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HSE MANUAL
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REVISION NO. 0
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API WATAN (M) SDN BHD CLIENT
REV
NO. DATE
PREPARED BY REVIEWED BY APPROVED BY REVIEWED BY APPROVED BY
NAME SIGN DATE NAME SIGN DATE NAME SIGN DATE NAME SIGN DATE NAME SIGN DATE
0 1OCT15 HA 1 OCT 15 AZMAN 1OCT15 AA 29OCT15
HSE MANUAL
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REVISION LIST
SECTION REV. DATE DESCRIPTION OF AMENDMENT
Attention User: Portions of this procedure have been changed from the previous revision. The locations of changes have been marked with a vertical bar in the left margin of the paragraph being amended. COPYRIG
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TABLE OF CONTENTS
SECTION DESCRIPTION PAGE
1 ADMINISTRATION 4 1.1 INTRODUCTION 5 1.2 HSE POLICY 6 1.3 GOVERNMENT ACTS AND REGULATIONS 7 1.4 MANAGEMENTS RESPONSIBILITIES 8 1.5 DEPARTMENTAL HEAD’S RESPONSIBILITIES 9 1.6 SUPERVISOR’S RESPONSIBILITIES 10 1.7 EMPLOYEE’S RESPONSIBILITIES 11 1.8 SUB-CONTRACTOR’S RESPONSIBILITIES 12 1.9 SUB-CONTRACTOR’S HSE REQUIREMENTS 13 1.10 SAFETY OFFICER’S RESPONSIBILITIES 15 1.11 WORKSITE HSE COMMITTEE ORGANISATION
CHART 16
1.12 ROLE AND FUNCTION OF WORKSITE HSE COMMITTEE
17
1.13 PROJECT HSE COMMITTEE ORGANISATION CHART
18
1.14 ROLE AND FUNCTION OF PROJECT HSE COMMITTEE
19
1.15 ACCIDENT/INCIDENT REPORTING 20 1.16 “U-SEE U-ACT” PROGRAM 26 1.17 EMERGENCY RESPONSE PLAN 30 1.18 DISCIPLINE PROGRAM 33 1.19 PERSONAL PROTECTIVE EQUIPMENTS (PPE) 37 1.20 HOUSEKEEPING 41 1.21 PERSONAL CONDUCT 43 1.22 EMPLOYEE INDUCTION AND TRAINING 45 1.23 FIRE PREVENTION AND FIRE FIGHTING
EQUIPMENT 46
1.24 NOISE CONTROL 48 1.25 STANDARDIZED SAFETY SIGN 49 1.26 VISITOR AND SUPPLIER SAFETY 53 1.27 OCCUPATIONAL HEALTH 55 1.28 MEDICAL FACILITIES AND FIRST AID 59 1.29 SAFETY PROMOTION PROGRAM 60 1.30 SAFETY AUDIT 61 1.31 JOB SAFETY ANALYSIS 62
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SECTION DESCRIPTION PAGE
2 SAFE WORK PRACTICES AND PROCEDURES 64 2.1 CONFINED SPACE ENTRY 65 2.2 PERMIT-TO-WORK SYSTEM 69 2.3 LOCK-OUT AND TAG-OUT PROCEDURES 71 2.4 LIFTING, RIGGING AND HEAVY LIFTING
PROCEDURE 74
2.5 RADIOGRAPHY SAFETY 78 2.6 WELDING SAFETY 85 2.7 SCAFFOLDING 86 2.8 LAUNCHING AND LOADOUT PROCEDURE 94 2.9 PNEUMATIC AND HYDROSTATIC TESTING 96 2.10 HOSE TESTING 97 2.11 SAFE USE OF HANDTOOLS 98 2.12 ABRASIVE CUTTING AND GRINDING 100 2.13 EARTHING FOR ELECTRICAL EQUIPMENT AND
TOOLS 101
2.14 HANDLING AND USE OF COMPRESSED GASES AND CYLINDERS
104
2.15 SAFE USE OF FORKLIFT TRUCK 106
2.16 FOOD SAFETY AND SANITATION 2.17 KITCHEN SAFETY, AVOIDING FALLS, CUTS
PREVENTIONS
112 113
3 ENVIRONMENTAL CONTROLS 110 3.1 HAZARDOUS MATERIAL MANAGEMENT 111 3.2 CONTROL AND USE OF HAZARDOUS
CHEMICALS 114
3.3 WASTE DISPOSAL 116
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SECTION 1
ADMINISTRATION
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1.1 INTRODUCTION This HSE Manual which contains the company’s HSE policy, rule and regulation, safe work procedures and practices was formulated by the safety department and has been periodically reviewed to keep abreast with new techniques and programs to safeguard the health & safety of the workforce and the conservation of the environment in all areas of activities that the company has undertaken. This manual is designed to supplement existing local statutory requirements and regulations as outline in section 1.03. It reflects current knowledge to know work hazards and the best means of mitigating those hazards. Any questions regarding safe work practice or suggestions for a safer workplace are encouraged and should be submitted to the Safety Department. The prime objective of this manual is to guide the company in the following areas:- * To achieve an acceptable standard of safety performance by controlling
and directing activities in the work place. * To aid as a reference to all yard activities to ensure safe work methods
are followed. * To outline the safety, health and environment control rules for a
workplace needs. Recipient
This manual shall be distributed to company employees, clients and sub-contractors. The manual is a Controlled Document and shall remain the property of the company. In the event that the holders of the manual terminate their services with the company, they must return the manual of the Safety Department on or before the last day of their employment.
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1.2 POLICY STATEMENT ON HEALTH, SAFETY AND ENVIRONMENT (HSE)
HEALTH, SAFETY AND ENVIRONMENT POLICY We at API WATAN (M) SDN BHD recognise that implementing good Health Safety and Environment practices is critical in achieving, maintaining and continually improving our business sustainability. We will comply with all applicable HSE legal requirements and other requirements regardless of where we operate. We remain committed in striving towards the prevention of injuries, occupational illnesses, property damage and protection of the environment in which we operate by:
Establishing and implementing a Health Safety and Environment Management System in accordance with legislative and other standards to eliminate or minimize an HSE risk to our employees, subcontractors, clients and to the environment.
Demonstrating leadership commitment in championing all HSE initiatives.
Periodically measuring and reviewing HSE performance against HSE objectives and standards.
Ensuring integrity in our services o safeguard people, property and environment.
Encouraging a proactive intervention culture and transparency in HSE reporting as part of our HSE practices and;
Communicating the intent of this policy to our employees and others.
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1.3 GOVERNMENT ACTS AND REGULATIONS
1.3.1 PURPOSE
These sections define the local Government Act and Regulations requirement in respect of HSE Management, and shall be identified and complied with Transerve accordingly.
1.3.2 SCOPE
All requirement therein defined shall be applied for all activities carried out by API WATAN as well as its Sub-contractor and Third Party associated with API WATAN.
1.3.3 PROCEDURE
API WATAN (M) SDN BHD shall comply with all relevant statutory requirements currently enforce in Malaysia. The relevant Statutory Act and Regulation are as follows.
Occupational Safety and Health Act, 1994 & Regulation
Atomic Energy Licensing Board
Environmental Quality Act 1974
Radiation Protection (Licensing) Regulations 1986
Merchant Shipping Ordinance 1952
Ports and Harbours (Laid-Up Vessels) Reg. 2008
Dangerous Drugs Act 1952
Construction & Industrial Development Board 1994, Act 520 (CIDB)
Factories and Machinery Act 1967
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1.4 MANAGEMENTS RESPONSIBILITIES
i. Establishing promoting and maintenance of safe practices and procedures to ensure a healthy, safe and efficient working environment in yard.
ii. Conscientious observances of all safety statutory requirement met by the
Company and local statutory requirement pertaining to Safety Health and Environment, including the Factories and Machinery, Safety Health and Environmental water and air pollution.
iii. Ensure effective implementation of safety policy. iv. The formation of the following committees is to look into the occupational
health safety and environment in all activities undertaken by the company: a) Health Safety and Environment Committee. b) Projects HSE Committee.
v. The upgrading of safety standards and control and training of all employees.
vi. The provision of personal protective equipment (PPE) to all employees
and visitors to. vii. The maintenance and manning of a medical centre to immediately attend
to all occupational injuries and illness sustained in the Company’s premises.
viii. Conduct HSE Audit of the yard and work place when requested by client.
The audit findings shall be documented and deficiencies rectified as soon as possible.
ix. Conduct a “Walk-about” of all sites in the yard at least once every six
months by the Chief Operating Officer to demonstrate top management visible safety/health commitment.
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1.5 DEPARTMENTAL HEAD’S RESPONSIBILITIES
i To maintain safe working condition and practice for all employees under supervision.
ii To maintain good house keeping. iii To ensure that adequate personal protective equipment are issue,
maintained and used in accordance with Company’s Safety Rules and Code of Safe Practice and/or as recommended by clients.
iv To encourage safety suggestions and act upon them immediately. v To ensure that safety rules and regulations are complied with and
explained to all employees in his Section. vi To rectify all unsafe conditions and hazards when required to do so by
any member of the Safety Department, Safety Committee or Management.
vii To conduct regular safety meetings and such meetings should be
documented. viii To identify training needs in respect to safety skill of employees under his
supervision. ix To participate in safety walk-about when request. x To assist Safety Officer in carrying out investigations of any
accident/incident inclusive of compiling a report and recommendations to prevent recurrence.
xi In any accident, to carry out follow-up action to ensure recommendations
are complied with.
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1.6 SUPERVISOR’S RESPONSIBILITIES i Responsible for the prevention of accidents in his section. ii Accountable for all accidents occurring in his section. iii To enforce all Company’s safety rules, regulations and all relevant Local
Legislation pertaining to Safety, Health and Environment in work sites. iv To investigate and report all accidents and near misses. v To ensure that all persons are in safe working environment. vi To inspect work sites, tools and equipment regularly. vii To conduct regular section’s safety meetings at work sites. viii To take stop-work action against any unsafe act. ix To rectify hazards pointed out by safety personnel or any other person. x To ensure good housekeeping at work areas.
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1.7 EMPLOYEE’S RESPONSIBILITIES i To obey all Company’s Safety Rules and Regulations so as to prevent
any one from injuries. ii To report all unsafe acts and conditions immediately. iii To check surrounding areas for potential hazards before commencing
work. iv To report all accidents immediately. v To seek first aid treatment immediately for any injury sustained in the
yard. vi To seek advise & assistance from a direct supervisor. vii To utilize all personal protective equipment provided. viii To maintain good housekeeping in the work area. ix Not to create unsafe conditions. x To rectify and hazards or unsafe conditions found at area of work. xi To attend safety meetings or training when requested.
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1.8 SUB-CONTRACTOR’S RESPONSIBILITIES i To ensure that all sub-contractor employees comply with the company’s
safety rules and procedures, and local statutory regulations currently in force.
ii To provide all necessary personal protective equipment (PPE) to the sub-
contractor employees as a mandatory condition. iii To ensure that all PPE issued are adequately maintained and replaced
when necessary. iv To maintain good housekeeping to Occupational Safety, Health and
Environment when requested by the Company. v To attend all meetings pertaining to Occupational Safety, Health and
Environment. vi To carry out immediate rectification of unsafe conditions and hazards
when these are reported by employees, or by any member of the Safety Committee or the Safety Department.
vii To ensure that all tools and equipment used at the work sites are free
from defects and suitable for intended use and conform to the approved safety standards.
viii To participates actively in all Occupational Safety, Health and
Environmental conservation programs organized by the company. ix To report immediately all accidents and near misses to the Company’s
line supervisor in-charge and Safety Officer.
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1.9 SUB-CONTRACTOR’S HSE REQUIREMENTS A large number of yard’s workforce is made up of contract workers. In order to maintain yard’s safety standard, it is essential that the sub-contractors comply with the following fundamental rules of the company. * The sub-contractors shall be conform to all the HSE requirements as laid
down by the Company and not be in breach of the Local Statutory Regulations and any other relevant regulations currently in force.
* A HSE coordinator or HSE Supervisor responsible for the safety of the
contractor’s workforce must be appointed and he must liaise effectively with the HSE Department on all matters pertaining to occupational safety, health and environment.
* Sub-contractor‘s labour should be provided with personal protective
equipment as and when required by each specified job. * To wear approved type Personal Protective Equipment (PPE) similar to
shipyard standard such as safety hat with chin strap, safety shoes and safety spectacles while in the “Safety Zone Area “of the yard.
* All hot work and cold work to be carried out in confined space shall be in
compliance with the yard’s Permit-To-Work System. No work to be carried out unless a written permit is obtained.
* All contractors’s lifting gears, appliances and machines to be used in the
yard must comply with the shipyard standard. A copy of the certificate of test and examination must be produced to the HSE Section.
* The standardized safety signs displayed in yard and work sites must be
adhered to all workers. * The Company will only provide First-Aid service for injuries sustained in
the yard and all medical expenses incurred. * All accidents occurring within the yard’s premises should be reported to
the line Supervisor in-charge and HSE Section immediately without fail. A written report as per attached shall be submitted to Safety Section within 24 hours from the time of the accident (Please refer to Accident/Incident Reporting Section 1.13).
* Should there be a violation on any of the above rules, the contractor will
be penalized.
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* Sub-contractor HSE Coordinator or Supervisors shall conduct Daily
Toolbox Talk before commencing work. * Sub-contractor shall be responsible for maintaining daily housekeeping at
their respective work area acceptable to the company. * Never operate or carry out any repair on any machine unless one has
been trained in the correct and safe methods of use. * Report immediately to site supervisor/HSE/coordinator any defect of
failure of plant, lifting equipment. * All gas hoses shall be removed from confined spaces/tanks/engine
room/control room during rest breaks and after completion of the day’s work.
* All portable hand tools e.g. grinder, drilling machine etc. shall be switched
“OFF “and disconnected from the supply during rest breaks and after completion of the day’s work.
* No unauthorized personnel shall drive/operate any form of vehicle or
machine.
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1.10 SAFETY OFFICER’S RESPONSIBILITIES i Formulating, administering and periodically reviewing the Company’s
Occupational Health, Safety and Environmental conservation programs. ii Submitting directly to the General Manager, project manager regular
monthly, quarterly and annual reports on the status of safety whichever is required.
iii Acting in an advisory capacity on all matters pertaining to Occupational
Safety, Health and Environment as required for the guidance of Managing.
iv Maintaining the accident record system. Making necessary reports,
personal investigations of fatal of serious accidents, securing supervisor’s accident reports and checking corrective actions.
v Co-relating safety work with the Medical Centre. vi Making personal inspection and supervising inspection for the purpose of
discovering and correcting unsafe conditions of unsafe work practices to prevent accidents.
vii Maintaining outside professional contacts to exchange information with
others and to keep the program up-to-date. viii Ensure that laws, ordinances or orders bearing on Occupational Safety,
Health and Environmental Conservation are complied with. ix Securing necessary help or advice from the Occupational Safety, Health
and Department, HSE Committee or others on matters pertaining to Health, Safety or Environmental conservation.
