1. Alarm Timings 2. Auditorium Emergency Exists 3. Access ... file4.8 Plant Maintenance and Repair...

1. Alarm Timings

2. Auditorium Emergency Exists

3. Access Stairs

4. Break Timing

5. WC Location

IndexIndex1. Introduction

1.1Petrofac’s Construction activities

1.2 Petrofac’s Construction Culture

1.3 Geographical Areas of Operation

1.4 Up stream and Down stream Oil & Gas Projects

1.4.1 Oil / Gas fields’ Geology

1.4.2 Up stream Projects

1.4.3 Down stream Projects

2. Construction HSE

3. Construction Disciplines - Introduction

3.1 Civil Works

3.1.1 Earthworks

3.1.2 Foundations

3.1.3 Buildings

3.1.4 Roads

3.1.5 Miscellaneous Concrete Works

3.1.5.1Pre Cast

3.1.5.2 Paving

3.1.5.3 Culverts

3.1.5.4 Pits & Manholes

3.1.5.5 Drains

3.1.5.6 Tanks

3.1.5.7 Landscaping

3.1.6 Underground Networks

3.2 Structural Steel Erection

3.2.1. Structural Steel Categories

3.2.2. Structural Steel Classification

3.2.3. Type of Structural Steel members

3.2.4. Structural Steel Fabrication

3.2.5. Erection Methodology

3.2.5.1 Assembly Erection Sequence

3.3 Mechanical Works:

Introduction, 3D Drawings, On site/off site

3.3.1 Equipment Erection

3.3.1.1 Introduction

3.3.1.2 Static Equipment

3.3.1.3 Rotating Equipment

3.3.1.4 Equipment Erection

3.3.1.5 Associated Installation

3.3.1.6 Standard Lifts

3.3.1.7 Heavy Lifts

3.3.1.8 Equipment Transport Logistics

3.3.2 Piping

3.3.2.1 Introduction

3.3.2.2 Piping Fabrication

3.3.2.3 Process Piping Erection

3.3.2.4 Hydro-test

3.3.3 Pipelines

3.3.4 Miscellaneous Activities

3.3.4.1. Scaffolding

3.3.4.2. Hot taps & Stopples

3.4 Electrical Works

3.5 Instrumentation and Control

3.6 Painting and Coating

3.7 Insulation and Fire Proofing

4. Temporary Facilities:

4.1 Site Offices4.2 Camp Facilities4.3 Piping Fabrication Shop4.4 Civil Temporary Facilities comprising:

4.4.1 Batch Plants4.4.2 Pre-cast Yard4.4.3 Rebar Shop4.4.4 Carpentry Shop4.4.5 Civil Lab

4.5 Electrical/Instrumentation Shop4.6 Paint Shop4.7 Insulation Shop4.8 Plant Maintenance and Repair Facilities4.9 Material Warehouses & Lay-down Area

4. Planning and Scheduling

5. Material Management

6. Quality Control

7. Sub-Contract Management

8. Mechanical Completion and Pre-commissioning

9. Commissioning

1. INTRODUCTION1. INTRODUCTION

The intent of this presentation is to introduce new graduate andJunior engineers to the construction activities presently being executed by Petrofac.

This presentation is intended to address not only the main concepts of construction in each discipline, but to also highlights specific Construction practices that enhance efficient and safe execution of works through the adoption of proven methodologies and practicesthat encompass lessons learned through out Petrofac’s years of Construction execution.

1.1 PETROFAC1.1 PETROFAC’’S S

CONSTRUCTION ACTIVITIESCONSTRUCTION ACTIVITIES

Petrofac executes several types of Construction and Construction related activities that are all linked to the Oil &Gas industry.These Construction activities encompass:

1. Construction activities that comprise part of Petrofac’sresponsibilities under an EPC contract. These Construction Scopes are awarded by Petrofac to selected Construction Contractors whom Petrofac manage in order to ensure the timely and proper delivery of their respective scopes.

2. Construction Management Contracts working with or on behalf of clients to manage Construction Contracts awarded by the client to various Contractors.

3. Construction activities related to Exploration, Commissioning, Maintenance and Operation of Oil & Gas production centers and / or development of fields acquired by Petrofac.

1.2 PETROFAC1.2 PETROFAC’’S S CONSTRUCTIONCONSTRUCTION CULTURECULTURE

Petrofac adopts a construction culture that takes into consideration the following parameters:

1. Meeting satisfactorily Contracts’ scope of work, schedule, Contract specifications, terms and conditions.

2. Implementing fully Petrofac’s policies and guidelines with aspect to HSSE, Quality, and Code of Conduct

3. Implementing, as applicable, Petrofac’s established

Construction procedures, plans, methods, and Lessons learned.

1.3 GEOGRAPHICAL AREAS 1.3 GEOGRAPHICAL AREAS OF OPERATIONS.OF OPERATIONS.

The Coutries in which Petrofac is/has executed Construction Projects, to date, are:

1. Middle East 2. Ex Soviet Union1. Iran 1. Azerbaijan2. Kuwait 2. Georgia3. Oman 3. Kazakhstan4. Qatar 4. Kirgistan5. Syria 5. Russia6. UAE7. Yemen8. Iraq9. Saudi Arabia

3. Asia 4. Africa

1. Bangladesh 1. Nigeria

2. India 2. Algeria

3. Malaysia 3. Egypt

4. China 4. Sudan

5. Pakistan 5. Tunisia

6. Kyrgyzstan 6. Angola

7. Chad

5. America

• USA

• Bolivia

• Venezuela

• Peru

• Brazil• Ecuador

UK

VARIOUS PHASES OF A PROJECTVARIOUS PHASES OF A PROJECT

OIL / GAS SOURCE IDENTIFICATIONEXPLORATIONCONCEPTUAL & ECONOMICAL VIABILITY STUDIESBASIC ENGINEERING & COPEX STUDIESFEED (FRONT END ENGINEERING DOC) / ITB

(Invitation To Bid)EPC PROPOSAL CONTRACTOR SELECTION & AWARD OF CONTRACTPROJECT DETAILED

ENGINEERING,IMPLIMENTATION & COMMISSIONINGPLANT OPERATION

1.4. UP STREAM & DOWN 1.4. UP STREAM & DOWN STREAM O&G PROJECTSSTREAM O&G PROJECTS

1.4.1 OIL & GAS FIELDS GEOLOGY & EXPLORATION

a) EXPLORATION

1. Life on earth possibly began during the infancy of the planet, and for the first long epochs of time it existed primarily in the form of marine creatures and plants thatinhabited the great inland seas covering the continents.

2. As the marine creatures and plants died, their remains mixed with silt from erosion and deposited in beds of sediments in the ocean bottoms. Some beds of sediment compacted into dense shale rocks, and some became limestone and sandstone.The organic matter in the rocks was converted to oil and gas – by the action of heat, bacteria, radiation, and other processes.

3. If we accept that oil was formed by the action of bacteria, pressure and temperature on the remains of marine life, the question is how it has been preserved for million of years and why we find it todaymany miles from the sea?

The fact that sea level has been subject to variation through the ages is a good reason to believe that sea waters covered the Arabian Peninsula terrain some times in the distant past, forming down to its present position. This is one explanation why oil is found in remote offshore areas.

4. The oil was squeezed out of the shale beds into more porous sandstone and limestone. Then, as the crust of the earth was warped, the oil migrated along the rock beds until it became trapped in some places in the rocks. These traps are geological structures called reservoirs.

5. There are three principal types of reservoirs:

→ Anticline

The anticlincal trap is one where the rocks are bent upwards into an arch. If a porous bed with oil lies under a non-porous bed then the oil collects in the arch beneath the non-porous bed. An oil reservoir is formed.

→ Anticline

→ Fault

The fault trap is formed when the layers of rock have been broken and the rocks on one side of the break have moved down further than those on the other side. If a porous layer on one side of the break is sealed by the non-porous layer which has moved down on the opposite side, oil in the porous layer is trapped.

