scaffolds site safety standard btcp/btrf owner: · pdf filebtcp/btrf scaffolds (owner:...

BTCP/BTRF

Scaffolds

(Owner: Personnel Safety Section Supervisor)

Site Safety Standard No. 4130

Rev. 12, 04/16 of 31

Introduction

Scope This standard covers general safe practices that must be followed in the erection and use of scaffolds.

The regulations issued by the Occupational Safety and Health Administration (OSHA) concerning scaffolds must be followed. The additional information in this safety standard must be used as a supplement to provide safety and precautionary measures to cover unusual conditions.

References • SSS-4100, Working at Heights

• SSS-4101, Overhead Work Safety Precautions

• ATO Training Module - Scaffold User Safety

Table of Contents/

Topic See Page

Attachments Introduction 1

General Requirements 2

Guideline Steps 3

Scaffold Use/Inspection 3

Electrical Safety on Scaffolds 5

Determine if Fall Protection is Required 5

Scaffold Components and Approved Anchor Points 6

Scaffold Erection/Dismantling 7

Requirements for Specialty Scaffolds 13

Scaffold Management During Turnarounds 14

Mobile Scaffolds 16

Suspension Scaffolds 16

Tank Builder's Scaffolds 21

Attachment 1, Scaffold Use Tags 23

Attachment 2, Scaffold Inspection Tag 24

Attachment 3, Fall Protection Required Sign 25

Attachment 4, Suspension Scaffold Pre-job Safety Checklist 26

Attachment 5, Certification of Support Rigging 28

Attachment 6, 30-Day Equipment Suspension Scaffold Inspection Checklist

29

Attachment 7, Shutdown/Startup Turnaround Scaffold Tag 30

Attachment 8, Requirements for Specialty Scaffolds 31

http://ishareteam2.na.xom.com/sites/chemmbta23/Sub02/Manuals%20Central/Site%20Safety%20Standards/SSS-4000/SSS-4100.pdf


Scaffolds Site Safety Standard No. 4130

Rev. 12, 04/16 of 31

Introduction, Continued

Safety, Health and Environmental Precautions

WARNING:

IF PERSONAL FALL ARREST EQUIPMENT WITH LARGE HOOKS IS USED TO SECURE AN ANCHORAGE ON A VERTICAL MEMBER OF A SCAFFOLD, THE HOOK MUST BE RATED FOR A SIDE LOAD, OR

THE HOOK CAN DISENGAGE DURING A FALL.

Prerequisite • Anyone who will use a scaffold must have completed training. Contractors will provide their employees with equivalent training.

• Inspect all scaffold material before using. If the material is damaged or deteriorated so that it cannot be safely used or meet OSHA standards, it must be immediately removed from the job site.

General Requirements

Training Appropriate training is required for:

• Erecting/moving/adjusting/dismantling/approval of scaffolds (for scaffold builders only). Refer to Contract Exhibit G.1 for crew staffing requirements.

NOTE: A competent person is one capable of identifying existing and predictable hazards in surroundings or working conditions which are unsanitary, hazardous, or dangerous to employees and has authorization to take prompt corrective measures to eliminate them. The competent person MUST have thorough knowledge of this standard and OSHA regulations. When this term is applied to building, dismantling, modifying or the initial inspection and approval of scaffolds, a “competent” person is usually an approved scaffolding contractor.

• Use of a scaffold. Users must have completed scaffold user training and Working at Heights awareness training. ExxonMobil personnel must complete the Scaffold User WebCAT module. Contract companies are responsible for having their workers trained through a Local Safety Council and other means that meet the OSHA Scaffold User training requirements. If the scaffold requires the use of fall protection, the workers must also be trained in the use of personal fall arrest.

Work-shift inspection of scaffold.


Rev. 12, 04/16 of 31

Guideline Steps

Scaffold Use/ Inspection

All scaffolds must have two tags, one for scaffold use and one for scaffold shift inspection.

• If a Scaffold Use Tag is not present do not use the scaffold. See Attachment 1.

• If a scaffold shift inspection tag is not updated, perform the inspection prior to use. See Attachment 2.

Use the recommended Scaffold Use Tagging System to indicate stage/state of erection and use as follows. See Attachment 1.

• Green Tag: The scaffold meets all requirements of OSHA and this standard for scaffolds.

• Yellow Tag: Caution--States Unusual Conditions or Hazards. Use is permitted with extra precautions. The user is responsible to evaluate the applicable means to mitigate the hazard or condition noted. Unusual conditions or hazards could be due to scaffold configuration, congestion, uneven decking or physical hazards such as head knockers or hot lines, or scaffolds that require an anchor point independent of the scaffold.