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1.11 WORKSITE HSE COMMITTEE ORGANISATION CHART
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1.12 ROLE AND FUNCTION OF WORKSITE HSE COMMITTEE
It is the company policy that a Worksite Health, Safety and Environment (HSE) Committee shall be established to review circumstances in the yard which affect the safety and health of the employees or the conservation of the environment. The composition of the Worksite Health, Safety and Environment (HSE) Committee shall be determined by the management with the exception that the Senior General Manager and the HSE manager hold the position of Chairman and Secretary respectively with representation from four management representatives and four employee representatives. The HSE Officer will be appointed as Deputy Secretary. Function of Worksite Health Safety and Environment Committee i Promote co-operate amongst all levels of management including sub-
contractors. ii Inspect the yard to uncover deficiency in health, safety and environment
control and scene of accident or dangerous occurrence. iii Review and update the Company’s HSE Manual from time to time and
keep abreast with the development of new technology or the introduction of new products in the industry.
iv Keep under review the measure taken to ensure the safety and health of
all employees in the yard. v Assist in organizing safety promotion activities to arouse safety interest
among all employees. vi Contribute safety suggestions and participate actively in areas that would
improve the overall safety performance of the Company.
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1.13 PROJECT HSE COMMITTEE ORGANISATION CHART
HSE Personnel
Works Supv
Welding/Fitters Representative
Scaffolding Representative
Rigging Representative
QA/QC Representative
Secretary HSE Coordinator
Client Representative 4
QA/QC Representative
Client Representative 2
Client Representative 3
Chairman
API WATAN Client
Client Representative 1
Project Engineer
Project Manager
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1.14 ROLE AND FUNCTION OF PROJECT HSE COMMITTEE
i Develop HSE work procedure and make recommendations to the employee.
ii Review and update the effectiveness of the HSE Plan/ Program iii Review the effectiveness and adequacy of JSA’s. iv Report & discuss of the solution on any unsafe or unhealthy conditions or
practices v Review HSE training requirements. vi Inspect the place work at least once in every week during HSE walkabout vii Discuss observations of the members of the committee made during
inspections viii Make recommendations on the remedies measures to be taken on any
matter prejudicial to HSE ix Inspect the workplace as soon as it is safe to do so after any accident or
dangerous occurrence take place x Causes of accident shall be discussed and practicable measures are
taken to prevent the occurrence of such accident xi Discuss and formulate action to resolve workers HSE grievances.
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1.15 ACCIDENT/INCIDENT REPORTING 1.15.1 DEFINITION
Accident
An accident is an event which has, or could have caused injury or illness. Such an event may also involve damage to equipment, product loss or interruption of work.
Incident
An event that does not have potential for injury or illness but it may involve damage to equipment, product loss or interruption of work.
Fatality A fatality is death resulting from a work related injury, regardless of the time intervening between injury and death.
Permanent Total Disability (PTD) Permanent Total Disability (PTD) is any Work Injury which incapacitates an employee permanently and result in termination of employment.
Permanent Partial Disability (PPD) Permanent Partial Disability is any work Injury which results in the complete loss, or permanent loss of use, of any member or part of the body or any permanent impairment of functions of parts of the body, regardless of any pre-existing disability of the injured member or impaired body function.
Lost Time Injury (LTI) A Lost Time Injury is any work injury other than a Permanent Partial Disability which renders the injured person temporarily unable to perform any regular job or restricted work on any day after the day on which the injury was received. CO
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Restricted Workday Case (RWC) A work related injury which requires the injured to be treated by a doctor and is declared fit to return to do part of his/her normal work on restricted or light duties on any day after the day on which the injury was received. If panel doctor deems the man fit for restricted or light duties, it will be up to line management to decide if restricted or light duties relating to the normal duties were available. If such restricted or light duties were allocated, line would contact the panel doctor to ensure that said duties were compatible with causality’s injuries.
Medical Treatment Case (MTC) A work related injury that involves neither Lost Workdays nor Restricted Workdays but which requires the injured to be treated by or under the specific orders of a physician or could be considered as being in the province of a physician.
First Aid Case (FAC) A work related injury which requires minor treatment by a nurse or self treatment by a medically untrained person whereby the injured is able to resume the total scope of normal job function immediately after treatment.
Near Miss (NMC) A near miss is an accident which does not result in injury. Illness, damage or product loss. It is however an event an event which is recognized as having the potential to cause injury of illness or damage to equipment.
Company Vehicle Accident (CVA) This is an accident involving one or more vehicle hired, owned by or operated by the Company or its employees whilst on company business.
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1.15.2 NOTIFICATION AND REPORT
All accidents must be reported to appropriate Supervisor/Department Head, who will then take the required action. All Heads of Department / section shall instruct their employees to report all job related accidents and occupational illness to their respective supervisor, no matter how minor it maybe. The Company Representative e.g. Medical Assistant, Safety Officer. Project Manager will notify the client within 24 hours, Notification to the authority concern shall be managed by Personnel Manager and/or Head of Safety. A formal Accident/Incident Investigation & Reporting procedures shall be developed and approved by the client prior to start of projects
1.15.3 INVESTIGATION, ANALYSIS AND FOLLOW-UP
Direct supervisor will manage the response to the reported event or potential event, in accordance with the following process and notify the appropriate authorities when necessary.
1.15.4 INVESTIGATION OBJECTIVE The objective of the accident Reporting, Investigation, Analysis and Follow-up Process is to find facts, not fault. Facts finding will : i describe what happen ii determine the actual and potential loss (es) iii determine the root (or real) causes iv determine the risks v develop controls vi define trends vii demonstrate concerns
1.15.5 ACCIDENT INVESTIGATION
Every incident should be investigated to the point of determining potential severity and the probability for recurrence. Once this assessed, high potential incidents are investigated in depth to allow adequate control of the root problems. Refer Table 1 for a suggested response matrix to incident potential.
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If no corrective action is taken to eliminate suspected root causes, what is the probability that the incident could occur.
PROBABILITY OF RECURRENCE
DESCRIPTIVE WORD DEFINITION
Frequent Likely to occur repeatedly during life cycle of system
Probable Likely to occur several times in life cycle of system
Occasional Likely to occur sometime in life cycle of system
Remote Not likely to occur in life cycle of system but possible
Improbable Probability of occurrence cannot be distinguished from
Table 2
Based on the Probability of Recurrence and the Potential Consequences, the level of risk and type of investigation is specified by the following matrix.
RISK/INVESTIGATION ASSESMENT MATRIX
High Risk
Unacceptable for long term, must reduce risk, team investigates with full written report and forms completed.
Medium Risk Undesirable, evaluate risk reduction measures, supervisor. Investigates with full written report and forms completed.
Low Risk
Acceptable, but reduced as low as practical, supervisor completes all form.
Probability Severity
Frequent Probable Occasional Remote Improbable
Catastrophic
Critical
Serious
Minor
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Table 3
SUPERVISOR’S REPORT OF ACCIDENT/INCIDENT
PART 1 – IDENTIFY (Supervisor To Complete)
Date of Occurrence Time Date Reported
Exact Location Department/Contractor
Non Injury
Injury
Occupational Illness
Property Damage
Fire
Near-Miss
Vehicle Accident
Other
PART II – PATICULAR (to complete)
Name Of Injured I / C No. Age
Designation Years of Experience Time Into Duty
Identification of Property Damage
Witness I/D NO. Designation
PART III – MEDICAL (Medical Assistant to Complete)
Nature of Injury Part of Body
Injured
No Injury Involve
First Aid Case Medical Treatment
Lost Time Injury
Disable Injury (Temporary/Permanent)
Fatality Case
Others
Remark …………………… Medical Assistant Name : Date :
PART IV – DESCRIPTION OF ACCIDENT (By Supervisor or Employee)
Narrative : Include : Who What When Where, And How Facts Are Important – Not Finding Fault
PART – SUPERVISORY OPINION (Super to Complete) I think accident might have been prevented if : ……………………………… Name : Date :
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API WATAN (M) SDN BHD
ACCIDENT/INCIDENT INVESTIGATION REPORT
1. COMPANY
2. DEPARTMENT
3. LOCATION OF INCIDENT
4. DATE OF INCIDENT 5. TIME AM PM
6. DATE OF REPORT
INJURY OR ILLNESS OTHER INCIDENTS
7. INJURED'S NAME
14. PROPERTY DAMAGE 18. NATURE OF ACCIDENT
8. PART OF BODY 9. DAYS LOST
15. NATURE OF DAMAGE
19. INCIDENT COST IF
APPLICABLE
10. NATURE OF INJURY OR ILLNESS
16. COST ESTIMATED 20. REASON REPORTING
ACTUAL
ACCIDENT
11. OBJECT/EQUIPMENT/SUBSTANCE INFLICTING HARM
17. OBJECT/EQUIPMENT/SUBSTANCE INFLICTING DMG 21. OBJECT/EQUIPMENT/
SUBSTANCE RELATED 12. OCCUPATION 13. EXPERIENCE 22. PERSON WITH MOST CONTROL OF ITEM 17
23. PERSON WITHMOST
CONTROL OF ITEM 21
EVALUATION OF LOSS
24. LOSS SEVERITY POTENTIAL
POTENTIAL IF
HIGH
MEDIUM
LOW
NOT CORECTED 25. PERSON WITH MOST CONTROL OF ITEM 21
HIGH
MEDIUM
LOW
26. DESCRIBE HOW THE EVENT OCCURRED
27. IMMEDIATED CAUSES: WHAT SUBSTANDARD ACTIONS AND CONDITION CAUSES OR COULDCAUSES THE EVENT?
28. BASIS CAUSE: WHAT SPECIFIC PERSONAL OR JOB FACTORS CAUSED OR COULD CAUSE THIS EVENT? CHECK ON BACK EXPLAIN HERE.
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1.16 “U – SEE U - ACT” PROGRAM 1.16.1 INTRODUCTION
In pursuing excellence in safety performance managing lost time injuries alone is not adequate. To achieve an accident-free work environment. It is also required to address other types of incidents which do not result in loss time and also those incidents or events that have resulted in untoward outcome. These include non lost-time injuries (N-LTI’s), near misses, unsafe acts and conditions which normally occur more frequently than lost-time incidents. Analysis of accidents at workplace have shown that a large proportion (approximately 80%) of these accidents are caused by human errors, unsafe acts or unsafe practices, while the remainder are caused by unsafe un-safe condition, machine failure and act of God. It is therefore logical to pay more attention to controlling human errors in accident/incident prevention efforts. “U-SEE U-ACT” is one a program when effectively implemented would further assist in controlling human errors in accident/incident prevention.
1.16.2 SCOPE The scope of “U-SEE U-ACT” covers mainly all work locations offices. It involves employees as well as contractors and clients, i.e. * HSE Committee * Project Team/Supervisor * HSE Personnel * Client * Sub-Contractor key personnel
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1.16.3 OBJECTIVE The objective of “U-SEE U-ACT” is to prevent workplace injuries (all types) and incidents through observation of unsafe acts and conditions and immediate corrective action taken by the observer and reporting of the observations for further long-term corrective actions and follow-up “U-SEE U-ACT” is based on the following principles:
A simple and workable safety progress that everyone can participate.
It provides useful information for HSE database which can be processed further for enhancement of our HSE performance.
It must not be punitive in nature, no names or incriminating particulars need to be mentioned in the reports submitted by the observers.
Its implementation at the work is to be coordinated by field supervisors and the HSE Committee; HSE Department will provide support, guidance and overall coordination.
Its implementation should promote TOTAL HSE awareness of the workforce and install pro-active safety attitude among the workforce.
1.16.4 THE PROCESS
“U-SEE U-ACT” is a 3-step process: STEP ONE - observation of safety hazards, namely
- UNSAFE ACTS/PRACTICES OF INDIVIDUALS AT - THE WORK SITE. - UNSAFE CONDITIONS/SITUATIONS IN THE
WORKPLACE.
STEP TWO - Correct the observed hazards immediately. The observed will take immediate corrective action. For example, if a colleague was committing an unsafe act/practice of not wearing proper protective equipment for the job. The immediate corrective actions to be taken are as follow:
1. The person concerned to wear correct protective equipment before
resume to work. Ask why the person concerned to wearing proper protective equipment, address the reasons, and suggest further follow-up actions.
STEP THREE - Report the observation.
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- Use the “U-SEE U-ACT” Observation Report Card provided.
- Describe briefly the unsafe act or unsafe condition observed. Remember: no names., etc.
- Describe the immediate corrective action (s) - Submit the report to Safety Department.
(Safety Department will compile a database of unsafe acts and unsafe conditions and will issue periodic feedback, analysis reports, etc.)
1.16.5 THE REPORT CARD
The report card is used to report the observation and corrective actions as shown in Figure 2 Attached. The cards are obtainable from the Safety Department.
1.16.6 EXAMPLE OF UNSAFE ACTS & UNSAFE CONDITIONS
A. Unsafe Acts
Operating without authority, permission
Failure to secure object, material, work piece
Operating with Unsafe Devices
Nullifying Safety Devices
Failure to warn or signal
Using Defective Equipment
Using Equipment unsafely
Taking Unsafe Position
Servicing repairing, cleaning equipment/system not rendered safe
Horseplay
Using improper tools
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B. Unsafe conditions
Inadequate Guards & Device
Inadequate Warning System
Fire & Explosion Hazards, Hazardous atmosphere
Unexpected movement hazards
Poor Housekeeping
Projection Hazards
Congestion, close clearance
Hazardous Placement or Storage
Unsafe/Defective Equipment
Hazardous Personnel attire
Inadequate Illumination or Noisy 1.16.7 CONCLUSION
“U-SEE U-ACT” is a simple process of observation for hazards, correcting them and reporting them for further action/follow-up. It is a worksite initiative which is meant for everyone to participate. It is one of the efforts that would further enhance the safety performance.
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1.17 EMERGENCY RESPONSE PLAN
1.17.1 OBJECTIVE To achieve a smooth co-ordination in the event of an emergency, employees and Sub-contractor are expected to respond to their assigned duties and responsibilities within the period of occurrence in well coordinated manner.
1.17.2 PURPOSE The emergency procedure which list all necessary details of action, communication and responsibilities are to be observed by all levels in the organization in the event of an emergency.