→ Fault

→ Stratigraphic trap

The stratighraphic trap is formed in different ways, in the illustration; the reservoir rock finally terminates between beds of non-porous limestone.

→ Stratigraphic trap

6. The first oil fields were discovered in the simplest way by finding places where oil seeped out of the ground. The most famous early oil well was drilled at Titusville, Pennsylvania, alongside a millstream on which oil floated and had been collected for a number of years by skimming.

7. Geologists, scientists who study the earth, have learned much in the past century about the kinds of rock that may hide an oil field. They look for signs on the surface which indicate that oil is nearby. A lot of experience is needed for this detective work. Just as a skilled doctor can examine a patient and diagnose a complaint from a number of small symptoms, so the oil geologist looks for a number of features which may indicate the presence underground of oil bearing formations

8. Aerial Survey: Aerial photography is an important method of making maps. An aircraft equipped with a special camera files on an exactly known path and takes a series of overlappingphotographs. This process has now been further enhanced with satellite scanning for surface minerals, topographical features (release of gases, rock foundations, etc…)

9. Ground Survey: the next step is to choose likely areas from such maps and explore them on the ground. Their geological history is studied and various clues looked for, such as possible cap rocks, impermeable rocks that might be acting as a seal to oil underneath. The rocks are studied and classified with the help of fossils; animal remains were buried with the sediment that formed the rocks.

10. Gravimetric Survey: Oil is sometimes found near underground salt domes which can be located by lower gravitational readings.This is the basis of gravimetric survey. Using instruments to measure the gravity with extraordinary precision, slight changes can be found which indicate different densities below the surface. The sensitivity required in a gravimeter is such that it must be able to measure differences of about one part of ten million, the equivalent of weighing a motor car and being able to detect the presence of a few drops of water on the roof.

11. Magnetic Survey: the technique of magnetic surveys is to measure the earth’s magnetic field at a number of spots over the area under examination.

12. Seismic Survey: by detonating high explosives under controlled conditions. The waves produced are picked up on geophones or receivers placed at a number of points on the surface and connected electrically to the recording apparatus.Seismic Surveys are in three types:13. A. The 2D seismic survey13. B. The 3D seismic survey, where the shot locations and the geophone locations are laid along perpendicular lines with clearances between the lines ranging from 25 to 50 meters13. C. The 4D seismic survey, which is a repetition of 3D seismic survey at determined times.

Seismic Reflection SurveyingSeismic Reflection Surveying

Test Drilling: All the results of exploration up to that point lead only to an assessment of the probability of finding oil. The last step in exploration, therefore, is to drill a test well. Only by doing so can the existence of an oil accumulation be proved or disproved.The proof of oil this search for oil is determined by the actualdrilling of a well to test underground formations.

b) DRILLING FOR OIL

From seismic records, contour maps of underground structures that may be favorable for oil accumulation can be drawn.

Basic Principles: In principle the technique of rotary drilling is quite simple. It is in many ways similar to the use of a hand drill for drilling a hole in a piece of wood, the basic requirements being a cutting tool or “bit”, means of applying weight to the bit, and a method of rotating the bit. In addition a fluid circulation system is needed to keep the bit cool and to carry away the cuttings from the bottom of the whole.

In rotary drilling, the bit usually consists of three or four hardened steel toothed rotary cutting cones, which are individually mounted on roller bearings. When the bit is rotated, each of the cutters is revolved in a circle, and the teeth bite into a chisel off fragments of the rock at the bottom of the hole.

The bit itself is fitted to the end of a number of lengths of steel pipe called “drill pipe”. This drill pipe is smaller in diameter than the bit and it is usually manufactured in sections 30 feet in length. Additional sections are screwed together as the hole becomes deeper.The top length of surface is deliberately made square, and this square pipe, called the “Kelly”, this through a square a hole in what is called a “Rotary Table”. Thus when the rotary table is rotated the Kelly rotates and the sections of drill pipe beneath it, together with the bit at the bottom of the hole also rotate.

A commonly used size of drill pipe has an outside diameter of 5 in. with a wall thickness of about 3/8 in. Drill pipe is extremely flexible in the long length which is involved in drilling a well. For example, 10.000 feet of 5 in. drill pipe is to the same scale as human hair approximately 3 feet long.

To apply downward pressure to such a long thin column in order to transmit weight to the bit would obviously impossible, so it is arranged to the first few sections of pipe immediately above the bit to be especially heavy. As many as 20 to 30 of these heavy sections of pipe, called “drill collars”, each 30 feet long and up to 10 in. in outside diameter, provide weight for the bit. Thus we now have aheavy weight of drill collars with the bit at the lower end, suspended from what is known as a “string” of drill pipe.

The fluid or mud circulation system is arranged so that theliquid is pumped from the surface down through the hollow drill pipe and drill collars to nozzle in the bit, where it is jetted at high velocity against the bottom of the hole, removing the cuttings as soon as they are chiseled away by the bit. The cuttings are then carried by the returning mud to surface through the space or “annulus” between the drill pipe and the sides of the hole.

Directional Drilling: As drilling progresses holes are surveyed frequently for inclination and, if necessarily corrective measures are taken. Sometimes wells are deliberately drilled at an angle from the vertical. This technique, known as directional drilling, is known well advanced and in constant use for such work as drilling to an undersea structure from a derrick on shore, drilling under a built up area from a site more easily accessible, drilling offshore a cluster of wells from a central platform instead of erecting a platform for each well and drilling to reach a well which has gone wild, from a safe location, in order to kill it. Frequent compass bearing and inclination surveys, taken with a topographic instrument, and ofremarkable degree of accuracy, are then directing the bit to a position thousands of feet below and horizontally distant from the start of the hole at the surface.

Rock samples or cores are taken from deep in the earth and examined in the laboratory. From these samples, data is obtained to estimate the volume of oil, gas and water in the reservoir rock.

Tubing and Christmas Tree: after the well has been perforated, a string of smaller pipe called tubing, usually 3 ½ inches in diameter is lowered into the hole. If the well is intended to be a duel producer, a packer is inserted between the tubing and casing above the lowerproducing zone so that production from the lower formation can flow separately through the tubing and that from the upper formation from the annulus between tubing and casing.

During the drilling operation, the hole is filled with mud heavyenough to overcome the pressure in the reservoir. During the completion phase, this allows for the safe removal of the blowout preventors; a well control head is then fitted and connected to the tubing and casing of the surface. It is an assembly of valves and fittings to control the flow of the oil and known as the “Christmas Tree”.

To produce the oil, the low solids completion fluid in the casing is displayed by water until the pressure of the water is less than that of the oil and gas in the formation.When this happens the oil and gas push out the water and the well starts to flow.

c) PRODUCTION OF OIL

When oil is found at a location it should be assessed to establish if it has commercial viability. Therefore it must not be assumed, that the exploratory effort is completed. One well alone cannot indicate the full extend of an oil accumulation and it is necessary to drill several carefully located wells to determine the size of a reservoir. It is also essential at an early stage to obtain some idea of the quantity of oil, and gas which is recoverable, so that the proper type of surfaceproduction plant can be selected.

The mechanism for producing oil to the surface and handling it thereafter will depend largely on its characteristics. Crude mayrange from a heavy viscous oil, almost a tar with little or no gas dissolved in it under a very low pressure, to an extremely light straw colored liquid with a considerable volume of gas, known as condensate. Between these extremes there is an infinite variety of crude oil. The optimum way to produce them can only be decided after observing their physical characteristics.

Oil is produced to the surface from the pore spaces which it occupies in the reservoir rock. There are various ways of accomplishing this, depending on the kind of oil and its potential energy, which is a function of its initial pressure in the reservoir, and the amount of dissolved gas it contains. In many cases the reservoirs has sufficient potential energy to permit a well to flow to the surface at significant rates without artificial assistance. This natural flow period may continue for many years, as is frequently the case in the Middle East Fields. When the reservoir pressure declines to the point were the wells will no longer flow unaided, the wells may then be put on artificial lift to extract the remaining recoverable oil.