• Red Tag: Danger--Do Not Use. The scaffold is incomplete or unsuitable for use.

NOTE: Always read the Scaffold Use Tag before climbing the scaffold to determine if hazards exist which may require you to take additional mitigation steps to protect yourself.

All platforms, porches on trailers, ramps, weight-bearing support structures and walkways built of scaffold materials are considered scaffolds and must be tagged and inspected per this standard. Hard barricades, barriers and welding hooches erected from scaffold materials are not considered to be scaffolds and do not require a scaffold use or inspection tag.

NOTE: Scaffold Use Tag and Scaffold Inspection Tag procedures apply to all scaffolds including scaffolds purchased by the Operating Unit. If a unit purchases a scaffold, they must ensure that a PM is put into the Work Order System so that the On-site Scaffold Supplier can perform the 6 month competent person inspection of the scaffold and change out damaged components as needed.


Rev. 12, 04/16 of 31

Guideline Steps, Continued

Scaffold Use/ Inspection, Continued

Use the Scaffold Shift Inspection Tagging System. The Tan Tag contains the following information. See Attachment 2.

• Latest shift inspection.

• Checklist items to be verified for shift inspection prior to use.

Scaffold Shift Inspection Tagging:

The scaffold contractor overseeing the construction must affix the initial Shift Inspection Tag. The scaffold contractor’s competent person must perform an inspection immediately after construction and sign the first shift inspection. Tags must be affixed at approximately eye height at each point of access for the scaffold. It must be located with the Scaffold Use Tag.

Step Guideline

1 Shift cursory inspection must be done by a properly trained person (i.e. person has completed Scaffold User Training).

2 Shift period is defined as 6am - 6pm, and 6pm - 6am.

3 Spot (partial area) use inspection may be done on large or complex scaffolds when the user will only use a limited section of the scaffold. This type of an inspection is good for immediate use only. This inspection may be done progressively for areas not visible from access area.

4 If the scaffold does not meet the inspection requirements, it cannot be used. The scaffold must be Red tagged and appropriate adjustments be made by a competent person before use.

5 Scaffolding must be re-inspected by a competent person (scaffold builder) when any of the following apply:

• Scaffold has been revised or modified

• Scaffold has been subjected to severe weather that could have damaged the scaffold, such as hurricanes or tornadoes

• Scaffold is damaged due to collision or overloading

• The Scaffold Use Tag is missing

• The scaffold has been up for six months (periodic inspection)

NOTE: If a Scaffold Use Tag is not present, DO NOT USE the scaffold.


Rev. 12, 04/16 of 31


Electrical Safety on Scaffolds

Step Guideline

1 Electrical tools used on scaffolds shall be equipped with Ground Fault Circuit Interrupters (GFCIs).

Scaffolds supporting any nonportable electrical equipment (e.g. equipment without shock protection as outlined above) must be grounded by a method approved by site electrical subject matter experts (contact Central I/E Power Supply Execution FLS 4-3252).

Scaffolds must not be erected, used, dismantled, altered or moved such that any conductive material handled on them might come closer to exposed and energized sources than that allowed by the limited approach distances defined in MWP-6011, Work On or Near Energized Electrical Equipment (typically 10 feet but refer to table in MWP-6011 for voltages over 50kV).

Determine if Fall Protection is Required

After the completion of the scaffold and the initial inspection by the scaffold builder competent person, a determination has to be made if fall protection is required to access and work on the scaffold. Fall protection is required If exposed to a fall hazard of 6 feet or greater and any of the following are applicable:

• There are missing handrails or mid-rails, or

• The handrails and mid-rails are not at proper height. Handrails must be between 38" and 45" from the scaffold deck. Mid-rails must be approximately halfway between the scaffold deck and the handrail, or

• Handrails are not capable of withstanding a load of at least 200 pounds applied in any direction at any point, or

• There are gaps in the decking of 12 inches or greater that have not been covered with decking materials.

If any of the above is applicable, fall protection is required and the scaffold builder will install a "Fall Protection Required" sign at the base of the scaffold near the access ladder so it is clearly visible to users and check the “Fall Protection Required on Scaffold” box on the Scaffold Use Tag. See Attachment 3.