1.17.3 EMERGENCY
An emergency exists when there is an unexpected condition resulting in:
Explosion
Uncontrolled Fire
Radiation Leak
Rescue Requirements
Multiple Casualties
Spills The EMERGENCY SIREN will be activated at 5 seconds continuous blast with intervals of 3 seconds, subsequently followed by “mass announcement” from the security command post indicating an EMERGENCY e.g. fire, spill, dangerous occurrence etc. the siren will be activated until and when the situations is under control. The ER Commander will make a mass announcement to indicate that everything is under control and when instructed, employees/contractors will be allowed to get back to their respective work stations.
1.17.4 DUTIES & RESPONSIBILITIES All employees should be thoroughly familiar with their assigned duties and responsibilities as outline below. CO
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1.17.4.1 Emergency Response Commander
Inform the relevant authorities on cases involving Government Jurisdiction.
Ensure all teams are functional in a well and smooth coordinated manner
Report the extent of damages to client
Inform telephone operator the nature of an emergency with brief description/report
1.17.4.2 Emergency Response Coordinator – Command Post
Record brief description the nature of the emergency.
Inform all department heads regarding the emergency.
Limit Time on all telephone inquiries/communication.
Remain in place until instructed to leave by the Emergency Response Commander.
Contact Ambulance, Fire Department and Police when directed by the Emergency Response Commander.
Coordinate the sequences of the emergency with ER Commander, DCT Team, Traffic Control, First Aid Team and the departmental Floor Monitors.
1.17.4.3 Damage Control Team
DCT Team leader will take lead to fight the fire with available fire fighting equipment and will advise the ER Commander to seek external emergency help if fire is not under control.
DCT Team leader will be organize his assistants to carry out search and rescue if need arises, whereby people missing during head counts.
1.17.4.4 Plant & Service Manager/Engineer
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1.17.4.5 First Aid Emergency Service Team
Medical Assistant leads the first Aid Team.
Arrange for ambulance/emergency vehicle services.
Provide first-aid team treatment to the injured personnel.
Record and report any casualty or injury.
1.17.4.5 Security Point - Traffic Control
Man the gate to provide free access to essential services.
Control crowd in panic situation to ensure smooth movement.
Prohibit unauthorized entry.
1.17.5 YARD AND OFFICE FLOOR MONITORS
Shut off utility supply in yard and office (including gas).
Remove any obstruction along the passageway.
Assist and guide the employees/contractors/clients/visitors to safely evacuate from the yard or office and in orderly manner to assembly point.
Keep the employees/Contractors/clients/visitor remained at the assembly area point and do a headcount.
Wait calmly at the assembly point for further instruction.
1.17.6 COMMAND POST – SECURITY POINT
Manned by the ER Commander to delegate and coordinate the overall movement and logistics of the emergency situation.
The command post in the focal center for communication and progress center to update the Management.
1.17.7 PROJECT EMERGENCY RESPONSE PLAN
A specific Project Emergency Response Plan shall be developed and approved by the client prior to start of project. CO
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1.18 DISCIPLINE PROGRAM
1.18.1 PENALTY SYSTEM It has been found necessary to penalize employees should they violate any of the safety rules to ensure that the safety standards of the company are maintained and accidents kept to minimum. The unsafe acts and their respective penalties are enumerated in the attached.
1.18.2 PROCEDURE
All Safety Personnel, members of the Safety Committee and Heads of Department/Section are empowered to initiate disciplinary action against any employee found violating the company’s safety rules.
When an unsafe act is spotted, a report of the investigation shall be submitted to the Head of Safety, The Head of Safety on considering the report shall recommend appropriate penalty not exceeding the guideline to the Personnel Manager, or the Project Manager in the case of Sub-contractor employees, for necessary action.
Any fine imposed on indirect employees would be charged from their employer.
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SAFETY VIOLATION EMPLOYEES
1ST 2ND
1. Failure to use personnel protective equipment. W.W 1D.S
2. Smoking in prohibited area. 3D.S 7D.S
3. Speeding in company’s premises (15 kmh) 1D.S 3D.S
4. Carelessness and/or indifferent attitude affecting Own safety or other safety
3D.S 7D.S
5. Improper use of air, oxygen of fuel gas. 3D.S 7D.S
6. Tampering with electrical appliance or fitting 3D.S 7D.S
7. Failure to comply with ‘PERMIT-TO-WORK’ System
5D.S D.
8. Vandalism involving fire, safety or health D. -
9. Not complying with instructions pertaining to safety from superior and/or safety personnel
5D.C D.
10. Using defective lifting gear, appliance, tools or Machine.
W.W 1D.S
11. Failure to report personal injury resulting of duty W.W 1D.S
12. Using wrong or unsafe tool, or handling tool in a manner to create a safety hazard.
W.W 1D.S
13. Failure to observe fire precaution duty 3D.S 7D.S
14. Performing unauthorized Hot Work. 5D.S D.
15. Failure to remove gas hoses with or without Torch From confined space during breaks or at the end of shift
7D.S D.
16. Failure to disconnect gas hoses at lunch break ad at the end of shift.
7D.S D.
17. Failure to switch off welding machines after use 1D.S 7D.S
18. Riding on forklift truck/crane or earth moving vehicle
W.W 1D.S
19. Gross negligence of work resulting in dangerous Occurrence/serious accident and/or causing damage to Company’s property. Improper use of air , oxygen of fuel gas
D.
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SAFETY VIOLATION EMPLOYEES
1ST 2ND
20. Indifferent attitude of failure to rectify unsafe Acts/ conditions when advised by his superior of safety personnel
3D.S 7D.S
21. Violent aggression, threatening or using abusive Language or behaviour toward safety personnel and/or supervisors 7D.S D.
22. Consuming food or drink on board vessel. W.W 1D.S
23. Bringing of consuming intoxicating liquid or drug in Company’s premises. D. -
24. Using unchecked hoses, torches or lifting appliances. W.W 1D.S
25. Removing, tampering or using other’s identification tag hot work tool. D. -
26. Littering W.W 1D.S
27. Failure to disconnect plug of electrical hand tool during breaks and at the end of shift. W.W 1D.S
28. Horseplay W.W 1D.S
29. Creating health hazard D -
30. Other safety violation
Note Upon 3rd violation of the same offence, “Dismissal” action would be institute
against the employee and “Bar” for indirect employee should the word dismissal or bar not spelt out earlier on.
Key W.W - Written Warning
D.S - Day Suspension D. - Dismissal
* - To be determined by the HSE Manager or the Chairman of HSE committee.
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1.18.2 MAJOR OFFENCES The safety courses conducted for all employees were designed not only to educate them in all matters pertaining to Safety and Health but also in particular to bring to their attention the hazards in the normal daily operations and to highlight safe practices at work place. The effectiveness and success of the courses would only be achieved through the co-operation and good attitude of each employee. To ensure that every individual plays their role, the following shall be classified as Major offences and the consequences of any breach shall be disciplinary action which may lead to a dismissal. a) Working without personal protective equipment b) Unsafe use of ladder or platform c) Working under suspended load d) Smoking in prohibited area e) Failure to take fire precaution f) Tampering with electrical appliances g) Improper use of compressed air h) Evidence of horseplay i) Using obvious unsafe electrical equipment j) Failure to remove hazardous material e.g. thinner, paints etc. k) Improper grinding l) Improper eye protection m) Ineffective ventilation n) Failure to remove gas hoses from confined space during meal
breaks or at the end of shift o) Failure to comply with Permit: To-Work-System
1.18.3 DRUG AND ALCOHOL
It is the policy of the company that stern disciplinary action including dismissal will be taken against any employees found consuming and/or distributing drugs/intoxicating beverages in the company premises. In addition, drug abusers will be referred to the local police.
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1.19 PERSONAL PROTECTIVE EQUIPMENTS (PPE)
1.19.1 CLOTHING
Suitable clothing such as coveralls, long trousers and shirts must be worn whilst in the yard.
Shorts and sleeveless T-shirt are not permitted.
Cotton clothing is preferred than synthetic clothing in preventing accumulation of electric static charges, especially entry in flammable atmosphere.
Personnel carrying out hot work shall ensure that their skin areas are covered by appropriate clothing to prevent burns from sparks and splatter.
1.19.2 SAFETY HATS (SIRIM APPROVED TYPE OR EQUAL)
It is the Company’s policy and a condition of employment that all employees and contractors labour shall wear approved safety helmets when in the safety Helmet area.
The Safety Helmet Area are all worksites bounded by the perimeter fence of the Fabrication Yard and other sites indicated by “SAFETY Helmet” signboards.
Any employee who fails to wear safety helmet in the Safety Helmet are other than when reporting for work or returning home and at the end of shift, and during meal breaks will be disciplined as stipulated in the Penalty Systems. The wearing of aluminium helmet in the yard is strictly prohibited.
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1.19.3 SAFETY SHOES (SIRIM APPROVED TYPE OR EQUAL) To prevent injuries to the feet caused by protruding or falling objects, all employees whilst in the yard shall wear approved safety shoe. Safety shoes are issued to direct employees under the following conditions:
To issue a pair of safety shoes to each direct employee upon his date of commencement of employment.
Contractor’s shall ensure that all their agents and employees wear safety shoes before entering the yard.
1.19.4 EYE PROTECTION (SIRIM APPROVED TYPE OR EQUAL)
To prevent eye injuries in processes where flying particle are evolved, employees shall wear approved eye protection.
To provide a pair of safety spectacles with side shields to each direct employee upon the date of commencement of their employment. Employees who are wearing prescription glasses will be issued with clip-on side guard.
Subsequent pairs will only be provided if the former pair has been damaged without any fault on the part of the employee.
Lenses, which have pitted, blurred or damaged as a result of normal use shall be replace without cost to the employee.
Employees who left the employment with the Company shall return the safety spectacles or clip-on safety lenses to the Store on the last day of their employment.
Contractors shall provide safety spectacles/clip on side guard to all their employees or agents upon their commencement of employment.
Employees engaged in other traces which may require the use of specific eye protective equipment shall obtain them on a loan basis form the Store.
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1.19.5 HEARING PROTECTION In the event that continuous noise in a work place cannot be reduced to a safe level by engineering means, all employees working therein shall wear approved ear plugs. Ear plug are issued are direct employees under the following conditions:
To issue every employee upon their commencement of employment.
Every employee must wear ear plugs in areas designated as “Hearing Protection Area“.
Contractors shall provide ear plugs (same quality to the one used by yard employee) to all their employees or agents upon their commencement of employment. A record of their employees/agents issued with the ear plug be kept and made readily available for inspection by members of the Safety Committee or Safety Section.
In areas where the sound pressure exceeds 98 Dba, Ear muffs should be worn over the ear plugs. Ear muffs are obtainable from the Store on a loan basis.
1.19.6 SAFETY HARNESS (SIRIM APPROVED TYPE OR EQUAL)
It is mandatory that every employee shall wear approved safety harness while working aloft on any project where there is a risk of falling a distance of 2 meters or more. Safety harness will be issued to direct employees under the following conditions:
Safety harness shall be printed with the employee’s badge number at the side with suitable marker for easy identification.
User shall submit the safety harness for a 6-monthly inspection by a competent person nominated by the Management.
Contractors shall provide safety harness (of same quality as yard) to all their agents or employees in accordance with the company’s safety requirement.
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1.19.7 SAFETY GLOVE (SIRIM APPROVED TYPE OR EQUAL) Glove will prevent many minor injuries wear them whenever practicable.
When carryout weld work.
When handling rope.
When handling rope or other relatively sooth surfaced material.
When working on electrical work on an energized circuit.
When handling chemical.
Specific glove shall be used when handling acids, alkalis or other chemicals.
When handling steam hose, extremely cold material such as dry ice, liquid nitrogen.
When conducting steam piping work.
1.19.8 RESPIRATORS (SIRIM APPROVED TYPE OR EQUAL)
When working in an atmosphere contaminated with harmful substances such as dust, fog, mist, gas, smoke, vapor and fume.
When working in dusty areas for protection against toxic dust.
When carrying out painting work for protection against specific gases.
Use canister gas masks for protection against specific gases.
In oxygen deficient atmosphere (less than 19% oxygen), air-line respirator or self- contained breathing apparatus shall be worn. It is recommended to use positive pressure self-contained breathing apparatus. CO
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1.20 HOUSEKEEPING
1.20.1 GENERAL It is the policy of the company to keep its premises in a clean and organized workplace at all times and it shall be the responsibility of each supervisor to maintain daily good housekeeping at work sites under his supervision. Good housekeeping breeds good morale, good workmanship and reduction of common accidents.
1.20.2 RULES
Personnel should not leave equipment of any kind along the passageway even though it is for a short period of time owing to its potential tripping hazard.
Differences of floor elevations in aisles should be indicated clearly and where necessary, handrails should be erected.
All work floors including scaffold platforms shall be kept free of loose materials.
Areas around machines should be kept clear of obstruction and in a non- slippery condition. All spilled oil, grease or any liquid shall be removed immediately.
Access must always be free of obstruction especially to emergency equipment such as fire fighting equipment, first aid boxes, control levers and electric control switches.
Aisle lines draw on the floor in workshop shall be repainted often enough to ensure their visibility and such lines must be obser
All protruding nails must be removed from all scrap wood or be bent over.
All lighting fixture should be cleaned.
Loose materials, objects or waste will not be allow to be deposited along foot-path, on top of machines, lockers, etc. No needless accumulation of scrap or old parts will be tolerated. It should be disposed into the trash bin provided.
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Hoses and cables shall not be allowed to criss-crossed over one another but neatly hung or laid as far as practicable.
Clean up after any work; ensure that all tools, equipment and supplies are stored in a safe manner.
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1.21 PERSONAL CONDUCT It is responsibility of every employee to perform duties in a safe manner. Personnel shall be observed the following requirements:
Follow all safe practices rules and regulations when in the yard.
Maintain an active interest in all Safety Programs initiated by the company. Give undivided attention to on-the-job safety discussion conducted by the supervisor in charge.
Always be alert to high risk and hazardous conditions. Where feasible. Correct or eliminate an obvious hazard alone, otherwise, report it promptly to supervisor.
Never attempt to do a job alone when common sense and safe working practice tell you that assistance is needed.
Exercise extra care whilst walking or moving around the work area so as to avoid slipping, tripping or falling.
Beware of falling objects. Always keep and handle materials with care.
Never leave tools or other materials on scaffolds or other elevations where they may dislodge and fall.
Never throw tools, materials, or equipment up or down from one working level to another. Such articles shall be sent up or down by means of a rope or by some other safe practice method.