Artificial flow may be induced by the use of pumps or by gas lift, which is a method of injecting gas at sufficient high pressure into the oil column in the well bore, with gas bubbles so that the well is made to flow by the same mechanism as a natural flowing well.

These methods of assistance to wells, which have ceased to flow naturally due to the decline of bottom hole pressure and gas content of the crude, can obviously be applied also to wells for which initially the crude has insufficient potential energy to flow to the surface.

In some cases, depending on reservoir characteristics, it is advantageous to re-inject either gas or water into a producing reservoir to maintain its pressure and consequently its ability to produce under water or gas drive.

When the crude oil and gas have been brought to the surface,the next step is to separate the two phases and to transport theoil ultimately to a refinery for processing. Oil at the well head varies considerably from one field to another in its characteristics. Also, in some cases, it may contain salt and water which has flowed into the well from the reservoir along with the oil. In such cases it is not only essential to separate the gas from the oil treatment is required to separate the salt and water from the oil before the oil is delivered to the refinery or the Tank Farm, which is done by means of desalterdehydration facilities.

Type of plant required for the gas-oil separation process will depend upon the volume of gas dissolved in the oil as it exists in the reservoir, and the flowing well-head pressure. Obviously, a crude oil that has a low gas-oil ratio and low flowing well-head pressure will require a small separator vessel and the gas-oil separation may be accomplished in steps or stages. This is known as “Two Stage Separation”

Gathering Center Booster Station A Tank Farm

TANK FARM

TANK FARM

There are various design of separators for single or multi-stage separation. For multi-stage separation, the individual vessels may be horizontal or slightly titled, and are to all intents and purposes pipes for very large diameter. The crude oil and gas enter at a selected point and the oil flows towards the outlet at the lower end. During the time it takes to do this, which is just few minutes, gas bubbles out of the solution and leaves the separator by the gas outlet at the top. The vertical-type separator is frequently used to accomplish the same purposes.This is a separator. This separator takes fluids from the header above its midpoint and processes the fluids, usually oil, gas, and water, by gravity segregation. The gas rises to the top, the oil is taken out in the middle, and water is removed for disposal.

Since producing wells are spaced over the area of the oilfields, the production system must allow for the collection of the separated oil at convenient centers from which it can be pumped to the tank farm, to the refinery or export point. Complete production systems will depend in layout and magnitude on the characteristics of the oil and the quantity involved.

The field is divided into sectors in each of which is a gathering Centre to which the wells in that sector flow. At each GatheringCentre there is a series of connected separators to form three stages of separation. The last stage, which is only slightly above atmospheric pressure, is actually a flow tank. From this flow tank the gas-free crude is pumped by the transit pumps to the storage tanks.

Natural gas which is produced in association with oil and which has been separated from it in the normal way, is “rich” that is, it contains an appreciable portion of the heavier gaseous hydrocarbons, including pentanes and hexanes. This is particularly true of the gas evolved from the last separation stage, i.e. the tank vapor. With tank vapor gases, is to remove those constituents which can be liquefied and kept as liquids under pressure. These products are known as “Liquefied Petroleum Gas”(LPG).

The separated gas from the Gathering Centers will be sent through the collecting system to the booster stations, than compressed and transmitted to the LPG plant. After the gas has been processed there it will be fed back to high and low pressure fuel distribution networks as “lean” fuel gas.

Part of this gas is also utilized for re-injection, electrical power generation, water distillation and other general purposes.

This is a combination of the water knockout with heat applied. The vertical vessel is also a heater treater, or separation unit.

For high pressure crude with high gas content, the “Multi-Stage Separation” method is used. In this, a number of steel vertical or horizontal vessels are connected in series, the crude passing from one vessel to the next while undergoing successive reductions in pressure, so that in each vessel only a portion of the gas is allowed to come out of the solution and be withdrawn. As many as three stages of separation have been used to ensure the maximum retention of the light fractions in the oil.

Once the oil and gas leave the producing well, it proceeds through a battery of valves called a header. The large horizontal tank is used to separate oil and water and is sometimes referred to as “Water Knockout”.

On the other hand there are certain types of reservoir where it may be desirable at first to inject gas at the top of the reservoir to maintain the pressure and in this way to improve recovery from the upper part of the reservoir by gas-cap drive and gravity drainage, to be followed and augmented by water drive which might be developed in the long run into a full-scale secondary recovery water flood in the last stages of the field’s life.

Pumping water into a reservoir is called water-flooding. A water-flooding simply involves pumping water into the reservoir through selected wells. The water pushes trough the reservoir and moves the oil toward the production wells. Water-flooding can be a fairly efficient method of getting about another 16 percent of the oil, but still leaves nearly two-thirds of the original water in the reservoir.

The recovery efficiency of a reservoir, that is the amount of oil which can be recovered by a given method of production, expressed as apercentage of the oil originally in place, varies from reservoir to reservoir and depends on several factors. These govern the relative ease with which oil, gas and water can move through the pore-space of the reservoir from points of high pressure remote from the well towards the well bore where pressure is lower. It also depends on the pressure existing on the reservoir and how pressure behaves whenoil is produced from it.

The nature of the reservoir rock is important. Its porous nature may be due simply to a homogenous arrangement of pores, which are spaces between the grains of sand or crystals of limestone, or on the other hand it may be fractures and cracks in the rock, or a combination of both.

The average porosity or sum total of all the holes and openings in the reservoir rock is important. It is expressed as the percentage volume of holes or voids in the total volume to the rock. The larger it is, the greater will be the available space for the reservoir fluids. The permeability of the rock is also very important. This is the measure of the freedom of flow through the rock and depends to some extent on the size of the pores or voids and the size of the channel between one pore and the next.

The second consideration which governs the ease with which the oil and gas can flow through the reservoir towards the well is the physical characteristics of the oil with the dissolved gas. The less viscous the oil the more readily it will flow through the pores of the rock, into the bottom of the well. The viscosity of oil depends on its specific gravity (heavy components are more viscous than light ones) and also to a considerable extent on the quantity of gas in solution. A crude oil with a lot of gas solution is less viscous than the same oil with less gas in it.

Lastly and most important, the reservoir behavior as production proceeds will depend on the pressure system it possesses as a result of its geological history. The oil in migrating to the upper part of the reservoir trap in which it has come to rest, will have displaced salt water which was originally occupying that part of the formation. Not only was there water in that portion of the trap which the oil occupies, but in many cases there is a further considerable volume of water in the reservoir rock extending downwards and sideways fordistances which might vary from several hundreds of feet in somecases, to several miles in others.

This part of the reservoir, which is known as the aquifer, is under pressure, and the vast volume of water involved is therefore a source of potential energy, some or all of which may be applied to help the production process by maintaining pressure on the oil zone of the reservoir as the oil is withdrawn.

At the time of discovery, most oil contains dissolved natural gas, which is held in solution by high pressure. This is much like the way gas in a bottle of soda water is held in solution until the bottle is uncapped. When we “uncap” the reservoir by drilling wells into it, the gas in solution can push some of the oil to these producing wells, resulting in what we call “Primary Production”. On the average, only about 16 percent of the oil in the reservoir can be produced in this manner before must of the gas is gone, leaving about 84 percent of the oil.

After primary and secondary methods are exhausted, only about one-third of the oil has been recovered. The remaining oil is hard to obtain and requires more expensive processes called Enhanced OilRecovery methods. Several different approaches might be applicable in Enhanced Oil Recovery. One method called “Thermal recovery”uses steam to thin heavy oil which makes it easier to produce.

Miscible Recovery incorporates a special fluid injected into thereservoir under sufficient pressure. It dissolves into the crude oil just like the carbon dioxide is dissolved in a bottle of soda water. This reduces the oil’s viscosity, swells it, and in some cases strips the lighter hydrocarbons out of the crude oil, forming a solvent bank.