If the scaffold has multiple decks and only one deck requires fall protection, the scaffold builder will install the "Fall Protection Required" sign at the base of the scaffold and document in the "Unusual Hazards or Conditions" section of the "Scaffold Use Tag" which deck levels require fall protection. If there is no information on the "Scaffold Use Tag" designating which deck requires fall protection, then users must assume all decks require fall protection if a "Fall Protection Required" sign is posted on the scaffold or the “Fall Protection Required on Scaffold” box is checked on the Scaffold Use Tag.

http://ishareteam2.na.xom.com/sites/chemmbta23/Sub02/Manuals%20Central/Maintenance%20Work%20Practices/MWP-6000/MWP-6011.pdf


Rev. 12, 04/16 of 31


Determine if Fall Protection is Required, Continued

If a vertical retractable lifeline is installed on a scaffold ladder, then a "Fall Protection Required" sign must also be installed and the “Fall Protection Required on Scaffold” box checked on the Scaffold Use Tag. The scaffold builder will designate on the "Scaffold Use Tag" that fall protection is required when climbing the ladder and if fall protection is required when on the scaffold deck.

NOTE: On hanging or suspended scaffolds (i.e. hanging from pipes or beams, or suspended by cables), an anchor point independent of the scaffold must be used for tie-off to protect the worker if the integrity of the scaffold is compromised. Scaffold builders will identify these types of scaffolds and the need for an independent anchor point on the Scaffold Use Tag.

Scaffold Components and Approved Anchor Points

The only scaffolding types allowed are Cuplok Type System scaffolding that meet or exceed the old SGB patent specifications, Safway System scaffolding, Excel Modular System scaffolding or Ring Lock type scaffolding. The scaffolding must be installed by trained employees in accordance with the applicable Technical Manual. Adjustable handrail components may not be used. Scaffold test data was submitted and found to be technically adequate. The selected tie-off components are provided in the following Note box.

NOTE: The following components of approved scaffolds may be used as tie-off points provided that both ends are secured with either Cuplok, Excel Modular, Ring Lock or Safway System scaffolding connections:

• Runners

• Handrails

• Vertical members and large holes in rosettes – up to 2 rings above a handrail system secured in two directions and only one person per vertical member or rosette

The following components must not be used as the tie-off points:

• Cross bracing or diagonal members

• Access/Engineers swing gate

• Swing gate support post

• Ladders and ladder brackets

• Components secured with bolted clamps

• Small holes in rosettes

• Open ends of verticals or horizontals past the last cup or rosette that would allow the hook to slide off


Rev. 12, 04/16 of 31


Scaffold Components and Approved Anchor Points, Continued

NOTE: Scaffold builders may utilize additional anchor point locations while erecting, modifying or demoing scaffolds provided that these points have been approved by their Corporate HSE group. Scaffold companies using additional anchor points must have test documentation and approval from their Corporate Office available for review at the Site.

NOTE: Workers should anchor to approved scaffold components above their heads when feasible to minimize free fall distance and swing falls. (Reference SSS-4100 for more information on fall protection.)

Scaffold Erection/ Dismantling

Step Guideline

1 All scaffolds will be erected, dismantled and revised according to OSHA standards, industry standards and manufacturer recommendations.

2 Components used on scaffolds must be designed for scaffold service. Only compatible components are allowed to be used.

3 All scaffold material must be inspected to ensure it is in serviceable condition and must not be stored in the vertical position unless they are secured. Inspection of scaffolding must occur as follows:

Scaffolding coming into the Site from outside will arrive with Written Documentation that it was inspected before arriving at the Site.

Upon arrival at the Site, scaffold shall be unloaded at a storage yard. The storage yard will have areas segregated for different components and an area with signs designated for damaged components. Before components are sent to the field they are to be visually inspected.

When material leaves the storage yard and is being erected or torn down, the scaffold builders must visually inspect each component as it is installed or demoed. Any damaged pieces are to be removed from service, flagged and segregated and sent back to the storage yard for removal from the Site.

4 No scaffold shall be erected, moved, dismantled, or altered except under the supervision of competent persons (Site-approved scaffold company).

5 Scaffold crews will have an erection/dismantling plan showing the proper erection and dismantling sequence available at the job site for reference.

6 As the scaffold is erected, install access ladders. Scaffold builders must use the ladders for accessing deck levels and must not climb the scaffold frame.



Rev. 12, 04/16 of 31


Scaffold Erection/ Dismantling, Continued

Step Guideline

7 Personal fall protection equipment must be utilized during the erection/ dismantling of scaffolds. Special erection/dismantling methods, shorter lanyards, self-retracting lanyards and/or lifelines with rope grabs may be necessary to ensure workers are protected from falls to equipment or grade below.