1.21.1 COMMUNICATION
The following are highly significant in accident prevention: Report promptly to duty supervisor detail of any significant incident (near miss) that did not result in personal injury or property damage but could do so if it should occur again.
To inform the duty supervisor upon leaving to perform work in an isolated area, the approximate time expected to return.
Use of walkie-talkie.
Name tag system whichever is suitable.
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1.21.2 PROHIBITIONS Smoking shall be prohibited at work sites in the yard.
1.21.3 NARCOTICS OR ILLEGAL DRUG
All personnel (employees, contractors and any person) are prohibited from using, possessing, transporting or selling narcotics, illegal drugs or drug paraphernalia while they are on company premises.
Personnel who are taking prescribed medication shall report the fact to the supervisor in charge.
1.21.4 ALCOHOL AND FIREARMS
All personnel (Employee, contractors and other third party) are prohibited form Consuming, possessing, transporting, or selling intoxicating beverages firearms or other offensive weapon, unless specifically authorized by the management. This rule also applies to personnel while they are on company’s business, operating or on company’s transport.
All personnel are prohibited from reporting to work under the influence of intoxicating beverages or drugs. If personnel must use a prescribed medication or controlled substance by the medical officer, it must be reported to the supervisor in charge.
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1.22 EMPLOYEE INDUCTION AND TRAINING
1.22.1 HSE TRAINING AND EDUCATION HSE induction will be given to each new employee on the day of commencement of employment. The induction should be conducted to aid the employee in becoming familiar with the company’s safety program, rules and regulations. The induction course should cover the following areas:
Company’s HSE Policy and Rules
Legal Requirement
Employee’s Responsibilities
Construction hazards
Personal Protective Equipment
Medical Facilities
Restricted Areas
Unsafe Act/Condition Reporting
Working over water
Response to injury and Other Emergencies
Fire-fighting Equipment 1.22.2 CIDB AND PETRONAS OGSP, BOSIET AND/OR STCW (95)
API WATAN will make arrangements for CIDB Induction, Petronas OGSP, BOSIET and/or STCW 95 as/when required. CO
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1.23 FIRE PREVENTION AND FIRE FIGHTING EQUIPMENT
It is a recognized fact that in order for a fire to start, three components (heat, air and Fuel) must be presented at the same time. i. Since these three components play a key role in the yard work
activities, it is the responsibility of every supervisor to take all reasonable steps to control their effect.
One of the most common causes of an unwanted fire is poor housekeeping. Allowing accumulations of trash and other waste materials in locations where there is a possible ignition source. Some basic rules can help to prevent this from occurring are:
Suitable containers shall be provided for waste materials and these containers regularly emptied and contents properly disposed.
Paints, thinners, oil and grease shall be store in well ventilated areas and away from any ignition source. Flammable liquids shall be kept in suitable containers and only handle in safe areas.
Oily or paint soaked rag shall be placed in metal containers.
Rags shall not be placed near engine exhausts or other sources of ignition.
ii. The planning and implementation of safety measure are necessary
for the prevention and extinction of fire on any structure and machine under construction or undergoing repair. To ensure that fire is put out immediately, the following procedures shall be complied with:-
Adequate fire extinguishers shall be conspicuously located by the Safety Section at all Strategic areas so that they are within the reach of the employees in the event of a fire.
The Safety Section shall conduct and keep a record of routine checks on all fire extinguishers to ensure that they are in good working order. All inspection and maintenance must be carried out in accordance with manufacturers specifications, and be carried out and recorded by a trained person.
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All employees, as far as possible, in the Company shall be trained in the use of portable fire extinguishers.
The identification of the various types of portable fire extinguishers use in the Company are as follow :-
Type of Fire Extinguisher Identification
Dry Chemical Light Blue
Carbon Dioxide Black Foam Beige Water Red
iii. Recharge
Extinguisher must be recharged after use, and only with the manufacturers recommended chemical. Chemicals must never be mixed as this can damage the extinguisher and create a safety hazard.
iv. Fire Fighting Training Employees will be provided with training in the use of fire equipment and accepted techniques in fire management in fire management. The training will be provided through in house courses or at recognized training schools.
iv. For Laying up of ships API WATAN shall operate accordingly to industry best practice and As agreed by ship/vessel owners and as per Class recommendations.
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1.24 NOISE CONTROL
1.24.1 NOISE EXPOSURE Sound/noise level within all facilities shall be measured to determine whether or not the noise levels exceed 85 dB. In location where a high noise level is identified, access to that area shall be posted with standard hearing protection symbol.
1.24.2 HEARING PROTECTION EQUIPMENT Suitable ear plugs and/or muffs are available from the store. Supervisory staffs are responsible for ensuring that hearing protection is worn in noisy areas.
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1.25 STANDARDIZED SAFETY SIGN The use standardized pictogram signage using symbols in place of words for safety signs is to overcome the difficulty in communicating with employees who speak different local languages. Common safety symbols to warn employees to avoid danger, hazards or take precautionary measure would be used in the yard. All employees including the sub-contractors would be briefed during the Safety Orientation Course on the caption of each symbol. In addition, all employees would display a large board with all the various safety signs near the yard’s main entrance for easy reference. SYMBOL FOR FIRE EXTINGUISHER
Indicate location of fire extinguisher
Use the extinguisher in case of fire SYMBOL FOR FLXED CO² FIRE FIGHTING SYSTEM
Found on marine vessels
Do not tamper with the control valves SYMBOL FOR NOISY AREA
Warn person to wear ear-plug to prevent noise-induced deafness.
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SYMBOL FOR SUSPENDED LOAD
Keep away from suspended load… SYMBOL FOR RADIATION HAZARD
Entry prohibited SYMBOL FOR TOXIC AND POISONOUS SUDSTANCE
Keep away from the site. SYMBOL FOR ELECTRICAL HAZARD
Warning of electrical hazard from high voltages.
Only authorized personnel from Electrical Section.
Is allow to work on or near such hazards.
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SYMBOL FOR EMERGENCY EXIT
Indicating the escape route.
SYMBOL FOR WEARING OF HARD HAT
Compulsory wearing of hard hats.
SYMBOL FOR “NO ENTRY”
Entry is not allow…
SYMBOL FOR EXPLOSIVE SUBSTANCE
Warning against explosion hazards.
No smoking and naked lights allowed…. COPYRIG
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SYMBOL FOR “NO NAKED LIGHT “
Prevention of fire and explosion.
Storage of flammable substance.
Spray painting in progress. SYMBOL FOR “HIGHLY FLAMMABLE SUBSTANCE “
Warning for potential fire and explosion hazard.
Use on substance with flash point below 66 Degrees C
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1.26 VISITOR AND SUPPLIER SAFETY 1.26.1 OBJECTIVE
To ensure that all visitors/suppliers wear suitable personal protective equipment before entering yard Safety Zone.
To ensure that all equipment brought in by visitors/supplies is in good state of maintenance with all the required safety features such as guard, emergency cut-out devices or breaks, etc are in place.
To ensure that all visitors/supplies to with Transerve safety rules and regulations.
To ensure that all visitors/supplies do not intrude into the restricted zone of the yard.
1.26.2 PROCEDURE ON VISITOR/SUPPLIER ENTERING THE YARD
All visitors and suppliers entering the shall report to the Security Department for registration.
Safety personal in-charge shall check the safety shoes and safety hat with chin strip are by the visitor/supplier before allowing them to enter the Safety Zone.
Company official when entering restricted zone must accompany Visitors/suppliers.
Safety personnel shall check the personal protective equipment to ensure that all such equipments in good condition.
Safety personal shall brief all visitors/suppliers on the basic safety requirement including the emergency evacuation procedure before they are allowed to enter the “Safety Zone“ of the yard.
On accomplishing their purpose of visit, the visitor must report to security post to sign-out. CO
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1.26.3 CONTRACTORS OR SUPPLIERS GOING ON BOARD LAY UP VESSELS
Contractors or suppliers going on board lay- up vessels; shall attend basic safety induction and to record their personal particulars in the log book. Any requirement by ship/vessel owner must be communicated in advance.
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1.27 OCCUPATIONAL HEALTH 1.27.1 FIRST PRINCIPLES
In order to full fill responsibilities for the health and safety to personnel in their charge, all managers who may visit or be involved at construction sites will receive training in the fundamentals of occupational health. Managers, in conjunction with applicable Business Unit Safety Department, must ensure the following requirements are met: a) All work locations are to be assessed for potential occupational
health hazards. b) Personnel expected to work in conditions where possible health
hazards have been identified must be informed and properly trained to avoid exposure to and risk to their health.
c) In areas of potential health hazard at work, regular monitoring is to
be carried out to ensure that the possible risk to health is within Company limits of acceptability.
d) Hazard Data Sheets must be provided to cover every aspect of
operations involving dangerous substances, with instruction on handling, storage, use disposal and emergency treatment for exposure provided for each substance.
e) Personnel should be continually updated on occupational health
matters relating to their jobs.
1.27.2 OCCUPATIONAL HEALTH SURVEILLANCE Occupational Health Surveillance of personnel shall include; a) Pre-employment medical personnel b) Annual medical examination of:
Paint Sprayers and Blasters
Appointed Breathing Apparatus Operators
Crane Drivers (to include cardio-pulmonary examination) c) Annual medical examination of all employee and subcontractor
food handlers.
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1.27.3 DRUG AND ALCOHOL ABUSE The management of the company has determined that the presence of prohibited drugs and alcohol threatens its goals of safe and efficient business environment. Therefore:- a. Alcoholic beverages and drinks are prohibited on all Transerve
facilities, plants and offices. Drugs other than those which have been medically prescribed or are publicly available patent medicines are prohibited at or on any Transerve Facility.
b. From time to time, random tests may be asked of all employees.
Employees can not refuse these drug tests. While focus is on prevention, the company’s Management expressly preserves confidentially and the individual rights of its employees. Drug and Alcohol Screening In order to ensure that all employees engaged with company are free from drug and alcohol abuse, API WATAN shall conduct Drug Screen Test before they are allow to with API WATAN. Random DNA shall also be conducted as and when necessary.
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1.27.4 FIRST AND MEDICAL WELFARE Suitable provision shall be made for the effective treatment of injured and ill persons: a) Appointment of a designated medical officer, medical facilities and
evacuation program consistent with Company Policy will be carried out at each manned by a qualified medic, responsible to the Site Safety Officer for:
b) All construction jobsites shall provide first aid treatment centres in
cases where nearby medical facilities are not available, each manned by a qualified medic, responsible to the Site Safety Officer for:
Records of all first aid medical treatment given at the medical centre.
First aid kits sited at key points throughout the site under control of qualified First Aiders.
Sterile eye wash facilities to be provided and maintained in proximity to eye hazard location.
Control and accountability of all medical equipment and suppliers.
Coordination with all Foremen and Supervisors to initiate First Report of Injury / Accident.
Coordinated training and activities of First Aiders.
Routine site medical inspections by governmental inspectors and or the local Company Medical Officer as applicable.
c) Emergency procedures to be implemented for recovering injured or
ill. Person from remote of difficult parts of the site, including those working at height.
d) Emergency procedures to be implemented for dealing with serious
injury or emergency which may require a doctor, ambulance or hospital facilities.
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e) Environmental health monitoring of areas of operation to include noise surveys and surveys for control of substance hazardous to health.
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1.28 MEDICAL FACILITIES AND FIRST AID
1.28.1 FIRST AID TREATMENT Medical records have proved that minor injuries if not treated immediately, can lead to complication of even be fatal. Employees must seek first aid treatment from the Company’s Clinic during office hours should they fall sick of sustain minor injuries. Treatment after office hours shall be available from the Safety Office and the Security Post where First Aid Boxes are located. The contents of the First Aid Boxes shall be in the charge of the Medical Assistant who shall also be responsible for inspecting it once a month.
1.28.2 AMBULANCE SERVICE There may arise occasion when sick of injured workers may have to be conveyed immediately to a hospital or any other equipped medical centre. To facilitate this purpose in the event of an emergency, the person to contact is the Head of Safety or the Medical Assistant. This person will then arrange for the sick/injured to be transported to the nearest hospital. He will use any of the following mode of transportation depending on which is the most appropriate. The Company’s ambulance will always be on standby to transport the sick or the injured employee. Ambulance service is also available from the following source: - Safety Office Tel. No. : Panel Doctor Tel. No. : First Aid Center Tel. No. :
1.28.3 MEDICAL ASSISTANT In order to meet the Production targets, it is necessary for a bulk of the workforce to be recalled to work on Sundays and Public Holidays. On such occasions the service of a Medical Assistant would be on call. In the event that the Medical Assistant is not available, the Safety Section shall be called upon to assist.
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1.29 SAFETY PROMOTION PROGRAM The formulation of this procedure is to ensure that safety promotion activities to arouse and maintain safety interest amongst the employees including the sub-contractors are carried out as planned. The Company strongly believes that the maintenance of a high degree of safety consciousness would ultimately meet the common objective of the Company in achieving high productivity without losses through down-time in accidents or equipment damage. To realize the objective, the Head of Safety shall initiate appropriate safety activities to stimulate employee’s interest in working safely and observing all Company’s safety rules and regulations to prevent themselves and others from injuries. Such activities could be held once in every six months or on a project basis with the aim of controlling specific hazards associated with those projects.
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1.30 SAFETY AUDIT 1.30.1 HSE AUDIT
The safety audit is a technique for monitoring and evaluating the effectiveness of health and safety programs with the intent of identifying both the deficiencies requiring corrective action and the positive aspects of a program requiring commendation. The Company upon instruction from the client shall nominate or appoint an independent auditor to conduct the Health, Safety and Environment audit in the organization. A copy of the auditor’s report including the recommendations, if any, shall be extended to the client. All deficiencies identified shall be rectified without delay.
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1.31 JOB SAFETY ANALYSIS 1.31.1 INTRODUCTION
Job Safety Analysis can make a given job safe as humanly possible by finding hazards and eliminating or minimizing those hazards before the job is preformed and before those hazards have a chance to become an accident.
1.31.2 INSTRUCTIONS FOR COMPLETING JOB SAFETY ANALYSIS FORM Set priorities for doing JSA’s: jobs that have a history of many accidents, jobs that have produced disabling injuries, jobs with high potential for disabling injury or death. Supervisor in-charge shall carry out job safety analysis and know to workers. On completion, it should be reviewed and endorsed by the Head of Department or Project Manager. The JSA shall be completed at least one day in advance before the actual work is executed.