Chemical flooding comes in several varieties:Polymer, alkaline or caustic, and micellar or surfactant solutions. These highly complex processes have the greatest potential for recovering oil compared with other Enhanced Oil Recover methods.

On a Continuous steam flood, the condensed steam transfers heat to the reservoir, forming a hot water bank which is propagated by continuous injection of steam and hot air or water.

In many cases there are reservoirs where both gas and water recovery mechanisms operate. The relative extent to which these two main types of drive will operate will depend largely on the way the production operation is carried out and this, in turn, will significantly affect the recovery efficiency. Reservoir engineering studies, indicates just what measures are required to get the maximum recovery from the reservoir this may mean augmenting the water drive by injecting water.

In much the same way that water is pumped into a reservoir, we can pump gas into the reservoir to supplement the natural gas force. This moves the oil through the reservoir to the production wells, increasing oil recovery.

CONCLUSIONCONCLUSION

Success in the search for oil is achieved when:

1. Oil is found in commercial quantities. 2. Then the development drilling of the oil field. 3. The process of production of oil from the well through the

gathering centre to the storage tanks and refineries.

Then comes refining.Loading the tankers is the next step in delivering the oil, LPG and its products to the markets of the world.

1.4.1 1.4.1 UP STREAM PROJECTSUP STREAM PROJECTS

The projects that are executed for the receipt, stabilization, initial treatment and transportation of oil prior to its arrival to the refineries/Gas plants and other processing facilities are termed as up-stream projects.

They include:

- Well head facilities- Flow Lines- Transfer Lines and Pipelines- Gathering Centers - Crude Stabilization units- Desalting Units

- Water Separation Units (Dehydration)

- Gas Separation Units

- Gas sweetening Facilities

- Pumping Stations

- Power Generation Plants

- Related utilities

- Water and Gas injection Facilities

- Tank Farms

- Big Launchers and Receiver Stations

- Onshore receipt & loading facilities

1.4.3 1.4.3 DOWN STREAM PROJECTSDOWN STREAM PROJECTS

Down Stream Projects Include:

- Refining and distillation (both atmospheric & vacuum) of oil inclusive of hydro treaters, Catalytic Reformers, Isomerisation units, Naphtha splitters, amine treatment, Naphtha Stabilizers, Storage Facilities, Utilities, Buildings, etc…

- LPG/NGL Plants

- Acid Gas removal Plants/Gas sweetening/Sulphurremoval plants

- Ethylene Plants

- HDPE Plants

- Condensate Stabilization Units

- Water Treatment Units

- Gas Dehydration Units

- Gas Separation Units

- Asphalt Plants

- Cryogenic Gas Plant

2. CONSTRUCTION 2. CONSTRUCTION HSEHSE

Why is HSE implementation Very Important?Why is HSE implementation Very Important?

Protection of People’s well being

Direct Impact: Project Staff

Indirect Impact: Families, other 3rd party project personnel & Local Communities & Country Environment

Loss of Reputation

Loss of Progress

Financial losses

Direct: Material, Equipment, etc…

Indirect: Compensations, idle time inefficiency.

HSE Commitment StatementHSE Commitment StatementVisionPetrofac will be acknowledged by our industry as a standard setter in HSE management, an expert in delivering high HSE performance from diverse workforces in challenging operational environments.

CommitmentPetrofac Board of Directors has ultimate responsibility for health, safety and environmental performance. This responsibility and the Board’s commitment to the achievement of HSE excellence are foundations of our Business Management System.

We are committed to a target of zero accidents. We will ensure that our activities are not injurious to health and endeavour to minimise adverse impact on the environment.

All Petrofac employees and contractors are required to meet these commitments as an integral part of their work.On behalf of the Board of Petrofac Limited:

Ayman Asfari

Group Chief Executive Officer

Health, Safety & Environmental PolicyHealth, Safety & Environmental Policy

Project HSE Plan Project HSE Plan -- Key ConsiderationsKey Considerations

HSE considerations are fundamental to all aspects of our work including: -

Engineering & Design

Design safety dossier progressively developedHAZOP performedQAR performedPlot Plan reviewsEIA performedPHASER performed

Fabrication & Transportation

Complying with Journey Management PlanAll vehicle and Equipment to Comply with Project Requirements and Specifications.All Vehicles and Plant to be inspected before deploymentAll drivers to be assess by Transport Specialist

RISK BASED APPROACHRISK BASED APPROACH

Construction and Pre-commissioning Phases :

Objective is zero accidents.

This will be achieved by:

1. Defining formal line management HSE responsibilities within the Project Safety Plan down to Subcontractor level.

2. Appoint PEC Safety officer to oversee/coordinate subcontractor safety personnel and implement Petrofac compliant Emergency Procedures

3. Raising level of safety awareness(including EOD issues) among all site employees by regular safety meetings and high profile site publicity.


4. Strict adherence to and compliance audit of use of Petrofac permit to work systems & use of protective equipment/clothing.

5. Formal Induction & On- Job Safety Training.

6. Daily Tool Box Meetings.

7. Site wide safety education and reward/incentive programs.

8. Safety monitoring/auditing.


People at all levels are responsible for leading and engaging workforce in meeting HSE goals

Management participation extends to Corporate Managers

Project Sponsors are accountable for project success and will participate in HSE reviews

Project leaders integrate HSE into project planning

Lead by example

LEADERSHIP & COMMITTMENTLEADERSHIP & COMMITTMENT

Execution Execution -- HSE CommitmentHSE Commitment

Company HSE commitment forms the overall policy for the projectClear set of objectivesTo execute project in accordance with HSE Policy and defined HSE standards for the work To comply with Golden Rules of SafetyTo ensure that hazard assessments are performedTo comply with laws and regulationsEstablish and report against HSE KPI’s

POLICY, OBJECTIVE & TARGETPOLICY, OBJECTIVE & TARGET


Golden Rules of safetyGolden Rules of safetyExecution Execution -- HSE CommitmentHSE Commitment

DRIVING SAFETYAll categories of vehicle, including self-propelled mobile plant, will be operated only when:

vehicle is fit for purpose, inspected and confirmed to be in safe working order

passenger number does not exceed manufacturer’s design specification

loads are secure and do not exceed manufacturer’s design specifications or legal limits

seat belts are installed and worn by all occupants

safety helmets are worn by riders and passengers of motorcycles,bicycles, quads, snow-mobiles and similar types of vehicle

Drivers are authorised and:

– they are trained, certified and medically fit to operate the class of vehicle

– they are not under the influence of alcohol or drugs, and are not suffering from fatigue

– they do not use hand-held cell phones and radios while driving

Golden Rules of safetyGolden Rules of safety


GROUND DISTURBANCE

a hazard assessment of the work site is completed by the competent person(s)

all underground hazards, i.e. pipelines, electric cables, etc., have been identified, located and if necessary, isolated

Where persons are to enter an excavation:

a confined space entry permit must be issued if the entry meets the confined space definition

ground movement must be controlled and collapse is prevented by systematically shoring, sloping, benching, etc. as appropriate

ground and environmental conditions must be continuously monitored for change

• Work that involves a man-made cut, cavity, trench or depression in the earth’s surface formed by earth removal will only proceed when:

Golden Rules of safetyGolden Rules of safetyExecution Execution -- HSE CommitmentHSE Commitment

CONFINED SPACE ENTRY

all other options have been ruled out

permit is issued with authorisation by a responsible person(s)

permit is communicated to all affected personnel and posted, as required

all persons involved are competent to do the work

all sources of energy affecting the space have been isolated

testing of atmospheres is conducted, verified and repeated as oftenas defined by the risk assessment

stand-by person is stationed

unauthorised entry is prevented

Entry into any confined space will only proceed when:





LIFTING OPERATIONSLifts utilising cranes, hoists, or other mechanical lifting devices will start only when:

an assessment of the lift has been completed and the lift method and equipment has been determined by a competent person

operators of powered, lifting devices are trained and certified for that equipment

rigging of the load is carried out by a competent person(s)

lifting devices and equipment has been certified for use within the last 12 months

load does not exceed dynamic and static capacities of the lifting equipment

any safety devices installed on lifting equipment are operational

all lifting devices and equipment have been visually examined before each lift by a competent person(s)



ENERGY ISOLATIONAny isolation of energy systems - mechanical, electrical, process, hydraulic and others – will only proceed when:

the method of isolation and discharge of stored energy are agreed and executed by a competent person(s)

any stored energy is discharged

a system of locks and tags is utilised at isolation points

a test is conducted to ensure the isolation is effective

isolation effectiveness is periodically monitored



PERMIT TO WORKBefore conducting work that involves confined space entry, work on energy systems, ground disturbance in locations where buried hazards may exist, or hot work in potentially explosive environments, a permit must be obtained that:

defines scope of work

identifies hazards and assesses risk

establishes control measures to eliminate or mitigate hazards

links the work to other associated work permits or simultaneous operationsis authorised by the responsible person(s)

communicates above information to all involved in the work

ensures adequate control over the return to normal operations



MANAGEMENT OF CHANGEWork arising from temporary and permanent changes to organisation, personnel, systems, process, procedures, equipment, products, materials or substances, and laws and regulations will proceed only when a Management of Change process is completed, where applicable, to include:

a risk assessment conducted by all impacted by the change

development of a work plan that clearly specifies the timescale for the change and any control measures to be implemented regarding:

– equipment, facilities and process

– operations, maintenance, inspection procedures

– training, personnel and communication

– documentation

authorisation of the work plan by the responsible person(s) through completion

Execution Execution –– Objectives / TargetsObjectives / Targets

>90%HSE Audit action items closed out within 21 days8.

>90%HSE Audits performed to audit schedule7.

>90%Emergency Response drills performed to schedule.6.

>90%HSE Training carried out to training matrix > 90% of all training to matrix5.

>90%HSE Induction - All project site personnel within 2 days of arrival to site4.

<0.6Recordable Injury frequency rate 3.

LTI frequency rate to be less than E&C target for each project.

Goal = 0 LTIImproved Lost Time Incident frequency rate to that of previous year2.

ZeroNo fatalities and category 1 Environmental incidents1.

•Comment•Improvement Target•Key Performance IndicatorSerial No

Key Performance IndicatorsKPI are specific target criteria that are monitored continuously in order to assess the performance of the project team towards meeting these targets

>80%HSSE procedures and registers reviewed19.

>90%Incident investigations performed for all recordable incidents18.

All cranes and lifting equipment have current test certificate17.

Plant and equipment including lifting equipment and electrical tools inspected and maintained in accordance with maintenance schedule16.

<1 per 100,000kmVehicle Incidents causing loss or damage15

>90%Tool box meetings performed by project supervisor one per week per supervisor14

>90%Corrective action close out completed within 21 days for actions raised during inspections, audits and investigations13.

>90%Golden Rules of Safety Audits performed by project supervisors one per month per supervisor12.

>90%Hygiene Inspections Kitchens / Facilities performed monthly11.

>90%Office and Camp Inspections performed monthly10.

>90%HSE Site Management Walk around inspections performed one per week per manager9.

Execution Execution –– Objectives / TargetsObjectives / TargetsKey Performance Indicators

Execution Execution –– OrganizationOrganization

Emergency Response Plan

What is an Emergency Response Plan?

PEC is responsible for ensuring the co-ordination of EmergencyResponse systems for its area of responsibility and will maintain an Emergency Response Plan (ERP) at a high state of readiness.

Training exercises, to test the system and maintain the expertise of the teams involved, will be held at regular intervals and will include all personnel and contractors.

A Emergency Response Plan will be finalized and incorporated into the HSE Plan


Golden Rules of Safety

Emergency Response and Safety Regulations

Risk assessments

Method Statements

Pre-start Tool box talks

Weekly safety Tool box talks

SAFETY RULES & WORK INSTRUCTIONSSAFETY RULES & WORK INSTRUCTIONS


PLANNING & IMPLEMENTATIONPLANNING & IMPLEMENTATIONEstablished 90 day look ahead from level 4 schedule

HSE Managers Activity schedule

Corporate Audits and Inspections

Communication – HSE meetings

Craft weekly toolbox meetings

Daily Pre-start toolbox meetings

Monthly / Weekly reports

HSE Awareness, Highlighting inherent risks. Visual risks awareness (Videos, posters, accident location visits, etc…)

HSE Promotion/Incentive Plans


HSE Induction prior to work entry

EOD Training Prior to work entry

Specific Training for Supervisors

Specific Training for Craft

Established training Plan

HSE TRAININGHSE TRAINING


Established first response clinic

Trained First Aiders

Paramedics

Regular Health and Hygiene inspections performed

Compliance with host Country medical requirements for employment

HEALTH & MEDICAL ARRANGEMENTS


Regular ReportingRegular MeetingsReporting against KPI’sAudits and InspectionsEstablished action lists, both corrective and preventiveRegular Job site Inspections.Frequent Audits of HSE System.Golden Rules Of Safety Audits Every Month.Feedback of safe & Unsafe ObservationsShare Lessons learned from Other Petrofac projects & other worldwide Construction Safety Experiences.

MEASURING PERFORMANCE & CORRECTIVE ACTION


Execution Execution –– Measuring PerformanceMeasuring Performance

SAFE ACT &CONDITIONS OBSERVATION CARD( SAMPLE)

HSSE HSSE –– Responsibilities, SecurityResponsibilities, Security

HSSE HSSE –– Responsibilities, EnvironmentalResponsibilities, Environmental

HSSE HSSE –– Responsibilities, Integrity AssuranceResponsibilities, Integrity Assurance

HSSE HSSE –– Project Management CommitmentProject Management Commitment

Management commits to being HSSE leadersLeaders model positive HSSE behaviours by personal exampleLeaders integrate HSSE expectations into business planning and decision making processesLeaders establish clear HSSE goals and objectives, roles and responsibilities, performance measures Petrofac’s executive management (corporate & divisional) lead HSSE Inspections: visible commitment.HSSE Leadership workshops define Roles

HSSE HSSE -- ProgrammesProgrammes

HSSE improvement programme

Key performance indicators (KPIs)

Compliance assurance programme

Competency training programme

Health programme

Maintain certification to ISO 14001 and OHSAS 18001

HSSE HSSE -- Management System AlignmentManagement System Alignment

Petrofac HSEMSPetrofac HSEMS• Policy, leadership & commitment • Hazard & risk management• Planning, objectives, targets & legal

requirements• Organisational roles,

responsibilities & resources• Training & competency• Implementation, documentation &

operational approach• Behaviour, communication and

consultation• Crisis & incident management• Compliance assurance & corrective

action• Performance measurement, review

& improvement

Project HSSE planProject HSSE plan• Project leadership &

commitment• Objectives, targets & KPIs• Project organisation &

responsibilities• Subcontractor selection /

evaluation• Hazard &effects management• Safety rules & work instructions• Work planning, implementation

& emergency response• HSSE training• Health & medical arrangements• Measuring performance &

corrective action

HSSE HSSE -- In Design / EngineeringIn Design / Engineering

• Risk management

– Hazard identification & management

– Consequence modelling (fire, explosion & toxic or flammable gas dispersion)

– Safety studies (fire & explosion risk analysis, EERA, …)

