service and either be
repaired or replaced.

Tools shall only be issued to personnel who have the necessary

knowledge and skill to operate them safely. Supervisors shall ensure
that workers are competent to work safely with any tool prior to leaving
them to work unsupervised.

Tools shall be used only for the specific purpose for which they were
designed

Tools shall at all times be transported from one work location to

another in adequate containers and in such a way as not to endanger
the safety of others.

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5.2.2

When using hand tools on small work pieces, the work pieces shall be
suitably secured to the workbench using a vice or clamps.

The use of non-sparking tools is not recommended. In the event that

their use is justified in an exceptional case, then the condition of such
tools shall be thoroughly checked by competent personnel and users
shall be made aware that they are not a complete safeguard against
spark production.

Hand tools Used at Machines

The use of hand tools with powered machines such as lathes or grinders
shall be strictly controlled. Only competent personnel shall be allowed
access to such powered machines.

5.3
5.3.1

Portable Electrically Powered Tools

General Regulations
All portable electrically-powered tools shall be of a type approved by PDO,
and shall be inspected, tested, serviced and used in accordance with the
manufacturer's instructions. Only competent personnel shall be allowed to
use them.
Portable electrical equipment shall be in accordance with SP 1111
Temporary Electrical Supplies for Construction and Maintenance Work.
All portable electrically-powered tools shall have the following construction
features:

Fitted with adequate fuse protection, either in the tool body or its
electric plug.
Provided with an automatic shut-off device which renders it inoperative
if the operator releases grip, e.g. a non-sustaining trigger switch. The
use of trigger switch locking devices or sustaining buttons should be
avoided.

Portable electrically-powered tools shall not be used in potentially

hazardous or explosive environments. In addition, extreme care shall be
taken in working areas containing oil, water, caustic, corrosive or
conductive fluids, particularly with regard to routing of power leads.
Where applicable, protective guards shall be securely fitted, and correctly
adjusted.
5.3.2

Cartridge or Powder Actuated Tools

The use of cartridge or powder-actuated tools is prohibited.

5.3.3

Maintenance, Inspection and Testing

Maintenance of electrical tools, transformers and associated protection
devices like Earth Leakage Circuit Breakers (ELCBs) shall be carried out at
6 monthly intervals in accordance with guidelines given in GU 325
Electrical Maintenance Management Manual.

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Each piece of equipment tested shall be labelled to show that it has been
tested and to indicate when the next test is due. The procedure involves
the use of a portable appliance test unit which, by plugging the tool into
the unit, automatically carries out a test sequence and carries a register of
the equipment tested.
In addition, the inspection procedure shall include:

Inspection of leads for damage and that correct PDO colour codes are
used.
Checks on terminations and cord grips.
Verification of correct fuses fitted to plug tops.
Insulation checks, where applicable.

Special attention shall be given to the connecting cords. These shall

always be in sound condition and not kinked. They shall be replaced
immediately if they are in any way faulty or worn.
Tools found to be defective shall be labelled as such in the working
language of the work force and English, removed from service and
returned to the store for repair.
5.3.4

Electrically Powered Portable Hand Saws

All electrically-powered portable saws (circular saws) shall be fitted with
both a fixed guard over the upper half, and a movable guard over the
lower part. Both guards shall at all times be operative. Blocking open of
the lower guards is prohibited.
When cutting materials which generate dust, proper respiratory protection
shall be worn (ref SP 1234 Personal Protective Equipment). In addition,
when cutting in areas occupied by other workers, protection in the form of
dust extractors shall be provided.

5.3.5

Pneumatic Tools
General
All pneumatic hand tools shall be fitted with spring valves such that when
the operator releases grip, the tool is deactivated.
Where applicable, protective guards shall be securely fitted, and correctly
adjusted.
Use of Pneumatic Tools
Using high pressure air to clean or remove dust and chips from personnel,
clothing or workbench is prohibited.
Workers using percussive or rotary pneumatic tools are exposed to the
harmful effects of vibration. Since the harmful effect is related to the
length of exposure, frequency and vibration intensity, proper supervision is
required to identify vibration stress. Health risk associated with vibrating
equipment shall be managed in accordance with SP 1231 Occupational
Health.