1.31.3 ANALYSIS GUIDELINE Identify the hazards associated with each step. Examine each step to find and identify hazard-action conditions and all possibilities that could lead to an accident. It is not enough to look at the obvious hazards. It is also important to look at the entire environment and discover every conceivable hazard that might exist. Be sure to list health as well, even though the harmful effect may not be immediate. A good example is the harmful effect of inhaling a solvent or chemical dust over a long period of time. It is important to list all hazards that contribute to accidents, injuries and occupational illness.
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In order to do part three of a JSA effectively, you must identify potential and existing hazards. That’s why it’s important to distinguish between a hazard, an accident and an injury. Each of these terms has a specific meaning: HAZARD - A potential danger. Oil on the floor is a hazard. ACCIDENT - An unintended happening that may result in injury,
loss or damage. Slipping on oil is an accident. INJURY - The result of an accident. A sprained wrist from a fall
would be an injury.
1.31.4 RECOMMENDED ACTION PROCEDURE Using the first two columns as a guide, decide what actions are necessary to eliminate or minimize the hazards that could lead to an accident, injury, or occupational illness. List recommended safe operation procedures on the form, and also list required or recommended personal protective equipment for each step of the job. Give a recommended action or procedure for every hazard. If the hazard is a serious one, it should be corrected immediately. The JSA should then be changed to reflect the new conditions.
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SECTION 2
SAFE WORK PRACTICES AND PROCEDURES
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2.1 CONFINED SPACE ENTRY
2.1.1 INTRODUCTION The objective of this procedure is to prevent fire, explosion, asphyxia and other health hazards to personnel who are required to enter/work in a confined space. Compliance with the safe operations and precautionary measures for entry and hot-work is a primary responsibility for every employee concerned.
2.1.2 SCOPE Any individual or group of workers required to conduct any activity in a confined space must obtain a permit prior to entry.
2.1.3 DEFINITIONS
2.1.3.1 Confined Space Any space where natural light and/or air movement is restricted. (There is risk of oxygen deficiency or accumulation of toxic and/or flammable gases that are hazardous to life and health).
2.1.3.2 Residue Material or substances accumulated for a certain period of time, normally found on tank bottom when disturbed may gives off toxic and/or flammable gases, such as sludge, scale or deposits which may be potentially hazardous.
2.1.3.3 Hazardous Fumes Toxic residues from chemical process and/or welding operations.
2.1.3.4 Inert Gases Gases which have a characteristic of displacing oxygen from a confined spaces. CO
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2.1.3.5 Lack of Oxygen Lack of oxygen may be due to chemical reaction or the introduction of inert gases into a confined space. The normal concentration of oxygen should be 21%.
2.1.3.6 Hot-work Any activity that creates sparks or heat is considered hot-work such as welding, grinding, flame cutting and sparks from any electrical equipment.
2.1.3.7 Permit Applicant
Site supervisor in charge of the work force who will execute and mandate the flow of work (Company or Contractor employee), authorized as permit signatories and has received specific training in the Company’s PTW System.
2.1.3.8 Approval Signatory The safety officer of elected subordinate (Company Employee) authorized as approval signatory. Who has to visit the worksite, and be satisfied that all precautions have been implemented and agreed that the specific work is considered safe to proceed with.
2.1.3.9 Authorizing Signatory Company Authorized Gas Tester (AGT) A person able to use oxygen/combustible gas meter. He is authorized to carry out gas test, interpret the results, monitor conditions during work progress and stop the work and evacuate personnel in the event of any suspected deterioration of work conditions.
2.1.3.10 Non-hazardous Entry Condition Applies to confined spaces which have been determined to be safe for entry, positively isolated, depressurized, drained, cleaned, vented and have minimum oxygen contents of 20% but not more than 21%.
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2.1.3.11 Hazardous Entry Condition Applies to entry into confined spaces which have not been established as “Gas Free” and been positively isolated, depressurized and drained but do not have minimum oxygen contents of 20%, or are suspected to contain hazardous fumes or residues or in excess of 21% oxygen or having combustible gases of greater than 4% L.E.L.
2.1.4 RESPONSIBILITY The responsibilities for safety during entry/occupation of a confined space lie with the authorizing signatory and the Project Manager/Engineers who manage the project.
2.1.5 SAFETY PRECAUTIONS
Combustibles/burnable materials in way of hot-work shall be either removed or protected from the effect of the hot-work.
Regeneration of gas due to open pipes or other connections between clean and dirty tank should be recognized and guarded against.
Contaminated air shall be removed by suction, and where required, use explosion-proof type of equipment.
Discharge outlets of ventilating equipment must be so arranged that fume and vapor is discharged to the outside atmosphere only and cannot drift into other parts or areas where it can create a hazard.
Pipes on which work shall be performed should be isolated by sealing off interconnecting pipe lines, or by closing and securing the valves.
Water tanks are subjected to the accumulation of explosive methane (Marsh) gas from the decomposition of organic materials in stagnant water.
No person shall be assigned to work in any tank or compartment until it is assured that all valves leading to the space to the worked on are shut, locked and tagged.
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No person shall be allowed to perform work in any closed or poorly ventilated space, even though it is certified gas-free, without fire-watch and forced ventilation.
Personnel working inside tank or compartment who experience difficulties in breathing shall be removed to fresh air immediately, and the condition of the work area rechecked especially for the presence of toxic gases and fumes.
All gas hoses must be removed from confine spare/tanks/engine room/control rooms during rest breaks, changing shift, and after completion of the day’s work.
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2.2 PERMIT-TO-WORK SYSTEM The promulgation of this system is to ensure that all work which adversely affect the safety and health of employees shall be controlled and executed under close supervision by responsible supervisor in-charge. The types of works that require a permit are categorized below: - 1. Heavy lifting (50 tons and above) and/or use of multiple cranes 2. Work in confined Space 3. Radiography Work 4. Painting and Abrasive Blasting 5. Chemical Cleaning
2.2.1 PERMIT APPLICATION
Permit applicant must clearly filled-up the permit form. It should be specific and precise when describing the (exact) locations and nature of the work in order to prevent ambiguity.
2.2.2 SAFETY CHECKLIST Positive measures in making the working conditions safe should always be ensured by means of strict supervision. A list of safety requirements are included in the permit which shall be checked on an individual basis by the authorizing signatory.
2.2.3 GAS TESTING Type of gas test is specified by the approval signatory. Company’s authorized gas tester shall implement the specified test, results, time and date taken shall be recorded into permit form.
2.2.4 APPROVAL FOR ENTRY Specified parties must acknowledge and sign in the appropriate space provided. Authorised entrants will be trained according to industry best Practice.
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2.2.5 PERMIT SUSPENSION/RE-VALIDATION The permit shall be suspended immediately, when an emergency or unsafe condition occurred. Stop all work, recall individuals to come up particularly those working in confined spaces, and return the permit to the originator. Note: A permit can be invalid due to: i) Unable to commence work within one hour upon approval of
permit. ii) Unsafe condition (e.g. ventilation failure) iii) The work being interrupt for any reason.
2.2.6 VALIDITY A permit is valid for one shift period unless it is renewed. The frequency of monitoring and gas testing shall be decided by the approval signatory.
2.2.7 RENEWAL When renewing the permit, the confined space involved shall be tested and certified “Gas Free” by the Company’s A.G.T before allowing work to commence.
2.2.8 DISTRIBUTION The permit in quadruplicate must be distributed as follows: Original Copy - To be retained by Permit Applicant. 1st Copy - To be displayed at worksite. 2nd Copy - To be retained by Project Manager/Engineer. 3rd Copy - To be retained by Safety Officer.
2.2.9 COMPLETION OF WORK The permit applicant and approval signatory (Project Manager/Engineer/Superintendent) should satisfy themselves that all tools, scrap and waste are removed form the confined space, and that it is left clean and ready for next work activities. When all the relevant parties on the job are satisfied, the permit applicant shall endorse stage V of the permit and submit it to the approval signatory. At the same time he shall also notify the safety personnel in-charge.
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2.3 LOCK-OUT AND TAG-OUT PROCEDURES 2.3.1 OBJECTIVE
The aim of tag-out system is to prevent personal injuries or damage to property where work is to be carried out on or near remote controlled systems or on equipment connected to energized or pressurized lines.
2.3.2 APPLICATION The tag-out system applies to work on or near equipment which are electrically, pneumatically, hydraulically or mechanically powered and pressurized lines/vessels.
2.3.3 RESPONSIBILITY The Line Supervisor in-charge shall be responsible in ensuring that before the commencement of the work, the system is depressurized and de-energized and all relevant remote controlled switches, valves, levers, etc. are in “off” position, securely locked and tagged in compliance with the following requirement. a) Notify the Project Engineer, Safety Officer and the client with the
use of the attached “Tag-out & Lock-out Notification” before depressurized/de-energized the system.
The tag as shown below shall be duly completed and endorsed by the Supervisor in-charge before attaching it to the remote switches, valves, levers, etc. which has been rendered inoperative by means of chain or any other suitable devices together with the standard locks and tags.
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No one is allowed to remove the tag or lock except the person whose name appeared on the tag. On completion of the work, the supervisor in-charge shall complete Part II of the “Tag-out & lock-out Notification” and submit it to the Project Engineer. At the same time he shall also inform the Safety Officer on the job completed.
EQUIPMENT
LOCKED OUT BY
_________________
_________________
_________________
DATE___________
BAHAYA
DANGER
THIS TAG & LOCK
TO BE REMOVED
ONLY BY PERSON
SHOWN ON BACK
SIDE A SIDE B
BAHAYA DANGER
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TAG-OUT & LOCK-OUT NOTIFICATION
Part I Location : ___________________________________________________ Type of System : ___________________________________________________ Work Details : ___________________________________________________ ___________________________________________________ ___________________________________________________ Duration -Date : ___________________________________________________ -Time : From __________ am/pm To __________ am/pm Name : __________________ Date : __________________ (Supervisor In-charge) Approved/Not Approved by, Name : __________________ Date : __________________ (Project Engineer)
Part II
The above job was completed on ____________________________ and all tags & locks removed. The system is ready for testing/operation. Name : __________________ Date : __________________ (Supervisor In-charge)
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2.4 LIFTING, RIGGING AND HEAVY LIFTING PROCEDURE 2.4.1 LIFTING APPLIANCE
Lifting appliances in our yard are used periodically to move or align heavy item and it is important that they are of good construction, adequate strength and should be properly maintained. To avoid any mishap arising from poor communication in the upkeep of lifting appliances, the following procedures shall be followed closely.
The heavy lifting engineer/supervisor and the Safety Section shall keep a record of all lifting appliances in the yard and all certificates.
Before placed in service, the Plant & Service Section shall arrange for the lifting appliances to be thoroughly inspected and tested.
The lifting appliances should also be thoroughly inspected at least once in every twelve (12) months by the Plant & Services Section. On completion of the inspection, a copy of the inspection record shall be deposited with the Safety Section.
The Safety Section and Supervisors in-charge shall make periodic checks of lifting appliances to ensure that they are in good working order. Faulty lifting appliances should be removed from use and sent for repair or be replaced.
The heavy lifting engineer/supervisor in-charge shall ensure that the lifting appliances are provided with means of identification and marked with its safe working load.
User to check all kind appliances prior to use on every occasion.
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2.4.2 QUARTERLY INSPECTION OF LIFTING GEAR The promulgation of this procedure is to ensure that all lifting gear such as sling, shackles and lifting clamps in use in the yard are regularly inspected to assure that deterioration due to wear and tear are within the allowable limits for safe lifting. 2.4.2.1 Procedure
a) All lifting gear before being placed in service shall be
examined and tested by the manufacture. Original certificates of such tests shall be kept by the Plant & Services Section who in turn duplicates a copy each to the Safety Section.
b) The engineer/supervisor in-charge shall maintain a
quarterly inspection record card for each of the lifting gears used in the yard. The record cards shall be made readily available for inspection by the yard Manager, Safety Officer or the OSH Inspector.
c) All lifting gear shall be serialized by the
engineer/supervisor in-charge. A metal tag such as a sleeve will be used to indicate the serial number, date first placed in service and Safe Working load on a conspicuous place of the lifting gear. For slings, its length, diameter and classification shall also be shown on the tag.
d) All inspected lifting gears that are found to be in good
working condition shall be color coded with at least 3-inch band of paints as follows:
Period Color 1st Quarter Blue 2nd Quarter White 3rd Quarter Green Last Quarter Yellow
e) Lifting gears that are damaged shall be sent for
immediate repair or replacement.
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2.4.3 HEAVY LIFTING (50 TONS AND ABOVE) The promulgation of this procedure is to ensure that all heavy lifting operations are planned and carried out safely. As cranes are generally used in the operation, adherence with the following minimum requirement is mandatory: a. The Engineer/Supervisor in-charge of crane shall notify Safety
Section by completing the forms as shown in the attached of their intended heavy lifting operation at least one week in advance.
b. In the notification, the Heavy Lifting Engineer/Supervisor in-charge
shall sketch out the route of the lifting operation with due consideration of obstruction in way. If possible, the obstruction is removed.
c. Upon receipt of the notification from the Engineer/Supervisor in-
charge, the Safety Section shall ensure that the cranes designated for the operation are given a thorough inspection by a competent person.
d. Only a trained signalman is permitted to give signals and during
lifting operation, he is to serve on one crane only. e. The Supervisor in-charge of carnage shall be responsible for
ensuring that all lifting gears and equipment, such as slings, shackles, spreader bars, etc., are safe to be used in the lifting.
f. In the event that more than one crane is used, the operators and
riggers may use walkie-talkies for easy communication under the supervision of the Engineer/Supervisor in-charge or his representative.
g. Prior to lifting, a briefing on the operation should be conducted by
the Engineer/Supervisor in-charge or his representative to all personnel involved. Details of the crane movement and travel shall also be discussed.
h. During the lifting operations, all other activities within the vicinity of
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i. In the event that the lifting operation is to be carried out in darkness, the Engineer/Supervisor in-charge shall be responsible for installing adequate floodlights in the area. The floodlight shall be positioned in such a manner that glare is minimized.
j. Lifting operation during inclement weather is prohibited except in
an emergency where lives and properties may be jeopardized. k. The Engineering Department shall specify the size, type and
position of the lugs to be welded on the structure for the lifting operation.
l. The N.D.T Section shall inspect the welded lugs to ensure that
there is no welding defect prior to the lifting. m. Security personnel shall be posted to keep employees not involved
in the operation, a distance of 1 ½ times the boom length away.
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2.5 RADIOGRAPHY SAFETY
2.5.1 PURPOSE
The use of ionizing radiation in radiography has played a very important role in our yard for the inspection of welds and other articles. Despite their utility in assisting us to gain a greater insight in to the mechanism of the engineering processes, they are nevertheless a potential hazard and a danger to health if appropriate precautions are not taken in connection with their use.