– Qualitative & quantitative risk assessment

– HSSE case preparation

– Environmental impact identification & assessment

– HAZOP studies

– Reliability and availability assessment

– HSSE management system development

HSSE HSSE -- In Design / EngineeringIn Design / Engineering

• HSSE engineering

– Active and passive fire protection

– Safety equipment, escape and evacuation layouts

– Safety equipment, escape and layout specifications

– Noise attenuation

– Hazardous area classification

– Leak source assessment

– Fire and gas detection

– Shut down systems

HSSE HSSE -- In Procurement / FabricationIn Procurement / Fabrication

• Risk management

– Hazard Identification & Management

– Assessment of Sub contractors

– Transportation and logistics standards

– Lift Plans

– Vehicle and trailer inspections

– Journey Management

– Driver assessment

HSSE HSSE -- In Procurement / FabricationIn Procurement / Fabrication

Subcontractor selection / evaluation•• Approach Approach

– Minimise number of subcontracts, maximise local content•• StrategyStrategy

– Minimum focal points for HSSE in construction– HSEMS consistent with projects and across sub-contractors– Familiarity with project scope from pre-bid stage– Demonstrated commitment to incident & injury free

•• PhilosophyPhilosophy– Reduced number of lower tier contract interfaces to

maximise safety awareness– Full commitment from sub-contractor executive

management

HSSE HSSE -- In Construction & PreIn Construction & Pre--CommissioningCommissioning

Training & competencyTraining & competency

HSSE induction prior to work entry

EOD training prior to work entry

Specific training for supervisors

Specific training for craft

Established training plan

HSSE HSSE -- In Construction & PreIn Construction & Pre--CommissioningCommissioning

• Risk management

– Hazard identification & management

– Project HSSE plan

– Construction hazard identification and risk control (HEMP)

– JSA’s

– Method statements

– Environmental management plan

– Security plan

– Emergency response plan

– Risk and action registers

– Competency and training plans

– Performance reporting

HSSE HSSE -- In Construction MobilizationIn Construction Mobilization

Labour camps

• This specifications addresses

– Sleeping accommodation

– Food hygiene

– Pest control

– Toilets and washing facilities

– Waste management

– Water

– Barber shops

– Laundries

– Recreational facilities

HSSE HSSE -- In Construction MobilizationIn Construction Mobilization

Medical screening / fitness to work

• An applicant will be evaluated immediately as medically unqualified if he was assessed to have the following:

– Infectious disease like HIV/HBV/HAV/HCV/TB

– Carrier of the infectious disease Like HIV/HBV/HAV/HCV/TB

– All types of cancer

– Epilepsy

• Uncontrollable chronic diseases like Hypertension, Diabetic, Asthma, Heart, lung Diseases; for doubtful cases, a second opinion from a health specialist is needed then to be forward toPetrofac medical advisors for further follow up and appropriate action

HSSE HSSE -- In ConstructionIn Construction

• Planning & implementation

– Established 90 day look ahead from level 3 schedule

– Review environmental aspects & impacts

– Review hazard / risk register

– HSSE manager’s activity schedule

– Corporate audits and inspections

– Communication – HSSE meetings

– Craft weekly toolbox meetings

– Daily pre-start toolbox meetings

– Monthly / weekly reports

– HSSE promotion and awareness

HAZARDSHAZARDS

• Falling objects:– Workers on a building or structure above the scaffold could

drop something onto the scaffold– Scaffolding erectors could drop something during erection– Scaffold Users Could Drop Something Onto Other Workers

Below

• Overhead hazards:– Safety nets or fan protection could be erected out past the

edge of the scaffold as protection– Completely board out levels to provide overhead protection– Barricade the risk areas at ground level, where-ever possible– Be aware of the overhead hazards !

Material handling:

Access-ways must be kept clear of obstructions & debris, to avoid tripping hazards

Combustible materials must be segregated

Where materials are being stacked to a height above the toe-board, a brick-guard (or similar paneling) must be fitted upto the top guard-rail

Barricades & signage must be in place

Always use the correct handling procedures

When working near electrical lines, a designated person should be available to ensure the required clearance is kept

• Electrical Hazards:

The most common electrical hazards are:Shocks, burns arc-blasts, fire & explosionsShocks from high voltage lines are the most serious, causing severe burns & death

Burns, usually occur on the hands, as a result ofTouching badly maintained or badly earthed electrical equipment or wiring

• 5m Minimum Distance: • 5m Away & 4m Below Minimum Distance:

Scaffold HazardsScaffold HazardsScaffolding must only be erected, alerted or dismantled by

competent scaffolders. It must be regularly inspected and certified

fit for use.

Always get permission before going onto a scaffold Always check that is certified fit for your intended use.An access scaffold may nit be suitable for load-bearing work.Never use any incomplete or uncertified scaffold. Never make any unauthorized alterations.Never throw materials down from a working platformWhen you work over water, always wear a life jacket or other buoyancy aid. Your life may depend on it.

Scaffold Hazards Scaffold Hazards

• Anyone who is at risk from a fall must be protected by a fall protection system.

• Systems include guard-rails and full body harnesses.

• Guard-rails should be used where-ever possible, if not another method must be used.

• All scaffolders must always wear a full body harness & shock absorbing lanyard when working at heights.

• Suitable anchor points must be used, or lanyards must be fixed to life-lines.

• The scaffold should only be used as an anchor point if no other suitable anchor point is available.

Scaffold HazardsScaffold Hazards

Full body harness

Should fit correctly.Ensure it is adjusted correctly to give maximum protection. (Not loose fitting)Should distribute the shock load evenly through the body, under a fall arrest situation.Fitted with attachment points for lanyards/shock absorbers.

Should be inspected & tested.

FALL PROTECTION EQUIPMENTFALL PROTECTION EQUIPMENT

The rear of the full body harness should fit squarely across the shoulders, with the support ring positioned in the middle of the back.


Lanyard• Used to secure the wearer to a suitable

anchorage point, or life-line.• Should be inspected & tested.

Life-line:

A flexible line that connects to an anchorage point at one end, and is stretched taut to another point to provide a life-line to clip harnesses & lanyards to.

This is usually horizontal, and is often tied between steel-work.


Shock Absorbing Lanyard

A specially designed lanyard with a built in shock absorber.

Absorber elongates in a fall ,so fall arrest forces are significantly reduced.

DUAL CLIPDUAL CLIP--ON METHODON METHOD

• Some-times there might be An occation when a scaffolder has to climb up or down a scaffold, Although this is not good practice, it some-times happens.On these rare occations, the dual clip-on method is the preffered method.With this method the scaffolder is always clipped on by one of the harnesses clips.

Means of Access:Means of Access:

Access is usually obtained by ladder.

fixed at 2 points, top & bottom.

the ladder must extend past the work platform,

onto the extended guard-rail tube.

HSSE IncentivesHSSE Incentives

HSSE HSSE -- 5 Star Incentive Scheme5 Star Incentive Scheme

G h s e rEncourage individual site personnel to contribute to the deliverEncourage individual site personnel to contribute to the delivery of y of the Project in a safe manner.the Project in a safe manner.

Provide improved safety of the operations,

Provide clear incentive targets for all individuals

Provide shared responsibility of all site personnel

Provide a relatively simple incentive scheme to operate and manage

HSSE HSSE -- Key Success FactorsKey Success Factors

Established safe place and systems of work

Line management responsibilities for HSSE

Inter-party communication & coordination

Zero tolerance of HSSE violations

Strong HSSE construction organisations to drive the construction

programme to reach HSSE targets & to overcome identified

obstacles

Continual review of site conditions

Raising level of hazard and risk awareness

Dangerous Occurrences / Near Misses Dangerous Occurrences / Near Misses

Should any Incident occur which does not cause injury to personnel, but could have resulted in injury or damage to plant or equipment, report the incident to your supervisor.By reporting incidents, and acting to prevent them happening again, it is possible to prevent more serious accidents from happening.ALWAYSALWAYS report accidents, incidents and hazards which you witness or are involved in.Procedure for reporting, Investigating Accidents and Incidents should be referred to and all procedures followed.

Near miss,Near miss,

Report it!Report it!