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Workers using percussive or rotary pneumatic tools are also exposed to the
harmful effects of noise. Health risk associated with noise exposure shall
be managed in accordance with SP 1231 Occupational Health.
When the use of pneumatic tools generates dust, proper respiratory
protection shall be worn (ref SP 1223 Personal Protective Equipment). In
addition, when dust is generated in areas occupied by other workers,
protection in the form of dust extractors shall be provided.
The Compressor
The compressor supplying air shall be installed such that it:

receives an adequate supply of fresh, uncontaminated air.

does not represent a fire hazard.
does not represent a noise hazard.

The compressor shall be fitted with the following:

a manual isolation valve between its storage tank and the air lines to
permit their isolation.
a bleed-down valve to de-pressurise the air lines prior to disconnecting
them.
an automatic check valve operating to isolate the air lines from the
storage tank in the event of line failure causing an uncontrolled loss of
air.
an adequate purging system on the accumulator tank to remove any
water or oil contamination.

Airlines and Couplings

All airlines and couplings shall be fit for the specific application. Where an
airline is fitted with a quick-release connection, the female connector
should be fitted on the upstream (pressurised) side, and shall be fitted with
an automatic check valve.
Where twist lock connectors are used, i.e. on heavy-duty line to road drills,
compactors, etc., they shall be fitted with suitable safety wires or chains to
prevent both accidental disconnection and to secure the ends, thus
preventing flailing if disconnected accidentally under pressure.
In permanent installations of compressed air, the air supply shall be piped
as close as possible to the workplace and the minimum of flexible hose
used to connect the tools. Multiple access points with quick-release
connectors should be used to give maximum flexibility. It is advisable to fit
fluid traps and purges to permanent air piping in order to remove any oil or
water build-up, which could be a safety hazard, or cause equipment
malfunction.
Flexible airlines shall be protected from damage by vehicles and materials
and shall be routed such that they do not represent a trip hazard to
workers. Channel ways shall be supplied when crossing walkways and
roadways. Where carried overhead or vertically, they should be supported
by a messenger cable, bridging or other suitable support.
Unless fitted with a quick-release connection containing an automatic
check valve, pneumatic lines shall be de-pressurised and isolated from the

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HSE SPECIFICATION

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compressed air source prior to disconnecting either the tool from the line
or the line from the source of compressed air.
Prior to carrying out any repair, adjustment or cleaning of pneumatic tools
or equipment, the air supply shall be physically disconnected. Where
necessary the compressor shall be isolated and the lines de-pressurised
prior to disconnecting the tool or equipment.
Inflating tyres
Where a compressor is being used to inflate tyres, an in-line pressure
gauge shall be installed to guard against over inflation. The airline
between the chuck and the control valve shall be at least 3 metres.
Wheels of split rim type, typically used on heavy vehicles shall be placed in
a safety cage for inflation after tyre replacement or repair. Such safety
cages shall be supplied by an internationally recognised tyre manufacturer.
Alternatively, such safety cages shall be manufactured locally in
accordance with the standards set by such a manufacturer.

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5.3.6

Grinders
Grinding wheels shall be covered with a solid guard over that part of the
circumference not used for grinding, in order to protect operators in case
of wheel breakage. Also an adjustable guard shall be set over the usable
area of the wheel.
Grinders shall be fitted with a transparent eye shield.
In addition,
operators shall wear eye protection which meets the requirements of SP
1234 Personal Protective Equipment.
The spindle end shall be covered to prevent catching of clothing
An adjustable work rest shall be fitted to the machine and shall normally
be adjusted no more than 3 mm from the wheel face.
A dead man device (i.e. foot pedal actuation) should be installed to
prevent the grinder being left running unattended. Additionally visual
indication (flashing light) should be considered.
Operators shall use the circumference face of the wheel, never the side.
Only fit for purpose grinding wheels shall be used, i.e:
correct diameter for the grinding machine
correctly sized hole to fit snugly on the spindle, without either forcing
or slack.
Where grinding generates any harmful dust, a dust extraction system shall
be provided. Wheels containing free silica (sandstone for example) are
prohibited.