8 At no time can scaffold builders stand on runners, bearers or cups when erecting or dismantling scaffolds. Instead of standing on these scaffold components, worker(s) must:

Use a temporary work platform, at least 18" wide, normally consisting of two boards or metal planks placed side by side and cleated, hooked OR secured to prevent shifting during use. Upon completion of the scaffold, dismantle the temporary platform.

If a temporary platform is not feasible, then alternate methods such as personnel lifts, ladders, temporary scaffold or change in work method, etc. must be used.

Standing on structural steel or in pipe racks while erecting or dismantling scaffolds must be limited to short duration tasks where the building of a temporary work platform would expose the worker to a greater risk. Hazards and mitigation steps for these situations must be reviewed and approved with the scaffold foreman.

In all cases, 100% tie-off must be maintained when exposed to a fall hazard of 6 feet or more.

9 A Job Specific Work Plan, approved by the scaffold contractor's site management and safety department is required for hanging or suspended scaffolds. The work plan must address erection/dismantling method or sequence and precautions to ensure proper footing is available for the work crew and fall protection is maintained at all times.

10 Temporary work boards and platforms used during erection must be removed before the scaffold is tagged for use.

11 All scaffolds, regardless of height, must have a ladder or other suitable means of access. Ladder must extend at least 3 feet above the handrail. The clearance around scaffold ladders should be a minimum of:

7 inches behind the ladder for proper foot clearance

30 inches to the front and 15 inches to either side of the centerline of the ladder for adequate body clearance

3 inches from the vertical ladder side rails for hand clearance

If these minimum distances can not be maintained, a warning must be noted on the Yellow Use Scaffold Tag.


Rev. 12, 04/16 of 31



Step Guideline

12 Ladders must be installed between 90 and 135 degrees to the scaffold deck access opening to facilitate access/egress to the scaffold deck.

13 Ensure ladders have a rest platform and break every 20 feet.

14 Two or more ladders or some additional means of egress must be provided on scaffold decks longer than 30 feet.

15 Ladder cages or retractable lifelines must be used on scaffold ladders with a fall potential of 20 feet or greater. The fall hazard can also be mitigated using an enclosed scaffold barrier provided the horizontal members of the barrier have no vertical openings greater than 21 inches. Fall potential is measured from grade or the lowest level that a person could fall to.

When retractable lifelines are used, they must be attached to an engineered anchor point.

When a ladder cage is used, the bottom of the cage must be a minimum of 7 feet and a maximum of 8 feet from the walking surface.

Scaffold builders will install the vertical retractable lifelines to engineered anchor’s points on scaffolds that require them.

16 Scaffold ladders inside vessel internals (inside furnaces, reactors, towers etc.) with a potential fall distance greater than 20 feet shall have vertical lifelines installed on the scaffold ladders. Ladder cages shall not be used in place of a retractable lifeline on scaffolds inside vessels. Scaffold companies will check out the vertical lifelines from the On-site Safety Supplier.


Rev. 12, 04/16 of 31



Step Guideline

17 Openings to vertical ladders where the fall distance exceeds 6 feet must be guarded through use of swing gates, hatches or other suitable barriers to prevent workers from stepping into the opening, or personal fall arrest equipment is required on that work level at all times.

18 All scaffolds 4 feet or more in height must have handrails, mid-rails, and toe boards (at least 3-1/2 inches tall) on all open sides. A side of a scaffold abutting a wall or an enclosure which prevents falling or dropping materials does not need to be enclosed with railings and toe boards

19 Self-closing swing gates must be installed on all scaffolds where practical. Swing gates must be installed so that there is not a vertical gap greater than 19 inches between the gate and the work deck. They must open freely at least 90 degrees and come to a close against a fixed contact point (gate stop) that is capable of supporting a force of at least 200 lbs. applied against it.

20 Fixed toe boards should not be placed at the opening of self-closing swing gates due to the tripping hazard presented by them. The swing gate should be located away from the planned work activity to minimize the potential for falling objects. If work will occur near the gate opening, then the crew performing the work must provide protection against any potential falling objects (Refer to SSS-4101, Overhead Work Safety Precautions).

21 When clamp and tube style scaffold components are used as weight bearing members or are holding up weight, a safety clamp (back-up clamp) will be installed on the connections.

22 All wooden deck boards must be a minimum of 2 inch x 10 inch nominal scaffold grade boards.

23 When it is necessary to erect a scaffold in a road or walkway, use reflective tape and/or caution lights to provide suitable warning. If a scaffold is erected over a road or equipment access way and there is less than 13 feet 6 inches of clearance, hang red streamers spaced 12 inches apart from the lowest scaffold horizontal to provide a warning of the low clearance. A sign with the clearance height must be posted to warn others of the low clearance. See SSS-4110, Barricades, for additional information.