Working in Hot Weather Working in Hot Weather

Health Hazards from Hot weather include:

Heat Stroke:Heat Stroke:

This is the most serious hot weather health problem. The victim’s heat control mechanism just stops. The victim has hot, dry skin with a high temperature, chills and mental confusion. If it is not cooled off quickly, the result can be brain damage or even death. Persons with a medical history of heat stroke are likely to get it again under the same conditions.

Heat Exhaustion:Heat Exhaustion:

This is caused by the loss if body fluids from sweating. The victim sweats, but is dizzy of very tiered. Rest and plenty of water usually produces quick recovery to this common heat ailment.

Working in Hot Weather Working in Hot Weather

Heat Cramps:Heat Cramps:

These result from loss of salt in the working muscles, usually as part

of heat exhaustion.

So watch out during a sudden hot spells,

until you get used to the heat.

Acclimatize the first day of hot weather,

until you get used to it.

Drink lots of water.

Be sensible with alcoholic beverages

after work, since the alcohol

dehydrates your system.

FireFireProtection from fire is of vital importance to all employees, lives, jobs, and financial loss.

EVERY EMPLOYEE SHOULD MAKE SURE THAT HE KNOWS WHAT IS EXPECTED OF HIM, IN THE EVENT OF A FIRE, BEFORE A FIRE OCCURS.

Learn your emergency procedures. If in any doubt, ask your supervisor NOW.

ALWAYS know your fire instruction. Find out how to sound the alarm and be sure where the fire escapes, emergency exists and muster point stations are.

ALWAYS keep calm in the event of a fire, panic causes disasters.

FireFireALWAYS make certain that you know the position of the fire extinguisher at your place of work, and you that know hoe to operate the.Fuel, Oxygen and Heat will result in fire when they are together in the correct proportions.Fire can be extinguished by any one or any combination of the following:

Removing HeatRemoving OxygenRemoving Fuel

ALWAYS obey all local instructions aimed at preventing fire, forexample the control of smoking and other ignition sources.Fire is a hazard. If you smoke take care. Refrain completely from smoking when in areas where “NO SMOKING” signs are displayed.

The fire TriangleThe fire Triangle

Eye ProtectionEye Protection

Your eyes are very vulnerable at work and cant be replaced.

You can loose your sight only once, You can loose your sight only once,

SO PROTECT SO PROTECT

YOUR EYES!YOUR EYES!

Eye ProtectionEye ProtectionAlways get your eyes tested if you have any doubts about your

eyesight

Always wear the goggles or face shields provided to protect your

eyes from dust, flying particles, molten materials, liquids, fumes or

injurious light and heat rays

Always make sure you have the correct eye protection for the

work and wear it properly.

Always remember the passer-by, particularly if you are welding,

chipping, grit-blasting or grinding, Screen off your workplace.

Eye ProtectionEye ProtectionNever Watch a welder at work with unprotected eyes. The UV

light from electric are welding will damage them. NEVER WAER

CONTACT LENCES while welding.

Never assume that one type of protection is suitable for all risks.

i.e. impact-resistant goggles may

not protect your eyes from

liquid splashes.

Never use scratched and damaged

safety spectacles.

Working at HeightsWorking at HeightsFalls from heights are less common than falls at ground level but

naturally the results are usually much more serious. Recognizing

this, there are strict rules applicable to working at heights over two

meters or on exposed locations.

Temporary and permanent working

platforms must comply with

the statutory requirements regarding

handrails, toe-boarding and

access ladders.

Working at HeightsWorking at HeightsIf you have to work outside a properly fenced, temporary or

permanent platform, and are liable to fall more than two meters,

you must wear a suitable safety harness and line properly attached.

Always wear a work vest when working over water or a place from

where a fall is likely into the water.

Ensure that platforms and gangways

have secured guard rails & toe boards.

Excavations & OpeningsExcavations & Openings

Check if permit is required before commencing work.

No person may work in an excavation if there any danger resulting from a collapse of the sides of the excavation. In such circumstances, suitable and sufficient shoring will be provided to ensure safe working, or the sides battered back to a safe angle.

Access into excavations shall be suitably fixed ladders only.

Where “Live” services are present, hand excavation must be carried out until the service has been identified and made safe.

Person engaged in excavating must be mindful of the possible presence of buried services and if unexpectedly discovered thesemust be checked by a competent person before excavation continued in the affected area.

Excavations & OpeningsExcavations & Openings

Excavation more than 2 meters deep must be guarded at the top

by barriers. During the hours of darkness any excavations,

openings or obstructions near or on roadways and walkways

must be indicated by a sufficient number of warning lamps, and

whether day or night, other excavation and openings suitably

protected in accordance with the circumstances.

Materials and equipments must not be stacked close to the edge

of excavations minimum 11/2 meters away from edge.

Platform walkways and pedestrian crossovers across obstacles or

trenches must be of sufficient width, 60 cm minimum, and shall

have a handrail on at least one side.

Work Permit SystemWork Permit System

When working on client facilities the clients (permit to work system)

will be used in this circumstances, the client will hold the

responsibility for the issue and control of all permits to work unless

other arrangements are made with the client. Check with your

supervisor first.

Before starting any hot work,

check the space for any flammable or

explosive mixture & for oxygen content.


In all cases the site agent will hold the responsibility for the issue

and control of all permits to work on site. All operations connected

with construction, maintenance and inspection of plant and

equipment must be carried out with full regard to safety of

personnel and equipment.

The permit to work is used to specify the detailed conditions of

work and the conditions must be strictly observed.


Your work may be controlled by any of following permits:

Hot Work Permit, for work involving the use or exposure of sources of ignition.

Cold Work Permit, for general work excluding the use or exposure of sources of ignition

Confined space Entry Permit, for any entry into a confined space.

Electrical Permit, for work by electrical staff on, for example, high voltage equipment.

Radiographic Permit, for work involving use of ionizing radiation

Excavation Permit, for work involving excavation on yards or on-site projects.


Permits to work stipulate & authorize the work you are to do, the area & time you are to do it in, the precautions taken to make your workplace safe & list of precautions you must take against any residual hazardsIt is your duty to make yourself conversant with the detailed Permits to Work procedures. Ensure all workers are properly trained and given orientation.

No hot work is to be done on an enclosed drum or tank which has contained flammable substances unless it has been tested & certified safe to work on.

Entry into Confined SpacesEntry into Confined Spaces

The potential hazards associated with entry into a confined space requires a strict adherence to a formal, safe system of work. It is company requirements that this be done under the control of a Confined Space Entry Permit. Remember a Confined Space can be a vessel, a pipeline, in fact anywhere where there maybe inadequate natural ventilation.

NOTE: Confined Space Training must be conducted prior to work in confined space area.

Follow instructions.Ensure that any confined spaceIs well ventilated prior to entering


Put on breathing apparatus & a harness when entering a confined

space that has not been gas freed

Always get a Confined Space Entry Permit to work inside confined

spaces

Always obey all the instructions written on the Permit to Work,

which may require you to wear breathing apparatus or use safety

equipment such as life line, a harness and protective clothing.

Always ensure that a standby man, is in attendance who is briefed

to keep constant watch on you and who is equipped and able to

raise the alarm if necessary.


Never enter the vessel if you are the standby man, raise the alarm

and await qualified assistance

Never attempt to rescue anyone from a confined space unless you

are a member of rescue team, fully equipment with breathing

apparatus.

Lifting OperationsLifting Operations

Rigging & SlingingRigging & Slinging

Always use properly tested, assembled, marked and color coded lifting tackle of adequate strength for the job

Always make sure there are no kinks or twists in the chain or slings.

Before using wire ropes or chain slings, examine carefully for breakage, deformity, corrosion, cracks or other defects.