5.3.7

Extension Cords
Extension cords shall not be used for any permanently installed
equipment.
Whenever utilised, electric power extension cords shall be in accordance
with SP 1111 Temporary Electrical Supplies for Construction and
Maintenance Work. They shall have adequate current rating for the
equipment to be powered and contain an independent (3rd) earthing
conductor. They shall at all times be fitted with a male plug on one end
and female socket(s) on the other, both of the same type and current
rating.
Extension cords shall never be left coiled when in use, shall be of an
adequate length and routed such that the do not represent a tripping
hazard to personnel. Power extension leads shall be routed in such a way
so as not to expose them to physical or chemical damage. For example,
routed through doorways and hatches which may be closed, across
walkways or corridors, over or in contact with hot surfaces or piping, sharp
or abrasive surfaces, or in contact with corrosive chemicals.

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5.4
5.4.1

Abrasive Blasting Operations

General
Abrasive blasting operations present two distinct hazards to workers:

Inhalation of hazardous dusts.

Physical external injury from the abrasive blast.

Abrasive blasting activities shall comply with the requirements of PDO-ESCS-48-06 Surface Preparation and Coating of Oil and Gas Facilities and the
requirements of 5.4 of this Specification.
5.4.2

Personnel Safety
Personal Protective Equipment
Personnel engaged in abrasive blasting operations shall always wear a
specifically designed blasting helmet. This consists of a helmet enclosing
the entire head and neck of the worker and extending down both the back
and chest area sufficient distance to prevent abrasive entry. It shall be
fitted with a wide angle transparent visor, which shall be specific to the
particular design of helmet and easily replaced when damaged. It shall be
supplied with fresh air operating under a positive pressure system, to
prevent entry of dust or abrasive.
The air supply to the blasting helmet shall be drawn from a clean air area.
Air
supply
volume/pressure
shall
be
as
per
manufacturer's
recommendations and fitted with sufficient in-line filtering to achieve the
air purity standard specified in SP 1234 Personal Protective Equipment.
In addition to the above, personnel engaged in grit blasting shall wear
suitable long-armed gauntlets, a long apron and high boots for body
protection, and hearing protection (ref SP 1234 Personal Protective
Equipment).
All personal protective equipment shall be subject to rigorous inspection at
the beginning and end of every shift or operator change over. Defective
parts shall be replaced to ensure adequate performance as described
above. Items requiring specific attention are the helmet visor, the air
filtering system and hoses.
Personnel Requirements
All personnel engaged in abrasive blasting operations shall be fully trained
in the safe operation of the equipment and safe working practices.
All personnel who are required to work in the vicinity of abrasive blasting
operations shall receive specific instruction on the hazards of the work and
procedures to minimise danger to themselves and their equipment.
At all times personnel engaged in abrasive blasting shall be supervised by
a competent person, who will ensure that the breathing air supply is
maintained at all times and that work is carried out in a safe and efficient
manner.

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At no time shall more than one person work at one specific blasting site. If
more than one abrasive blaster is employed on a particular operation, their
work areas shall be physically separated to prevent the blast of one
operation reaching the other.
Vibration
Workers using abrasive blasting equipment are exposed to the harmful
effects of vibration. Since the harmful effect is related to the length of
exposure, frequency and vibration intensity, proper supervision is required
to identify vibration stress.
Health risk associated with vibrating
equipment shall be managed in accordance with SP 1231 Occupational
Health.
5.4.3

Blasting Equipment
Abrasive blasting equipment shall be utilised
accordance with the manufacturers instructions.

and

maintained

in

The abrasive blasting tool shall incorporate an automatic safety shut-off

valve, such that if the operator loses his grip on the tool, air and grit
supply are immediately shut off. This shut-off valve shall be of a type
approved by the manufacturer of the grit blasting tool and shall be fitted in
accordance with the manufacturers instructions. It shall be functional at
all times and shall never be tied, clamped or otherwise secured in the open
position.
Air shall be delivered to the blasting tool through an electrically conductive
hose, electrically earthed to the mass of the tank, vessel or structure being
cleaned such that static electricity build-up is prevented, to avoid both
shock hazards to the operator and spark discharges which could ignite any
flammable dust generated in the blasting operation.
All couplings on the airline shall be secured with insurance wires or
securing chains to prevent accidental disconnecting while under pressure.
Abrasive Blasting Booths
Where blasting is carried out in a permanent installation, a dedicated
blasting booth shall be constructed. The location and design of such
booths shall be subject to PDO approval. For large pieces of equipment,
(e.g. a vessel), a dedicated blasting area is required. The following
features shall be incorporated in the design, where applicable, of the
blasting booth or blasting area:

SP 1256

Air exhaust system such that a slight negative pressure is maintained

in the booth. The exhausting should be in a downward direction, away
from the principal area of work, with the exhaust exiting at ground
level. Exhaust air shall be passed through a suitable filter to remove
grit and blast debris prior to release to the atmosphere.
Adequate lighting such that the operator may perform the blasting
work safely, and that an observer may clearly see the operator from
outside the booth.
An observation window of suitable material which should be placed
either in, or close to, the access door.
An interlock device linking the blasting air supply to the access door,
such that blast air is automatically disconnected when the door is

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Setting Clear Requirements

opened. This interlock shall require manual resetting from outside the
booth, such that should the door close after the air supply has been
interrupted, the air supply is not automatically resumed.
A control console close to the observation window. The console shall
be able to monitor and control:
blast helmet air supply temperature and pressure.
blasting abrasive air supply temperature and pressure.
manual shut off of blasting abrasive air supply.
A concrete floor sufficiently strong to support any work pieces and their
supports.
Adequate supports, trestles, clamps etc. to support the work pieces.
5.4.4

Abrasive blasting materials

Acceptable and unacceptable blasting materials are discussed in PDO-ESCS-48-06 Surface Preparation and Coating of Oil and Gas Facilities.
The preferred material for abrasive blasting operations is reduced sparking
copper slag.

5.4.5. Work Practices

On-Site Operations
All on site abrasive blasting operations shall be planned and executed in a
manner which ensures the safety of the blasting operators and all other
workers on site.
The blasting area, inclusive of the blast pod feeding area and lay down
area and an adequate peripheral safety zone, shall be cordoned off with
high visibility warning tape.
Warning notices shall be placed at all
accessible sides of the work area. Where practical, physical screens shall
be erected to isolate the blasting area.
When abrasive blasting is being carried out in confined spaces, adequate
air extraction equipment shall be deployed to ensure no build-up of
hazardous dust occurs in the work area.
Where abrasive blasting is performed higher than 2 meters above ground
level, adequate scaffolding or staging shall be used.
Abrasive blasting operations shall at no time be carried out from movable
platforms, or while suspended from cranes in man-baskets.
When working on scaffolding, blasters shall at all times be supplied with a
safety line, fixed securely to the structure prior to initiating blasting. Care
shall be taken when routing blast air and operator helmet air to the
elevated structure such that they are in no way strained or in danger of
pinching.
Abrasive blasters shall at all times be supervised, ensuring that their
helmet air supply is functioning correctly, and that they are blasting in an
area where they are not endangering co-workers.
The removal of used abrasive materials and blast debris shall be carried
out with adequate frequency and in a controlled manner, such that

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material build up is not permitted to become a safety hazard. All blasting

operations shall cease during material removal.
Abrasive blasting operators shall not work directly on blasting operations
for continuous sessions of greater then 40 minutes, with a minimum rest
period of 10 minutes between sessions.
Of-site Operations
All work practices as described for on-site operations shall apply to off-site
operations, whether in temporary or permanent facilities.
It is
recommended that whenever the size of the work piece permits, all regular
off-site operations are performed in a dedicated abrasive blasting booth.
5.5

SP 1256

Industrial Gases
Commonly used industrial gases, their characteristics and the colour of
their containing cylinder are given in the table below.
GAS

CHARACTERISTICS

CYLINDER
COLOUR

Compress
ed Air

No smell, non toxic. Will not burn but

supports and accelerates combustion.

Black
White

Oxygen

No smell, non toxic. Will not burn but

supports and accelerates combustion.
Materials
not
normally
considered
combustible may be ignited by sparks in
oxygen rich atmospheres.

Black

Nitrogen

No smell. Does not burn. Inert except at

high temperatures. Non toxic but does
not support life so could cause
asphyxiation in high concentrations.

Grey,
with
black neck

Argon

No smell. Heavier than air. Does not

burn. Will cause asphyxiation in absence
of sufficient oxygen to support life.

Blue

Acetylene

Distinctive garlic-like smell.

Fire and
explosion hazards are similar to those of
propane.

Maroon

Propane

Distinctive fish like smell. Will ignite and

burn instantly from a spark or piece of
hot metal.