5.2.2 PROCEDURES
In this connection, all radiographers must have a satisfactory knowledge of radiation safety and they shall be held accountable for the Safety of personnel in and around the radiation zone and all radioactive materials/equipment in the Company. To ensure that the necessary precautions are taken when radiography is being conducted, the following procedure shall be adhered to: i The Quality Control Section shall apply Radiography Permit to
Safety Section through the Project Engineer at least one day in advance of a scheduled radiography program.
ii Radiography work should be arranged, as far as possible, to take
place during the break periods or after office hours. iii The Radiographer shall arrange to rope off the area where
radiography is to be carried out and post standard radiation hazard symbol around the radiation zone. The boundary shall be continuously supervised while work is proceeding and darkness, warning lights shall be strategically placed.
iv The dose rate of radiation in the area where radiography is to be
carried out shall be minimized whenever possible by the use of shielding.
v Should any employee be affected by radiation, he is to be referred
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5.2.3 RADIATION PROTECTION RESPONSIBILITY
The Head of QC Section shall designate at least one Radiation Protection Supervisor who shall be qualified by training or experience and licensed to carry out the duties which include: i Insuring that all radiation works are carried out safely as per
operating procedures. ii Administration of Personnel Monitoring. iii Investigates any incident of abnormal exposure or suspected over-
exposure of personnel to determine the cause and take remedial action.
iv Safe keeping and maintenance of the radiation sources and the
equipment.
5.2.4 RADIATION SAFETY INSTRUCTIONS Radiation safety instructions, including emergency procedure in the event of radiation hazards, shall be furnished to all radiation workers. All radiographers shall undergo a training course on safety aspects of radiography with emphasis on biological effects of radiation, prior to their certification as a qualified radiographer.
5.2.5 SAFETY EQUIPMENT The following safety equipment shall be kept in good working condition at all times: a. Lead pot (with a capacity to accommodate the maximum
permissible strength of the radiation source). b. Lead sheets & lead shots. c. 1-meter tongs. d. Radiation warning signboards. e. Flashing lights. f. Nylon ropes or barrier tapes to cordon off the radiation zone.
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5.2.6 RADIATION MEASURING DEVICES The following measuring devices shall be made available in good working condition at all times: i At least two Radiation Survey Meters with capability to measure a
minimum dose rate or 0.1 ¥/hr. ii Personal Pocket Dosimeter – Individual radiographers shall have
one dosimeter each. iii Film badge to be worn by individual radiographer.
5.2.7 STORAGE OF RADIATION SOURCES
i The radioactive isotopes shall be store in appropriate projectors
and placed in an isolated storage pit. The projectors shall be checked against the maximum allowable leakage of radiation and the enclosure of the storage pit shall be inaccessible to the general public. Standard radiation warning signboard must be displayed conspicuously around the enclosure.
ii The storage pit and the enclosure must always be locked when
they are not in use. iii The names and contact telephone number of the Radiation
Protection Supervisor shall be displayed at the isotopes storage area.
iv The x-ray generator and the control unit shall be stored separately
in a safe place. v All the radiation source shall always be locked and the keys shall
be in the custody or the authorized personnel.
5.2.8 PRECAUTIONS FOR SAFE USE OF ISOTOPES
i Only authorized radiation personnel should handle the radiation source.
ii Any person engaged in radiation work must possess a film badge
which must be worn above the shirt pocket. iii All radiography equipment and accessories should be checked for
good working condition prior to their use.
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At least two survey meters must be available in good working condition during radiography work.
iv All survey meters must be calibrated once in every 12 months by
an authorized agent. v The isotope projector/container must be checked for radiation
leakage both before and after the operation. The leakage dose shall not be more than 10mR/hr at 1 foot distance from the surface of the container.
vi Transportation of isotopes is restricted to the location of
radiography work and storage pit. vii The source projector must always be locked and stored inside the
storage pit
5.2.9 SAFETY EQUIPMENT
i Before carrying out the radiography work, information regarding the location and extent of radiation restricted zone shall be given to the Safety Section and other Section affected by the radiography work.
ii The radiation zone shall be cordoned off along the safe distance
boundary by using nylon ropes or barrier tapes and adequate radiation warning signboards must be conspicuously displayed around the radiation zone. (Refer to attachment I) The safe distance shall be calculated using the formula: Safe distance = Specific X-ray Constant x Source activity x 1000Max. Permissible dose rate The Maximum permissible dose rate = 0.25mR/hr (for Public)
iii During the exposure, the cordoned area shall be checked for any
excess radiation outside the radiation barrier with a survey meter. The radiographer shall check the radiation level at all boundaries and will not exceed the maximum level of 2.5mR/hr for classified workers and 0.25mR/hr from non classified workers.
iv During darkness, radiation warning lights must be posted along the
radiation barrier.
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v No person other than the radiographers shall remain within the restricted zone. Prior to starting the exposure, radiographers must ensure that the radiation zone is cleared from other personnel.
vi During the time of exposure, the radiographers shall remain
outside the radiation barrier and invigilate the area in order to caution anybody approaching the radiation zone.
vii When X-ray machine is used for radiography, as far as practicable
the X-ray head shall be directed towards the ground. viii Radiographers must always remember the three basic factors;
adequate shielding, shortest operating time and being away from the source during the exposure.
ix Upon completion of the exposure, the source projector must be
checked for safe return of the isotope and for any excess radiation leakage around the projector with the use of a survey meter, the projector must be locked when the exposure is not taking place.
x All the equipment and accessories must be returned to the
appropriate storage area after the usage. xi The details of the projector, source serial number, date, time and
the identification of the job where radiography was carried out etc. shall be recorded in log book for each use of the radiation source.
5.2.10 MAXIMUM PERMISSIBLE LEAKAGE DOSE
i The exposure at any accessible and occupied area at one foot
from the outside surface of the enclosure shall not exceed 100mR in any one hour.
ii The exposure at any accessible and normally unoccupied area at
one foot from the outside surface of the enclosure shall not exceed 100mR in any one hour.
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5.2.11 PERSONNEL MONITORING DURING THE RADIOGRAPHY WORK
i Any individual engaged in radiation work must have a film badge and a pocket dosimeter.
ii Radiographers must ensure that the radiation zone is free from
other personnel prior to the starting of exposure. iii As far as practicable, the radiographers must remain far away from
the source and make use of the available shielding materials during exposure.
iv If any person happens to enter the radiation zone accidentally, the
incident must be reported to the Radiation Supervisor and Safety Section for further action.
v Should any radiographer be suspected of over-exposure or
accidental exposure to radiation, the film badge/dosimeter concerned shall be evaluated and the person investigated further.
5.2.12 PERSONNEL MONITORING RECORDS AND FILM BADGE SERVICE
i All persons engaged in radiation work must be registered with the
local Radiation Protection Inspectorate. Sub-contractor shall comply with the AELB licensing requirement.
ii The film badge shall be evaluated at least once a month and the
dose recorded individuals maintained in a file. iii The pocket dosimeter readings of individual radiographers shall be
recorded weekly and the dosage of radiographers are within the allowable range.
iv All radiographers must undergo medical examination once in a
year which includes the Blood test, and the results shall be recorded in a file.
v No person under the age of 18 shall be engaged in radiation work.
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5.2.13 EMERGENCY PROCEDURE FOR RADIATION ACCIDENT
In field radiography, accident may take place due to: i Accident dropping of radiation source during exposure. ii Malfunctioning of the source projector or control box. iii Source cannot be retrieved after exposure. In such cases, the following procedures must be followed by the radiographer. i The radiation zone must be cordoned off immediately in all
directions using the nylon rope (put up warning sign, flashing light). The exposure outside this zone shall be checked with a survey meter (not to exceed 0.25mR/hr). No person shall be allowed to enter this zone.
ii Report any incident immediately.
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2.6 WELDING SAFETY Welding is an inherently hazardous operation, however with adequate safety precautions in place and due care observed by all employees, there need be no danger to the health and safety of the welders or any other person. 2.6.1 HAZARDS
An understanding of the potential hazards common to moist types of welding is essential.
Injury to eyes and skin from infra red or ultra violet light.
Burns to skin or eyes from contact with hot molten metal or sparks.
Harmful physiological effects from breathing fumes or gases.
Shocks from electrical current.
2.6.2 CONTROLLING WELDING HAZARDS Welding hazards are controlled by using proper ventilation methods, adequate personal protective equipment such as respirators, welding shield, gloves, etc and adhering to safe work practices.
2.6.3 CLOTHING Both the welder and his assistant must wear adequate protective clothing including eye protection, helmets, and hand-shields will be determined by the nature of the task.
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2.7 SCAFFOLDING AS PER BS 1139 In the event that work at a height cannot be safely reached from a ladder or other means, suitable scaffold must be provided. For work involving the use of scaffolding, the following shall be complied with in respect of their use: i The scaffold for projects when being erected by independent contractors
shall be supervised by the Plant and Safety Department. ii The materials used for the erection scaffold shall be provided by the
Company. iii All scaffold materials and component must have the certificates of origin
(country and manufacturer) and should meet the standard stipulated in the Chinese standard or equal.
iv The Safety Department to ensure that the timber for use in the
construction of platform is scaffolding grade. v All scaffold materials prior to acceptance by the Company shall be
inspected by the Scaffold Inspector to ensure in particular: i) That the materials are sound; ii) That it is adequate for the purpose for which it is to be used. This is to ensure that sub-standard materials are not used in the yard.
vi Scaffolding should not be constructed, taken down or substantially altered
except under the direction of the Scaffold Inspector and by competent workers possessing adequate experience in this kind of work.
vii Scaffold after use shall be dismantled from top downwards. They should
not be thrown from heights or pulled down with the use of a crane. viii The Scaffold Supervisor shall ensure that barrier tape and appropriate
signs to warn employees shall be displayed around scaffold around scaffold under construction or dismantling. Supervisors of other trades should also ensure that their subordinates are kept away from the area.
ix All dismantled scaffold materials should be inspected by the Staging
Supervisor before sending them to the designated storage area. CO
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2.7.1 PLANK All planks for the construction of platforms shall be scaffold grade. The plank shall not be less than 225mm (9-inch) in width and 37mm (1.1½) in thickness. The Scaffold Inspector shall be notified to carry out Load Test at the “Inspection Bay” to insure that they are scaffold grade Quality.
2.7.2 STORAGE
All scaffold planks that are not in use shall be stored above the ground and protected by a well ventilated shed against direct sunlight and rain.
The planks shall be neatly stacked in horizontal position to prevent warping.
2.7.3 LOAD TEST
All planks taken down from a scaffold shall be sent to the “Inspection Bay” near the Stagers’ site for inspection and testing. The Load Test shall be conducted as shown in the sketch below: -
1 (Test Load)
\
2
\
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2.7.3.1 Load Test Of Plank
Dimension of Plank
Distance Between Support (x)
Test Load (F)
37 x 225 x 2400mm 1800mm 400kg
37 x 225 x 3000mm 2400mm 350kg
37 x 225 x 3600mm 3000mm 300kg
2.7.4 PAINTING
Scaffold planks shall not be coated with any paint that may conceal defects. Paint is only allowed at the ends for identification purpose.
2.7.5 SUPPORT SPAN In the construction of work platform, the span between supports for standard Kapur Plank (250mm width x 37mm thickness) shall not exceed 1800mm (6ft). The plank shall overhang the last supports between 50mm (2-inch) and 150mm (6-inch).
2.7.6 THE WIRE Tie wire shall be annealed wire of 3.25mm in diameter. It shall not be used in place of couplers for metal scaffolding except for lashing platform planks and toe-boards. After securing, the pointed ends of the wires shall be bent downwards to prevent injury.
2.7.7 GUARD RAILS Tubular pipe guardrails shall be provided on all open-sides of the platform except the side facing the structure where work is to be done. The height of the guardrails which must be secured with couplers onto the standard should be about 1050mm (42-inch) from the platform. In addition, a mid rail should also be provided at midpoint between the toe board and the guardrails.
2.7.8 PLATFORM Usually two planks (250mm width x 37mm thickness each) is the minimum requirement for a working platform. The planks should be boarded together as closely as possible but not to exceed a gap of 25mm (1-inch).
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2.7.9 BASE PLATE Adjustable base plate of at least 150mm square and 6mm in thickness shall be provided on each standard. Should the surface of the ground be unstable, wooden plank may be used as sole plate to distribute the load of the scaffold.
2.7.10 BASIC SAFETY REQUIREMENT FOR ERECTION
i The erection of steel scaffold shall be in accordance with the
Manufacturer’s recommendations. ii Ensure that the soil is capable of withstanding the total weight of
the scaffold. Should the ground be undulating, adjustable base plates and sole plates shall be used.
iii Ensure that the loads and weight of the scaffold is transferred
down to the ground by the vertical standards. iv Double couplers shall be used for all connections which are load
bearing. All nuts must be tightened sufficiently. v Sleeve couplers shall be used for end-to-end joining of all
horizontal tubes. vi Steel ladders for access shall be properly erected inside the
scaffold and at every 30ft length, a landing platform is provided. The ladder should protrude at least 1m above the stepping-off point.
vii The Scaffold Inspector and the Scaffold Supervisor shall inspect all
scaffolds in the yard at least once a week. viii Line supervisor shall conduct daily inspection of those scaffolds
under their charge. ix Only staging personnel is permitted to alter, extend or dismantle
any scaffold. x For general purpose independent tie scaffold, the tying-in to the
structure shall be at an interval of not more than every two lifts vertically and 6m horizontally.
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xi General purpose independent tie scaffold shall not exceed 45m in height and the maximum number of work platform permitted is four.
xii In free standing scaffold, the height shall not exceed 3 times the
width of the base. xiii Spirit level gauge shall be used to ensure that the standards are
vertical and the ledgers or transoms horizontal during erection. xiv As far as practicable, Steel Stair Tower shall be used for access to
the various levels of work platforms. Should it be used, it must be placed firmly and vertically on flat ground with adequate soil bearing load. Timber and steel plates may be used as sole plate to distribute the load if necessary. The upper part of the Stair Tower shall be properly secured to strong structure by suitable means.
2.7.11 OTHER SAFETY REQUIREMENT
i All Scaffolders must be properly attired, i.e. wearing close fitting
overalls or other acceptable work suits without loose ends. It is also mandatory that they wear safety hat with chin-straps, safety belts, safety shoes and safety spectacles.
ii Scaffold Supervisor must ensure that the scaffolders are provided
with tool pouches for carrying the necessary tools at side of waists. iii No person under the age of 18 years shall be engaged as a
scaffolder. iv The Company would provide adequate training to upgrade the
skills of Scaffold Supervisor, Scaffold Inspector and Scaffolders. v The construction of the lower level of a completed scaffold should
be in a manner that all protruding members are above a man’s height.
vi Excess scaffold materials must not be left on the completed
scaffold but must be brought down and returned to the respective storage areas.