Always use a proper safety hook, not a , makeshift one. See that end links, slings or shackles are riding freely on the hook.Always check that any support used to suspend the lifting tackle is strong enough for the jobAlways use wood or other packing to protect the sling from any sharp edges on the load.Always position the lifting hook over the load so as to prevent the load swinging when it is raised.Always see that the load is free before the lift is raised Always take your hands away from the sling before the lift begins and stand clear. Don’t leave the controls of a crane unattended when a load is being suspended.Always return lifting tackle to the store after useAlways store chains and slings off the floor.


Never use faulty or damaged lifting gear, report any defects to your supervisor.only Equipment with a valid test certificate must be usedall loose lifting gear must go through examinations at intervalsnot longer than 6 months all lifting gear must be color coded, stamped or marked with a unique I.D. number and their Safe Working Load (SWL)

Never use slings and lifting gear deemed to be unsafe, these must be destroyed and remove from site

Never Exceed the safe working load of the tackle. If in doubt about the weight of the load, ask your supervisor. Refer always to the standard sling charts to find out the suitability of the sling for the particular job.


Never drop lifting tackle or drag it from under a load, it weakens it.

Never guess the weight of the load to be lifted

Never tie a Knot in a chain to make it shorter

Never use rigging and slinging equipment unless you have been trained and instructed to do so.

Never stand or work under a suspended load, keep well clear of all loads in motion


Crane OperationsCrane Operations

Only Authorized, and competent persons may operate cranesOnly Authorized, and competent persons may operate cranes

Crane drivers are instructed to take their signals from a designated banks-man. Do not confuse him by giving ad hoc signals. Never work or walk under suspended loads.

Don’t operates cranes over or in the close proximity of power lines!!

Keep a minimum of 5 meters distance away.

ElectricityElectricity

Misuse of electricity can result in personal injury or death and fire

or explosion. It is essential that a standard code of behavior be

observed with all electrical equipment, in order that it is treated

with the considerable respect that it deserves. Only competent,

authorized personnel are permitted to work on electrical systems or

maintain electrical equipment.

Before working on electrical installations, ensure that the fuses are

removed & the circuit breakers are locked. Ensure the lock out/tag-

out procedure is utilized.


Always Report broken, ineffective or damage electrical equipment, such as loose connections and frayed cables, to your supervisor.Ensure that no one can come into contact with such

equipment until it is repaired.

Don’t tamper with any electrical wiring.

Always ensure that there is a clear access (1m)

to switchboards and other similar installations,

in case isolation is required in an emergency.

Always assume all electrical circuit are alive until

you are certain, and tested that they are not alive.


Always keep scaffolding poles, cranes and ladders well away from overhead wires.

Always switch off at the socket before removing the plug, whenever possible.

Always learn what to do in case of electric shock. Before attempting rescue ensure that the source is isolated

Always switch off when you have finished with the equipment

Never attempt unauthorized use, repair or maintenance of equipment.


Never improvise a junction box, e.g., never jam wires in sockets with match slicks or nails

Never run power tools from sockets so they cannot be earthed

Never force a plug into a wrong sockets

Never use the wrong fuse for the current that the equipment is carrying

Never hang cables on nails or leave them lying around where they can get damaged or wet


Never use equipment with the earth wire pulled out of its terminal.

Never misuse an earthing clamp on welding sets

Never use any cable with make shift joints. It should be of continuous length to the extent possible.

Pipeline Safety RulesPipeline Safety RulesRight of wayRight of way

Timber clearing and felling should be done under the direction of an experienced and competent person with the safety practices necessary in these operations

Dozers must be equipped with roll bar or protective cover constructed of material sufficiently strong to protect operator, when they are used in clearing operations

The dozer operator must make certain that all persons are in theclear

The dozer operator must not allow anyone to ride on the dozer blade, blade crew or draw bar.

The operator or others should never attempt to make any repairs or adjustment or to grease the machine without first switching off the engine

Pipeline Safety RulesPipeline Safety RulesDitchingDitching

All underground cables, conducts, oil and gas lines, and other pipelines must be properly spotted and uncovered before ditchingoperations are started

The operator is held responsible for maintaining his machine andequipment in safe and satisfactory operating conditions

Operator or other personnel should not grease or make repair or adjustment while machine is in operation.

Operator must make sure that all employees are in the clear accounted for, before moving machine or digging wheel.

Pipeline Safety RulesPipeline Safety Rules

No employee other than the operator should be in the cab while machine is in operation

Do not stay while the machine near the edge of the ditch

Normally, do not descent to the ditch, but when you must, make sure the sides of the ditch are stable and use ladders in going down.

Pipeline Safety RulesPipeline Safety RulesStringing & BendingStringing & Bending

Stay away from factor during loading and moving of pipes

Always make sure of the stability of the pipe after it is lowered

Check and verify periodically the equipment used for the pipe movement

All side-boom hooks must be equipped with a safety catch or lock to prevent cable slipping out.

Carry out the transfer of the pipe as close to the ground as possible

Lay down the pipes correctly to prevent the possibility of moving or rolling


Suitable signs or flags must be placed on access road at points where trucks are turning off to string pipe.

All men should stand in the clear when bending operations are inprogress

The bending machine operator is to be responsible for making daily inspections of the machine and any defects discovered should be notified immediately to the foreman.

Helpers should not ride pipe being moved to and from bending machine.

WeldingWelding

Do not go near the pipes during the jointing operations

Necessary precautions must be taken by the welders and helpers to protect their eyes when welding operations are in progress

Welder’s helpers should wear the proper type dark lens goggles

Pay attention when using the torch for pre-heating

Oxygen and Acetylene cylinders must be properly secured to prevent their falling

Oxygen and Acetylene hoses must be kept in good repair

Welding trucks must be equipped with approved fire extinguishers and first aid materials

Do not alter the position of the stocks being lifted without notifying side-boom operator.

Pipeline Safety RulesPipeline Safety RulesLoweringLowering

Lowering should be directed by the foreman in charge. Signals and other orders to the tractor operators must come from the foreman alone

No employee should be with in the ditch, on the pipe or between the pipe and the ditch along the entire length of the continuoussection of the line while pipe is in the process of being lowered.

Care should be taken in the operation of side-booms while lowering pipe into the ditch to prevent side-boom from falling into the ditch

All side-boom equipment (cables and hook) must be checked before each lowering operation.

During the wrapping process, make sure that there is nobody at the opposite side of the pipe.

Pipeline Safety RulesPipeline Safety RulesCrossing and tieCrossing and tie--inin

Barricades, warning signs etc. must be erected on each side of the road before excavation is started

Back-hoe, dragline and ditching machine operators will inspect ditch for any sign of uncharted lines etc…

Temporary bridges with guard rails on each side must be constructed over excavations crossing roads are repaired and leveled.

Warning signs and flashlights should not be removed while road crossings are repaired and leveled.

Before starting any type of welding operations verify the stability of the ditch

To go down use available laddersFor welding operations see rules for welders, grinders and helpers.


Backfilling and cleanBackfilling and clean--upup

Do not go near the ditch with the machine

Do not allow other persons near the work area

When working on a slope make sure that nobody is at the bottom.




The Delivery ManThe Delivery Man

The GrinderThe Grinder

The MasonThe Mason

The WelderThe Welder

The Luggage HandlersThe Luggage Handlers

The PaintersThe Painters

The shipyard mechanicsThe shipyard mechanics

The Air Conditioner InstallerThe Air Conditioner Installer

The Construction Site WorkerThe Construction Site Worker

The Expert in Biological WeaponsThe Expert in Biological Weapons

The WMD Warehouse ManagerThe WMD Warehouse Manager

The Car MechanicsThe Car Mechanics

The ElectricianThe Electrician

The Erection TeamThe Erection Team

The Power Cable InstallersThe Power Cable Installers

The Aircraft MechanicThe Aircraft Mechanic

The City Maintenance TeamThe City Maintenance Team






Hydro test Failure/Fall from heightHydro test Failure/Fall from height



Electrical IncidentElectrical Incident







Man eaten by a latheMan eaten by a lathe

Date post:	28-Aug-2019
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