Bright red and

bearing
the
words
"Propane
Highly
Flammable."

Hydrogen

No smell, non toxic. Much lighter than air.

Will collect at highest point in any
enclosed space unless ventilated. Fire
and explosion hazard.

Bright Red

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5.5.1

Industrial Compressed Gas Cylinders

All cylinders shall be manufactured to an internationally recognised
standard, such as BS5045 "Transportable Gas Containers".
All cylinders shall be maintained in good condition and shall be tested and
inspected in accordance with an internationally recognised standard, such
as BS 5430 "Periodic Inspection, Testing and Maintenance of Transportable
Gas Containers".
All cylinders shall be filled by qualified personnel, using proper equipment
and procedures, and in accordance with the filling ratios as given in BS
5355, "Specification for Filling Ratios and Developed Pressures for
Liquifiable and Permanent Gas".
The date of manufacture or the last hydrostatic test date shall be clearly
and legibly displayed upon the cylinder.
All cylinders shall be identified by colour coding in accordance with ISO
448 (or BS349 "Identification of the Contents of Industrial Gas
Containers"). The colours assigned to the principal common industrial
gases are given in Section 2.7 above.
All colour coding shall be maintained in a clear and legible condition.
In addition to the colour coding, the name of the gas contained within the
cylinder shall be clearly stencilled in letters not less than 7 cm high on the
cylinder body.
All couplings associated with cylinders containing flammable gases shall be
left hand threaded. For other gases right hand threads shall be used.
Cylinders shall be supplied with protective guards or caps for the valve
assemblies and the valves shall be in good operating condition.
Cylinder valves shall be of the correct type for the gas content and
pressure rating of the cylinder, and manufactured to BS341, "Specifications
for Valve Fittings for Compressed Gas Cylinders".
Valve spindles shall be held captive within the valve bodies.

5.5.2

Transport of Compressed Gas Cylinders

The transport of compressed gas cylinders shall comply with the
requirements of PDOs SP 2000 Transport Standards and the following:

SP 1256

All cylinders when being transported shall have the protective guards
or caps in place over the valve assemblies.
Cylinders shall be
transported in the upright position and be placed in sectional boxes or
containers in such a manner that they cannot knock against other
cylinders or obstructions.
Cylinders of different gas shall not be mixed together in the same
container when being transported. Oxygen cylinders shall under no
circumstances be transported together with acetylene or any other
forms of flammable substances.

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5.5.3

Cylinders shall not be rolled and dropped from vehicles onto rubber
tyres or similar packaging but shall be lowered to the ground under
controlled conditions.
Cylinders shall not be lifted using chains or metal slings. Lifting shall
be carried out using flat band slings.
If more than one cylinder has to be lifted, a properly designed and
certified cradle shall be used.

Storage of Cylinders
Cylinder storage areas shall be clearly identified, with the names of the
gases stored within prominently displayed.
Where gases of different types are stored at the same location, cylinders
shall be grouped by type of gas and the groups arranged to take into
account the gases contained, e.g. flammable gases shall not be stored
near oxidising gases.
Cylinders containing combustible gas shall be stored separately from
oxygen and wherever possible, not closer than 6 metres. If 6 metres
separation is not possible, a fire resistant wall shall be used to separate
them.
Charged and empty cylinders shall be stored separately, with the storage
layout such that cylinders comprising old stock can be removed first with a
minimum of handling of other cylinders.
Storage rooms shall be of fire resistant construction, well ventilated and
designed such that the cylinders are shaded from the direct rays of the
sun.
Stores shall be located as far as possible (but not less than 20 metres)
from flammable substances such as oil, gasoline or waste.
All electrical fittings in the storage area shall be rated for a zone II
application.
Cylinders shall be stored in an upright position within the store and
secured in such a manner as they cannot fall or be knocked over.
Protective caps or guards shall be retained in place on all full and empty
cylinders within the store.
No smoking, naked lights or sources of ignition shall be allowed within or in
the vicinity of cylinder stores.
Fire extinguishers shall be located outside the store entrance.