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2.7.12 HANDOVER SCAFFOLD TO USE
The Scaffold Supervisor shall notify the Scaffold Inspector to inspect any newly completed scaffold and verify that they are safe for use. On completion of the inspection with the Scaffold Supervisor, the Scaffold Inspector finding that it is safe for use should complete all the information requested on the scaffold-tag before endorsing on the space provided. Scaffold is then handed over to the user who would be responsible for its safe use and care.
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SCAFFOLD INSPECTION TAG
SCAFFOLD TAG LOCATION : _____________________________ DATE ERECTED : _____________________________ REQUESTED BY : _____________________________ BUILT BY : _____________________________
SCAFFOLD FOREMAN
SIGNATURE : ___________________________________
SCAFFOLD CLADD
VERY LIGHT DUTY GENERAL PURPOSE HEAVY DUTY
SCAFFOLD INSPECTION (SCAFFOLD INSPECTOR)
DATE SIGNATURE
________________________________________ ________________________________________ ________________________________________ ________________________________________ ________________________________________ ________________________________________ ________________________________________
FRONT VIEW
BACK VIEW
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WEEKLY SCAFFOLD INSPECTION
Location of/Scaffold : ____________________________________________________ Erected By : ____________________________________________________ (Name of Staff/Sub-contract) Date Erected : ____________________________________________________ Examined By : ____________________________________________________ ____________________________________________________ ____________________________________________________ Date Examined : ____________________________________________________
CHECK LIST Remarks
Sole Plate (Safe) (Unsafe)
Standard (Safe) (Unsafe)
Ladder (Safe) (Unsafe)
Transoms (Safe) (Unsafe)
Cross Brace (Safe) (Unsafe)
Planking And (Safe) (Unsafe)
Support Span (Safe) (Unsafe)
Couplers (Safe) (Unsafe)
Tie-In (Safe) (Unsafe)
Guard rail (Safe) (Unsafe)
Mid-rail (Safe) (Unsafe)
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2.8 LAUNCHING AND LOADOUT PROCEDURE The implementation of this procedure is to avoid any mishap and to ensure that the functions of the various sections involved in the launching or load out are properly coordinated. 2.8.1 OVERALL RESPONSIBILITY FOR LAUNCHING AND LOAD-OUT
The Project Engineer/Superintendent in-charge shall be responsible for co-ordination both the launching and load out activities. The Project Engineer/Superintendent shall be the authorized person to set the time of launching or load out. The Project Engineer/Superintendent shall seek the assistance from any other person if necessary.
2.8.2 PRIOR TO LAUNCHING AND LOAD-OUT The Project Engineer/Superintendent shall: i Inform the Sections concerned on the date and time of the
launching or load out in advance. ii Inspect the launch-ways/load out skids and the arrangement
together with the Safety Officer to assure that no defects are present for the intended purpose.
iii Ensure that the relevant local authorities are informed and
permission is granted for launching or load out. iv Obtain written confirmation form surveyor/owner to launch or load
out the structure. v Ensure that the structure is free from all loose objects.
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2.8.3 BEFORE AND AFTER LAUNCHING/LOADOUT
i Maintenance/Yard Services Superintendent shall also be responsible for directing the movements of the tug/s, which are involved, in the launching or load out; and crew shall only take instruction from him.
ii The Plant and Services Superintendent shall direct the tug/s to
move the launched vessel or loaded out structure to be berthed as arranged.
iii Safety Department shall issue identification cards to personnel
who are involved in the launching/load out operation. The identification card should be worn visibly at the shirt pocket.
iv Safety Department shall cordon-off the display of appropriate
safety signboards to warn others.
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2.9 PNEUMATIC AND HYDROSTATIC TESTING Pneumatic and hydrostatic testing of pipes of pipes or tanks if conducted in the absence of safety precautions can result in accident. To ensure that there is proper co-ordination between the various trades in the event of pipe or tank testing, the following precautions should be observed: i The Supervisor in-charge of the testing operation shall complete the
Permit-to-work form and submit it to the Project Manager/Engineer/Superintendent and Safety Department for endorsement and approval.
ii Before commencing testing operations, a physical check of the pipe or
tank should be conducted by the Supervisor overseeing the test or a person designated by him to ensure that no one is inside the pipe or tank and all outlet valves shut. “NO ENTRY” signs should be prominently placed at strategic locations leading to the test site.
iii In hydrostatic or pneumatic testing, the pressure gauges and safety
release valves used in the testing should be checked by a competent person to ensure that they are in good working order.
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2.10 HOSE TESTING In order to prevent fires and explosion due to the leakage of oxygen or fuel gas from twin-hose, the procedure for the testing of Company’s and contractors’ hoses have been formulated and shall be complied with:
All contractors should conduct their own daily inspection of twin-hoses and regulators for leaks. In addition, they are required to send their torches, gas hoses, regulators and fittings to a designated location identified by Safety Department for testing once in every month. The sub-contractors shall carry out leak test in the presence of the Safety Personnel and any leak shall be rectified immediately. On completion of the test, they shall be colour coded, tagged and serialized. A record of the test conducted will be retained by the Safety Department.
The Plant to assist them with the testing.
Any contractor who fails to send their hoses for testing by the due dates will be penalized.
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2.11 SAFE USE OF HANDTOOLS
MACHINE GUARD
Guards are for protection against injury, keep them in place at all times when equipment is being used.
Manual cleaning, oiling, repairing or adjusting must never be done when the machinery is in motion.
The power supply must be switched off and the plug removed from the source.
PORTABLE GRINDER
Report immediately any grinding wheel guard that appears to be defective.
Never use a grinder disc without both the guard and your eye protection in place.
Operate grinder only at the manufacturer’s recommended speed.
Ring test the grinder disc or wheel and check that the speed rating exceed that of the grinder.
HAMMERS
Cracked or split handles should be replaced immediately.
Hammer head should be securely wedged to the handle.
Do not use a hammer with its head chipped, mushroomed or badly worn. CHISELS
Burred and mushroomed chisel heads should not be used. They must be dressed or replaced.
When using chisels for chipping, always wear eye protection. CO
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SPANNERS
Do not use splayed open spanners or those which have shown sign of splitting.
Check wrench or adjustable spanner adjuster for free play. JACKS
Use only jacks with the stated rated capacity load enough for the job.
Always set the jack on solid footing to prevent sinking or slip.
The handle should be removed when not in use to prevent accidental turning the locking devices.
FILES
Do not use a file without a handle because a slip or knock may cause the tong to pierce the palm.
The handle should be smooth and crack-free.
Do not use a file for prying or levering as it is made of brittle metal.
When working on a lathe machine, do not wrap rag or cloth around the files handle which could get entangled in the revolving parts.
SCREW DRIVERS
Do not hold the work piece in the hand when using the screw drivers to prevent the edge or the tip pierce the palm of your hand or fingers when it slipped with excessive force.
Handles that are split must be replaced.
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2.12 ABRASIVE CUTTING AND GRINDING 2.12.1 BASIC SAFETY The following basic safety rules shall be observed when using abrasive wheel
grinding machines:
Operation of a grinder is considered a hot-work. Thus appropriate work permit must be obtained before it is used in restricted areas.
Proper personal protective equipment shall be worn during grinding work, such as safety spectacles and face shield.
Do not wear gloves when using bench grinders as they can be caught between the grinder and stopper.
Do not use any type of grinding machines unless you are familiar with the equipment.
A grinding machine shall not be operated without a protective guard. Check the position and security of the guard. Replace guard which is damaged.
Do not operate the abrasive wheel in excess of its rated maximum speed before operating.
2.12.2 SAFE OPERATION
Do not apply excessive pressure on the grinders when grinding.
When using a portable grinder ensure that sparks are not directed towards other employees or combustible. Fire blankets shall be used to contain the sparks.
Keep a safe distance from others while grinding.
Switch off and disconnect the power supply to the machine before making any necessary adjustments or corrections.
Do not use an abrasive wheel that has imperfection in it or the wheel is slightly chipped.
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2.13 EARTHING FOR ELECTRICAL EQUIPMENT AND TOOLS Each year in the industries, several fatalities or serious accidents due to contact with Live wires or electrical equipment of not only 380V or higher than but also as low as 220V was reported. Although electrical equipment and tools of voltage below 30V are generally considered safe to the human body, they can cause fire when short circuited and may result in serious personal injuries and damage to properties. To prevent fatal electrical shock and equipment damage by short circuit, the following minimum safety requirements are set forth for compliance by all employees: 2.13.1 EARTHING
All electrical equipment and tools except double-insulated tools, shall be properly grounded to the electrode conductor with resistance of not more than one (1).
2.13.2 FLEXIBLE CORD
i The flexible cords for electrical equipment and tools shall be the double-insulation types. The size of the wires shall be in consistent with the intended voltage and wattage used.
ii Under no circumstances shall the flexible cords be used as a
substitute for fixed wiring.
iii Flexible cords should not run through any opening with sharp edges, or wrapped round pipes or other support.
iv Flexible cords shall be kept dry and free from oil and grease.
v The flexible cords must be inspected daily by the workman
concerned before commencing work. It should also be inspected at least once a week by the Supervisor in-charge for any visible deterioration.
vi The standard color code for electrical wire are as follows:
Brown - Live Blue - Neutral Yellow & Green - Earth
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2.13.3 FUSE
Fuse of unknown capacity must not be used.
The installation and replacement of fuse shall only be carried out by electrician.
2.13.4 PLUG
Only approved types of 3-pin plugs are permitted to be used in the Company.
When installing the plug onto the flexible cord, the cord grip must be tightened to prevent slipping.
2.13.5 GENERAL PRECAUTION
Do not wear wrist watch, ring, bracelet or loose clothing while working with electrical equipment or tools. Shoes and clothing should be as dry as possible.
Treat all electrical wires as ‘live’ until it is positively proven by way of testing with volt-tester.
Do not allow oil, solvent or water to drop or seep into the electrical equipment or tools.
Before using the electrical equipment or tools, check for visual defects such as damage insulation, casing, wire, plug, etc. prior to inserting the plug into the receptacle.
Report to your supervisor in-charge immediately should the electrical equipment to tools is found faulty.
Do not touch any of the electrical wires to test your body resistance against current.
Do not attempt to repair or service any electrical equipment or tools by yourself. Leave them to the electrician.
When the electrical equipment or tools is not in use, switch off the power supply and remove the plug from the socket.
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The use of multiple-socket is prohibited in the Yard.
Do not use electrical equipment or tools in or near hazardous areas such as flammable storage areas, newly painted confined space or places where flammable gas is present.
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2.14 HANDLING AND USE OF COMPRESSED GASES AND CYLINDERS
2.14.1 GENERAL PRECAUTIONS IN HANDLING AND STORAGE
To avoid explosion or damaged to gas cylinders, it is necessary that they be stored, used and maintained in the manner as stated below:
The Store Section shall store fuel and oxygen gas cylinders separately. Cylinders which are filled shall not be store together with those that are empty.
The Project Supervisors shall ensure that all cylinders are stored and used in upright position and properly secured in a rack to prevent them from falling.
The Steel Fabrication Section shall fabricate and maintain an adequate number of racks to meet the yard’s requirement.
Never drop cylinders or permit them to strike each other violently.
Cylinders should be assigned a definite area for storage. The area should be dry, cool, well-ventilated and preferably fire-resistant. Keep cylinders protected from excessive temperature rise by storing them at least 5m away from sources of heat.
The valve protection cap should be left in place when the cylinder is not in transported of emptied.
Never tamper with the safety devices in the valves or cylinders.
When returning empty cylinders, close the valves before shipment, leaving some positive pressures in the cylinder. Mark or label the cylinder EMPTY. Do not store full and empty cylinders together.
No part of a cylinder should be subjected to a temperature higher than 12.5F. A flame or electric are should never be permitted to come in contact with any part of a compressed gas cylinder. Temperatures in excess of 12.5F may cause a cylinder to become liquid full and create dangerous hydrostatic pressures.
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2.14.1 CARE IN THE USE OF GAS CYLINDERS
Never lift a gas cylinder by the cap, and don’t use magnets either. Handle cylinders with chains or with ropes only when the cylinder rack has lugs sturdy enough for the purpose.
They should not be dropped from one level to another, nor used as work supports of rollers.
They should not be allowed to come into contact with electrical apparatus or live wires.
Oxygen cylinders, valves, regulators, hoses and fittings must be kept free of oil or grease.
Safe handling procedure and proper usage of gas cylinders set down be the manufacturer must be complied with.
When the gas cylinder is not in use, the valve must be shut to prevent gas leaks.
Always use gases in areas where adequate ventilation is provided.
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2.15 SAFE USE OF FORKLIFT TRUCK
FORKLIFT TRUCKS Forklift trucks are frequently used in the yard for handling various types of materials. Though they are indispensable machine, they present numerous hazards that require the exercise of alertness, care and common sense.
SAFE WORK STANDARD
Only qualified Forklift Operator is allowed to operate a forklift truck.
Report unsafe floor or road conditions, as defective flooring is a major cause of accidents involving material handling by forklift trucks.
Avoid overloading or overfilling racks or bins used for storage. Piling of material too high will cause them to tip of fall.
Remove all obstruction that is protruding into aisles or passageways.
A careful check should be made by each forklift operator at the start of operation to be certain that brakes, horn, clutch, steering mechanism etc. are in good working order, defective equipment should be reported without delay. Never operate faulty equipment.
When moving highly flammable, toxic, corrosive or other hazardous materials, be certain that all personnel are cleared from the exposed area and that other necessary precautions are taken.
The truck must be equipped with overhead protection such as canopy guard when operating in areas where there may be danger form falling objects.
Trucks capable of lifting load higher than the operator’s head should always be installed with overhead guards.
Special care should be taken when carrying or placing material near electric wiring, lights, pipes and other fragile or dangerous equipment. CO
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CAPACITY AND STABILITY
All forklift capacities are rated by the manufacturers and under no circumstances should this capacity be exceeded.
The capacity is defined by given weight with the centre of gravity at a longitudinal distance from the face of the fork. It is stated as a maximum weight at a maximum load centre.
