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 STEPOUT 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
AUTHORISED FOR ISSUE BY THE HSE IC 5/10/08......................................................................II
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 GENERAL PERFORMANCE REQUIREMENTS.......................................................................3
2.1 LEGAL REQUIREMENTS....................................................................................................................3
2.2 LOCATION, DESIGN AND CONSTRUCTION........................................................................................4
2.3 ELECTRICAL SUPPLIES, INSTALLATIONS AND EQUIPMENT..............................................................4
2.4 GENERAL HOUSEKEEPING................................................................................................................5
2.5 MAINTENANCE.................................................................................................................................6
3.0 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.....................................................................................8
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.............................................................................................11
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..................................................................................................................................17
5.3.7 Extension Cords......................................................................................................................17
5.4 ABRASIVE BLASTING OPERATIONS................................................................................................18
5.4.1 General...................................................................................................................................18
5.4.2Personnel Safety......................................................................................................................18
5.4.3Blasting Equipment..................................................................................................................19
5.4.4 Abrasive blasting materials....................................................................................................20

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5.4.5. Work Practices .....................................................................................................................20

5.5 INDUSTRIAL GASES........................................................................................................................21
5.5.1 Industrial Compressed Gas Cylinders....................................................................................22
5.5.2 Transport of Compressed Gas Cylinders...............................................................................22
5.5.3 Storage of Cylinders...............................................................................................................23
5.5.4 Use of Cylinders.....................................................................................................................23
5.6 GAS WELDING AND CUTTING........................................................................................................25
5.6.1 General Safety Requirements.................................................................................................25
5.6.2 Regulators...............................................................................................................................25
5.6.3 Hoses and Torches..................................................................................................................26
5.7 ARC WELDING................................................................................................................................27
5.7.1 General...................................................................................................................................27
5.8 BATTERY CHARGING AND STORAGE..............................................................................................28
5.9 TANKS AND VESSELS.....................................................................................................................29
5.9.1 Opening and Entry of Tanks and Vessels...............................................................................29
5.9.2 Hot Work on Contaminated Tanks/Vessels............................................................................29

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1.0 Introduction
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 Sub-Contractors
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 staff: 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).
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.

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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 Staff: There are no routine reporting requirements against this Specification.
Contractors: There are no routine reporting requirements against this Specification.

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2.0 General 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 PDOERD-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.
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 non-specialised personnel.
Portable electrical tools shall comply with the requirements of this Specification.

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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 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.

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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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3.0 Workshops
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 89-01 "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).

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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

SAFETY COLOUR
Red
Yellow
Green
Blue

3.2
3.2.1

3.2.2

CONTRAST COLOUR
White
Black
White
White

SYMBOLS OR WORDING
Black
Black
White
White

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.

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.

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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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4.0 Camps, 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 shall be supervised by competent laboratory staff to ensure the
cleaning personnel are neither at risk from chemicals, nor cause damage to
equipment.

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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.

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.

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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-forpurpose stores.

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5.0 Industrial 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, workgloves 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

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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.

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

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thoroughly checked by competent personnel and users shall be made aware that
they are not a complete safeguard against spark production.
5.2.2

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.
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:

SP 1256

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.

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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.
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:

SP 1256

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.
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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 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-ES-CS-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 longarmed 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.
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.

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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 and maintained in accordance with the
manufacturers instructions.
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 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.

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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-ES-CS-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 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.
Off-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.

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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

Compresse
d Air

No smell, non toxic. Will not burn but supports

and accelerates combustion.

Black and 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.
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.

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5.5.3

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 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.

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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 CO 2 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 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.
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5.8

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.
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:

SP 1256

dry powder fire extinguisher

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5.9
5.9.1

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:

5.9.2

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

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:

SP 1256

PR 1172 Permit to Work System Procedure Manual.

PR 1073 Gas Freeing, Purging and Leak testing of Process Equipment
(Excluding Tanks)

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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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