5.5.4

Use of Cylinders
Compressed gases shall be handled and used only by properly trained
persons.
The user shall verify the cylinder contents by the markings before putting
the cylinder to use. If unable to identify the contents by the markings, the
cylinder shall not be used but shall be returned to the supplier. Special

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care shall be taken in verifying inert gases before introducing them into
live equipment.
The protective valve assembly caps shall be kept in place until the cylinder
is required for use.
Before using gas cylinders, the user shall ensure that they are properly
supported and secured to prevent them being knocked over. Suitable
pressure regulating devices shall be used in all cases where gas is
admitted into systems having pressure rating limitations lower than the
cylinder pressure.
Threads on regulator connections or other auxiliary equipment shall be the
same as those on the cylinder valve outlet. Connections that do not fit
shall not be forced together.
Where a compressed gas cylinder is connected to a flexible hose, the hose
shall be of adequate pressure rating and made from a material that resists
any corrosive effects of the gas.
Cylinder valves shall be opened slowly with the valve pointed away from
the operator or any other person. Only the correct tools shall be used to
open and close cylinder valves. On valves equipped with hand wheels,
wrenches, hammers or other tools shall not be used to operate the valve.
Connections to piping, regulators and equipment shall always be kept tight
to prevent leakage. All hoses shall be kept clean and maintained in good
condition.
Compressed gas cylinders shall be kept either in trolleys designed and
manufactured to BS2718 "Gas Cylinder Trolleys", or secured to a part of a
structure such that they cannot be accidentally knocked over. Cylinders
shall be retained in an upright position.
Under no circumstances shall compressed oxygen be used for testing or
purging when compressed air or nitrogen is called for.
Under no circumstances shall oxygen be allowed to come into contact with
any form of grease or oil because of the risk of explosion and fire.
Extreme caution shall always be exercised to avoid knocking or jarring
acetylene cylinders, which can lead to internal self-heating and the risk of
explosion. If an acetylene cylinder shows signs of internal heating, cool it
with water. Partially empty or empty acetylene cylinders shall at all times
be maintained in an upright position.
Venting of partially empty cylinders should be avoided.

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5.6
5.6.1

Gas Welding and Cutting

General Safety Requirements
Gas welding and cutting shall, whenever possible, be performed in
dedicated work bays separate from other activities. When working on site,
welding and cutting operations shall be separated from other activities.
Adequate provision shall be made for the removal of welding fumes from
the workplace. In confined places, extraction fans shall be utilised.
All flammable materials shall be removed from the area of operation,
especially all greases, solvents, rags, etc.
Adequate fire extinguishers, of dry powder or CO2 type, shall be available
at the worksite. These extinguishers shall be supplemented with fire
blankets and/or sand buckets as appropriate. Water or foam extinguishers
shall not be used.
Personal protective equipment shall be worn by all welding/cutting
operators and assistants (refer to SP 1234 Personal Protective Equipment).
Burning/cutting shall not be carried out in close proximity to concrete
structures or floors, as build-up of heat could cause the concrete to
explode.
Burning/cutting and welding torches shall be ignited only by a welders flint
gun or piezo-electric igniter. Matches or "smouldering rope" shall not be
used.
All welding/cutting and burning activities shall be carried out by personnel
who have adequate formal training and certification for the work.
Gas welding or cutting of alloys containing magnesium or other
combustible metals is not permitted.

5.6.2

Regulators
All compressed gas cylinders utilised for gas welding shall be fitted with
adequate pressure regulators and associated high and low pressure
manometers.
Regulator sets shall be manufactured to BS5741 "Pressure Regulators Used
in Welding, Cutting and Related Processes" and subject to regular test and
inspection.
Prior to connecting a pressure regulator to the gas supply, all debris or
dust shall be removed from the supply points by momentarily "cracking"
(opening) the supply master valve.
The gas supply master valve shall always be opened slowly against a fully
closed regulator. Conversely, when shutting down, the master valve shall
be closed, and all pressure bled off from the regulator and line through the
torch prior to fully closing the regulator.