A forklift truck with a rated capacity of 4000lbs at 24” load centre will be able to carry only 3200lbs at 30” load centre:
Rated Weight x Rated Distance 4000 x 24 -------------------------------------- = -------------- = 3200lbs New Distance 30
Load Centres will vary with different types of material and are based on the assumption that there is always an even weight distribution although in reality this is not always the case. The following values of any material must be established.
a) Weight - normally stated on the material or on its
supporting document. - ensure that it is within the forklift truck’s
capacity. b) Load Centre - requires physical measurement of sound judgment gain through experience. - observe maximum rated load by manufacturer. c) The reaction of the load has to be watched when the initial lift is
made and the tipping forward or to either side gives a definite indication as to the position of its centre of gravity. The forklift truck has to be repositioned accordingly to achieve a stable load.
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The following factors affect the forklift truck stability: i) Forward Stability
Failing to insert the forks fully under the load.
Tilting the mast forward during travel.
Moving down an incline with load first.
Travelling with an elevated load, making sudden stops and operating on uneven surface.
ii) Sideward Stability
Long length cargo not centrally positioned.
Travelling with fully extended mast and negotiating a turn at excessive speed.
Unequal weight distribution and unleveled position of the forklift truck.
FORKLIFT TRUCK OPERATORS 1. Driving Rules
a) Operator should wear safety shoes and safety hat. Hands must be kept dry and clean.
b) Start and stop trucks gradually and slowly. Always look around before starting. Sudden stops are for emergency only. Avoid quick turns. Always drive at moderate speed.
c) Drive the truck with the forks between 2” and 6” from the ground and parallel to the ground.
d) Permit no passenger on the truck or on its forks. Do not use forklift trucks for any purpose other than transporting materials.
e) Sound the horn at exits, corners, lifts and when approaching other people at work: i) The horn should be used only as a warning device. ii) Several short blasts should be given. iii) Sounding of the horn does not give automatic right of
way.
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f) Always look in the direction of travelling particularly when starting from rest.
g) Care must be taken to watch the rear end swing of the truck, especially in confined areas.
h) Load materials so that they will not fall in transit. i) Do not permit any part of the load to obstruct vision when
driving. j) Tie down or bind the load if necessary. Avoid top heavy or
unbalanced loads. k) When moving heavy objects, do not load beyond the
capacity of the truck. l) Always start unloading with the top pieces. Avoid pulling
pieces out from the bottom. m) Do not descend steep ramps with a heavy load at the front
of the truck. The load might shift. It is preferable to back down such surface.
n) Do not park on a ramp or other inclined surface unless absolutely necessary in which case set the parking brake and chock the wheels.
o) Return the trucks to its proper storage place at the end of each shift.
p) Forklift trucks should never be left unattended unless parked as follows: i) Clear of doorways, vehicles and fire fighting
equipment. ii) Power off. iii) Control set in neutral position. iv) Brake on. v) Forks fully lowered and level. vi) Wheel chocked if on an incline.
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2.16 FOOD SAFETY AND SANITATION
Flow of Food Food Handling Practices
Purchasing 1.Buy food from reputable vendors, grocery or wet markets 2. Check “use by” dates to purchase the fresh foods. 3. Place frozen foods in a cooler during transporting. 4. Place fresh meats in separate hold from ready to eat food.
Receiving 1. Store foods immediately. 2. Avoid cross contamination. 3. Keep receiving area clean.
Storing 1. Record delivery/purchase date on food. 2. Use oldest food first (FIFO). 3. Avoid cross contamination. 4. Store chemicals away from food. 5. Maintain proper refrigerator, freezer and dry storage temperatures.
Preparing 1. Wash hands frequently, properly and at appropriate times. 2. Avoid cross-contaminations. 3. Keep food out of the “temperature danger zone” (41oF – 135oF) 4. Prepare food no further in advance than necessary. 5. Thaw food properly.
Cooking 1. Avoid cross-contamination. 2. Use a clean food thermometer. 3. Cook food to the proper initial temperature for appropriate time Without interruptions. 4. Record internal temperature.
Serving and holding
1. Avoid cross – contamination. 2. Hold food at proper temperature, either below 41oF or more Than 135oF. 3. Record internal temperatures. 4. Monitor the temperature of hot or cold holding equipment. 5. Follow rules for good personal hygiene. 6. Maintain sanitary food service operations.
Cooling 1. Chill rapidly. 2. Stir frequently. 3. Use shallow pre-chilled pan. 4. Record internal temperatures. 5. Store appropriately.
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2.17 KITCHEN SAFETY
Prevention of burns and fires
Use dry pot holders when handling hot items.
Do no leave pot holders near a hot burner.
Turn handles of pans so they don’t stick out over the edge of the range or over other burners.
Always lift the lids of saucepans away from the body o that the steam will not burn us.
Do not reach across hot burners or lit gas burners across.
Keep a fire extinguisher in or near the kitchen and know how o use it.
It there is a grease fire, immediately put the lid on the pan. If doesn’t work, smother the fire with salt, baking soda, sand or a fire extinguisher.
When finishing cooking, make sure all oven and range buttons or dials are turned off.
Avoiding falls
Wipe up spills immediately.
Pick-up objects from middle of the floor or from any traffic area.
Use a sturdy step stool or ladder o reach high places.
Be sure all floor mats or rugs have a non-skid back.
Avoid dangling electrical cords from appliances to wall connections.
Check for wear of shoe soles.
Make sure that cupboard or drawer left open or pulled out.
Use the right detergent for floor cleaning.
Cuts prevention
Always pick-up a knife by its handle.
Always slice, dice, chop, cut or dice food on a cutting board.
Wash sharp knives separately. Do not simply drop knives into the dish water.
Always cut food with the blade of the knife down and slanting away from the body.
Never put your fingers near the moving part of an electric mixer, food processor, blender or garbage disposal (macerator).
Be careful when discarding broken glasses. Do not pick-up pieces with bare hands. Sweep the larger pieces into a dust pan. Use a wet paper towel to pick-up smaller pieces.
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SECTION 3
ENVIRONMENTAL CONTROLS
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3.1 HAZARDOUS MATERIAL MANAGEMENT Many hazardous materials are used in industry. Employees using these materials are responsible for knowing the hazards they pose and how to handle the materials as carefully as possible. If for any reason the employee is unsure about any aspect of handling the hazardous material, he should refer to the Material Safety Data Sheet for further information. 3.1.1 MATERIAL SAFETY DATA SHEET (MSDS)
Material Safety Data Sheet information is an important element of the information system and is intended to supplement the “alert” information provided on the warning labels (supplier and workplace), for the safe use of controlled material. The Material Safety Data Sheet shall include the following categories:
a) Product Information Must include product identifiers,
manufacturer and supplier names, addresses and emergency phone numbers.
b) Hazardous Ingredients A list of ingredients for the material as required by the Government’s Regulations.
c) Physical Data Parameters that physically describe the product such as physical state, color, odor, boiling point, etc.
d) Fire and Explosion Hazard Characteristics of the substance which determine the ignition conditions, and the information of the best method of extinguishments.
e) Reactivity Data Information regarding the chemical stability of the product and other chemicals with it may react.
f) Toxicological Data Information on how the product is likely to enter the body and the short term (acute) and long term (chronic) health effects of exposure to it. CO
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g) Preventive Measures Personal protective equipment requirements, handling procedures, and engineering controls to be used during the shipping, storage, use and disposal of the product, and the procedures to use in an emergency.
h) First Aid Measures Specific first aid measures to be used relative to the acute effects of over exposure to the product.
i) Preparation Information Identification of the persons who prepared the M.S.D.S and when it was prepared.
3.1.2 LABELING AND INFORMATION
All containers with hazardous chemicals have labels indicating the contents and warning to the hazard.
Necessary information on safe handling and first aid measures is given on the label or as written instructions.
Workers dealing with hazardous chemicals must be trained in handling and avoiding health risk.
Training should include safe storage and transportation of chemicals.
3.1.3 TECHNICAL MEASURES
Whenever possible, chemical with the least toxicity should be used.
During work processes, minimize the emission of gases, vapors, dusts or fumes.
The source of emission of gases or vapors is completely enclosed.
Dust-producing machines or piles of dusty materials are isolated or enclosed as much as possible.
Work positions are chosen so that exposure to gases, vapors, dusts of fumes is minimal.
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Effective local exhaust ventilation is provided to safely extract gases, vapors, dusts or fumes.
Small portable ventilation units must be used for moving from one job site to another such as welding.
Exposure to hazardous substances is minimized.
3.1.4 PERSONAL PROTECTIVE EQUIPMENT
All necessary technical improvements must be taken before resorting to the use of personal protective equipment.
Adequate types or personal protective equipment are used:
- Helmet or head-protector
- Ear-plugs or ear-muffs
- Goggles, face shield or eye-protector
- Breathing mask
- Gloves
- Safety footwear
- Protective aprons or clothing
- Safety belt and life-line
Availability and suitability of personal protective equipment for the work being done.
Workers are trained to use personal protective equipment correctly and whenever necessary.
Personal protective equipment to be cleaned after each use.
Responsibility for overseeing the use and maintenance of personal protective equipment is clearly delegated.
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3.2 CONTROL AND USE OF HAZARDOUS CHEMICALS The promulgation of this procedure is to ensure that all chemicals (solid, liquid or gas) that are volatile, flammable, reactive, corrosive or harmful to health are controlled in the yard and used in accordance with the manufacturer’s recommendation and standard code of safe practices. 3.2.1 PROCEDURE
When procuring any hazardous chemicals, the purchasing officer shall ensure that the Material Safety Data Sheet (MSDS) issued by manufacturer be made readily available during the delivery of the product to the yard.
Security personnel manning the yard’s main entrance shall not permit entry of any hazardous chemicals into the yard unless it is accompanied with the MSDS.
Security personnel shall notify the Store Supervisor who will in turn direct the delivery-man to transport the hazardous chemicals to the designated storage area in the store with good ventilation and free from other incompatible substances. The Store Supervisor shall make copies of the MSDS and extend a copy each to the Project Engineer/Project Superintendent and the Safety Officer.
Sub-contractor shall not transport any hazardous chemicals into the yard unless prior written approval is obtained from the Project Manager, Project Engineer or the Project Superintendent. A copy of the MSDS shall be given to the Approval Signatory and the Safety Department. All hazardous chemicals brought into the yard by the sub-contractor shall be stored in designated area under cover with good ventilation and securely locked. Appropriate warning signs shall be displayed conspicuously around the area.
Under no circumstances shall the sub-contractor move or transfer the chemicals from the designated storage area to another location in the yard without the written approval of the Approval Signatory.
All containers in which hazardous chemicals are stored shall be labeled with standard warning signs in accordance with international accepted practice.
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A copy of the valid permit shall be conspicuously displayed at the worksite by the supervisor in-charge. The Project Engineer/Project Superintendent shall also monitor the movement of the chemicals to ensure that there is no incompatible work carried out during such activities.
Prior to handling the chemicals, the supervisor in-charge shall conduct a briefing with the workmen concerned on the hazards of the chemicals, precautionary measures to be taken and the required personal protective equipment to be worn.
Hazardous chemicals waste shall not be disposed in the yard or in refuse bin but deposited in its original container for disposal by authorized contractor.
All work activities involving the use of any hazardous chemicals shall be discussed in the toolbox meeting and only the department/section head is authorized to permit the commencement of the work.
3.2.2 CHEMICAL HEALTH RISK ASSESSMENT (CHRA) – USECHH
REGULATION 2000 Shall be conducted as and when required
3.2.3 CLASSIFICATION, PACKAGING AND LABELING (CPL) REGULATION – OSHA 1994 All hazardous chemicals handling shall be complied with the requirement of CPL Regulation.
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3.3 WASTE DISPOSAL
3.3.1 INTRODUCTION
a) Inadequate Waste Management may lead to significant environmental damage and financial liabilities. It is therefore in the interests of the Company and all employees to ensure that at all times waste is handled in a proper manner.
b) This guideline consist an introductory section comprising waste
information, an overview of Authorized Waste Disposal Legislation. The general waste minimization and the ultimate disposal methods for the various waste generated. An understanding or the problems involved in ultimate disposal of waste should enable the various Heads of Department to respond to the need for proper segregation, packaging, labeling and documentation of the wastes.
3.3.2 DEFINITIONS
a) Waste is defined as any unavoidable material resulting from an
industrial operation for which there is no economic demand and which must be disposed of. Three types of waste may be distinguisher:
i) Domestic Waste (including office and kitchen waste) ii) Hazardous Waste iii) Industrial Waste (waste, generated during industrial activity,
which is neither domestic nor hazardous). b) Hazardous Waste is defined as any liquid or solid waste which
because of its quantity, physical, chemical or infectious characteristics can result in hazards to human health and environment when improperly treated, stored, transported or disposed.
c) Waste Management refers to the identification, separation and
recording of the quantity, composition and/or nature and destination of domestic, hazardous and industrial waste including east minimization, provision for waste recovery, waste treatment and disposal.
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3.3.3 GOVERNMENT LEGISLATION The generation, handling, transportation, treatment, storage and disposal of wastes in Malaysia is governed by Legislation which are summarized below: i) The environmental quality (scheduled waste) regulation. ii) The environmental quality (prescribed premises) (facilities)
regulation. iii) The environmental quality prescribed premises (treatment disposal
facilities). The regulations define certain wastes as “scheduled wastes”, and for those are prescribe methods of storage, transport and disposal. Standards for disposal sites are set up and penalties for infringement of the legislation are identified. Documentation of all scheduled wastes and data to be returned to Department of the Environment are specified. Non-scheduled waste shall be disposed at Local Councils dumping area.
3.3.4 WASTE SEPARATION The main waste categories are ferrous metals, mixed industrial waste (which includes packing materials, rags, wood, etc.). Domestic and office waste, and specific waste such as drummed liquids or chemicals. Liquid and solid wastes should not be mixed.
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3.3.5 METHOD OF DISPOSAL 3.3.5.1 Garbage
Domestic and office waste shall be collected daily and dumped at approved dumping area.
3.3.5.2 Paint Can The paint cans shall be disposed accordance with scheduled waste guideline. It is advisable that the paint cans shall be returned to the supplier or cleaned & crushed to be sold to the metal can collector for recycling process.
3.3.5.3 Used Oil The used oil shall be disposed in accordance with scheduled waste guidelines or be kept in the oil drum and re-use for lubricating crawler cranes and tracks.
3.3.5.4 Used Copper Slag The used copper slag shall be disposed accordance with scheduled waste guidelines. Disposing of copper slag at outside the yard premises is prohibited.
3.3.5.5 Metal Scrap Metal Scrap which is generated from the yard activities shall be segregated in the scrap bin provided. It shall be transported out from the yard to the designated scrap area. The metal scrap shall be sold to a Local registered agent.
3.3.5.6 Lay-up of ships/vessels As contractors; API WATAN will follow all instructions given by ships/vessel owner. We will advise owner’s on local requirements.
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