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5.6.3

Hoses and Torches

All hoses and associated couplings shall be fit for purpose, and
manufactured to an international recognised standard, such as BS1389.
Hoses shall be colour coded as follows:

Oxygen
Acetylene
Propane

Blue or black
Red
Orange

Blowpipes, mixers and nozzles used in cutting, welding and associated

operations shall be manufactured to BS6503 Hand Held Blowpipes, Mixers
and Nozzles, Using Fuel Gas and Oxygen, for Gas Welding, Cutting and
Related Processes and subject to regular preventive maintenance, test
and inspection.
All welding/cutting sets shall be equipped with both flash-back arrestors
and check valves, which shall be manufactured to BS6158 Safety Device
for Fuel Gases and Oxygen or Compressed Air for Welding Cutting and
Related Processes and subject to regular preventive maintenance, test
and inspection.
All hose couplings shall be securely fastened. Care shall be exercised in
the laying of hoses to avoid kinking, sharp edges, hot spots and areas of
transit. Hoses shall be subject to regular inspection for damage and
leakage. All leak tests shall be carried out with soapy water only.
All maintenance, test and inspection shall be carried out in accordance
with manufacturers specifications.

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5.7
5.7.1

Arc Welding
General
Welding operations on Company pipelines and installations shall be
conducted in accordance with the following documents:

DEP-30.10.60.30 Welding on Pressurised Pipes

DEP-61.40.20.30 Welding of Pipelines and Related Facilities
(Amendments/Supplements to ANSI/API Std 1104)
SP 1096 Specification for Welding of Duplex Stainless Steel Piping
(Amendments/Supplements to ASME B31.3)
SP 1097 Specification for Welding of Duplex Stainless Steel Pipelines
(Amendments/Supplements to API Std 1104)
SP
1147
Martensitic
Stainless
Steel
Pipelines
(Amendments/Supplements to PDO Std 1097)
SP 1167 Specification for Welding on Pressurised Pipes
SP 1173 Specification for Welding on On-Plot Pipework
SP 1174 Specification for Welding of Class 2 Pipelines (Flowlines)
(Amendments/Supplements to API Std 1104)
SP 1177
Specification for Welding of Class 1 Pipelines
(Amendments/Supplements to API Std 1104)
PR 1272 Standard Welding PQRs for On-Plot Piping
PR 1272 Standard Welding PQRs for Class 2 Pipeline
PR 1272 Standard PQRs for Welding on to Pressurised Pipes
PR 1368 Procedure for the Approval of Welding Consumables

In addition, welding operations shall also be conducted in accordance with

the following:

SP 1256

Arc welding can cause serious eye injury.

Therefore, whenever
possible, it shall be carried out in dedicated welding booths. Where
this is not possible, adequate shielding, by means of fire resistant
screens, shall be provided to shield other workers in the vicinity from
the welding arc. Welders shall use adequate eye protection (ref SP
1234 Personal Protective Equipment)
Radiation from arc welding can burn the skin. Welders shall wear
appropriate personal protective equipment to protect themselves from
such burns (ref SP 1234 Personal Protective Equipment)
All arc welding power sources shall meet the requirements of BS 638
"Arc Welding power Sources, Equipment and Accessories".
All
equipment shall be subjected to regular preventive maintenance,
inspection and testing to ensure the safety of operators.
All power supply cables shall be of adequate construction and correctly
protected. Where portable installations are supplied by movable,
trailing cables, they shall be suitably protected and adequately
earthed.
Electric arc welding sets shall be located as close to the work piece as
possible, to avoid the use of long trailing cables.
When portable welding transformers are used, the central point on the
low tension side shall be bonded to the transformer before the

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5.8

transformer is connected up on the high tension side. The transformer

shall be effectively earthed.
In the case of portable motor generator welding sets, the frames and
bed plates of the DC generator shall be effectively earthed.
All arc welding shall be carried out with an independent earth
conductor from the welding power source to the work piece. All earth
connections shall be bolted or clamped directly to the work to ensure a
good electrical contact.
Electrode holders shall have a positive clamping mechanism for the
electrode. They shall be inspected regularly and maintained in a good
and safe condition at all times.
Electrode holders shall not be placed on the ground when not in use.
To avoid creating an electrical circuit in the vicinity, wooden rests to
support electrode holders shall be provided and used.
Adequate fire fighting equipment, in the form of dry powder or CO2
extinguishers shall be available at arc welding work sites to ensure
immediate fire fighting capability. Extinguishers may be supplemented
by sand buckets and/or fire blankets, as appropriate. Water and foam
extinguishers shall not be used.
When breaking the electrical continuity of any pipe or vessel which
contains, or has contained, any explosive or flammable mixture, a low
resistance cable bond shall be firmly connected to reach each side of
the point to avoid arcing by stray welding current.

Battery Charging and Storage

Charging of batteries causes the emission of flammable hydrogen gas.
Incorrect connecting and disconnecting of battery leads may cause
sparking which could explosively ignite any accumulated hydrogen. Thus
battery charging, connecting and disconnecting should be considered as
hazardous and adequate protective measures taken.
All battery charging shall be performed in a dedicated area, and all sources
of ignition (i.e. smoking, naked flames and the use of any electrical or hand
tools which might cause sparking) shall be prohibited within a radius of 3m
from the battery charging facility.
All battery chargers shall be fitted with a 3 core power cable, three prong
plug, and shall be properly earthed.
Adequate ventilation shall be provided to ensure the rapid dispersion of
any flammable hydrogen gas.
Eye protection shall be worn at all times in the battery charging facility
(ref SP 1234 Personal Protective Equipment).
The charger power supply shall be disconnected prior to connecting or
disconnecting batteries.
All battery cell covers or plugs shall be removed during charging, and not
replaced until all "bubbling" has stopped.
Electrolyte level shall be checked and if required topped up both before
and after charging batteries.

SP 1256

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Separate racks or shelving shall be provided for charged batteries and

batteries awaiting recharging. These shelves shall be a minimum of 1
metre from the charging bench and shall be open wooden shelving or
purpose manufactured plastic racks, to prevent the accumulation of
hydrogen gas.
The following equipment shall be available in the charging/storage area:

5.9
5.9.1

dry powder fire extinguisher

water source for washing away spilled electrolyte
neutraliser for spilled acid (i.e. baking soda)
eyewash station.
room drainage facilities

Tanks and Vessels

Opening and Entry of Tanks and Vessels
Hazards
Opening and entry of tanks and vessels for inspection or maintenance
activities (e.g. PVV replacement on tanks, relief valve replacement on
vessels, internal inspection and cleaning etc.) present a major hazard to
personnel and equipment. These hazards include but may not be limited
to the following:

Restricted access
Working at heights
Combustible materials (crude oil, fuel products, gas etc.)
Toxic substances (H2S, acid etc.)
Presence of pyrophoric iron sulphide (which could self ignite when
exposed to air)
Lack of oxygen in the tank (asphyxiation).

An additional hazard associated with multi purpose tanks or vessels (often

transportable or trailer mounted units) is that these may have contained
different substances.
Consequently its contents, and the associated
hazards at any one time, may not be known. All multi purpose tanks or
vessels shall therefore be considered as being contaminated by hazardous
materials and the pre-entry job safety plans and/or procedures shall be
based on this premise.
Pre-Entry Requirements
Opening and entry of tanks and vessels shall be conducted in accordance
with the following documents:

SP 1256

PR 1172 Permit to Work System Manual.

PR 1073 Gas Freeing, Purging and Leak Testing of Process Equipment
(Excluding Tanks)
PR 1077 Preparation of Tank and Vessel for Internal Work
PR 1079 Gas Freeing and Purging of Tanks
PR 1148 Entry into Confined Space
PR 1154 Gas Testing Procedure

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5.9.2

Hot Work on Contaminated Tanks/Vessels

Before any Hot Work (work that could result in the generation of a spark or
flame) is conducted on a tank or vessel which contains or has contained a
flammable substance, the tank or vessel shall be prepared to minimise the
risk of fire or explosion. This preparation shall be conducted in accordance
with the following documents:

PR 1172 Permit to Work System Procedure Manual.

PR 1073 Gas Freeing, Purging and Leak testing of Process Equipment
(Excluding Tanks)
PR 1077 Preparation of Tank and Vessel for Internal Work
PR 1079 Gas Freeing and Purging of Tanks
PR 1148 Entry Into Confined Space
PR 1154 Gas Testing Procedure

Prior to commencing Hot Work, the vessel shall be blanketed. Acceptable

means of blanketing a vessel are filling the vessel space with an inert gas
(such as nitrogen) or liquid (such as water) and providing a constant flow
of the blanketing medium through the vessel during the Hot Work.
Gas testing shall not be used as a means of testing for the absence of
flammable material if the vessel previously contained a flammable liquid or
solid since vapour may not evolve until after heat is applied.
Hot work shall be conducted in accordance with the following documents:

SP 1256

PR 1172 Permit to Work System Procedure Manual.

PR 1148 Entry into Confined Space.

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