24 Scaffolds must be provided with a screen between the toe board and the guardrail, extending along the entire opening, consisting of Number 18 gauge wire, 1/2-inch mesh, or equivalent where persons are required to work or pass under the scaffold. This includes all scaffolds in pipe racks, above walkways, and any scaffold which does not start at ground level.




Rev. 12, 04/16 of 31



Step Guideline

25 Deck tie-downs must be installed on all scaffolds to prevent uplift in high wind conditions. #9 wire or equivalent, double wrapped around the scaffold frame and the toe boards, should be used. All four corners of the scaffold must be secured in this manner. If the scaffold deck has overlapping boards, the boards must be secured at the overlap with a double wrap of #9 wire or equivalent securing the boards to the scaffold frame.

26 Scaffolds are typically built for only a couple of workers. If a heavier duty scaffold is required for additional personnel or equipment, the expected load must be communicated to the scaffold company during the planning phase. Refer to the Scaffold Use Tag for allowable loads.

27 Tools, materials and debris must not be allowed to collect on scaffolds. Do not overload scaffold. Refer to Scaffold Use Tag for load rating.

28 Scaffolds and their components must be capable of supporting without failure at least four times the maximum intended load.

29 Scaffolds must have solid decking except when a hole is required. The access to the work area must have toe boards installed. If the hole exceeds 12 square inches, personal fall arrest equipment is required.

30 Free-standing scaffolds with a height to base width (including outrigger supports, if used) ratio of more than three to one (3:1) must be restrained from tipping by guying, tying, bracing, or equivalent means.

31 The footing or anchorage for scaffolds must be sound, rigid, and capable of carrying the maximum intended load without settling or displacement.

32 Supported vertical posts of the scaffold must bear on steel base plates. Mud sills or pads, fabricated from scaffold grade boards, must be installed under the metal base plates. Base plates must be secured to the pads. The minimum mud sill and/or pad requirements for most scaffolds on different ground conditions are:

1. On soil (dirt, gravel and other unimproved ground)

Install cribbing as follows:

- Three 2 x 10 x 18 inch scaffold boards - Two boards for the base - One board across the bottom boards

If the use of cribbing is not feasible, install continuous sills under each vertical post of the scaffold.


Rev. 12, 04/16 of 31



Step Guideline

31 Continued

2. On sound concrete or asphalt 4 inches thick or greater

Either 2 x 10 x18 inch or ¾ x 12 x12 inch wooden pad

If the scaffold company competent person can determine that the concrete is capable of supporting the intended load, then no pad is needed on scaffolds four levels or less in height using 6 inch x 6 inch steel base plates

3. On steel grating or deck plate

One 2 x 10 wooden pad that is long enough to transfer the load to the beams which support the grating

On scaffolds five levels or greater and placed on soil, the competent person must determine the pad size by calculating the weight imposed by the scaffold leg on the pad (leg load). Then divide that number by the square footage of the pad to determine the pounds per square foot (PSF) imposed on the soil. When calculating the soil capacity, the competent person must assume that the soil is Type C soil and has a capacity of 1000 PSF or less, unless reclassified using 29CFR1926 Subpart P.

33 Unstable objects such as barrels, boxes, loose brick or concrete blocks must not be used to support scaffolds or planks.

34 Screw jacks are for leveling only. Do not use screw jacks for extending the height of the scaffold. Do not extend screw jacks over 12 inches.

35 Scaffolds over railroads must maintain a 22-foot vertical clearance above the top of the railroad rails, and a 10-foot horizontal clearance from the center of the tracks to either side. Contact ARM Operations FLS for approval to work near railroad tracks as per SSS-1031, Rail Movement Safety Guide.

36 Material being hoisted onto a scaffold must have a tag line to keep load from striking the side of scaffold.

37 Scaffolds that are multi-decked (cross capped or stacked plank) to increase the load limit of the decking will result in inadequate handrail height and a fall hazard. Either adjusted handrails or fall protection will be required to mitigate the fall hazard.



Rev. 12, 04/16 of 31



Step Guideline

38 Special precautions must be taken if a scaffold is to be located near high temperature equipment to prevent combustion of wooden boards or exposing metal scaffolding planks to extreme temperatures.

Wooden scaffolding planks must not be exposed to temperatures exceeding 150°F. Wooden boards must be located a minimum of 4 inches from the equipment shell.

Metal scaffold planks must not be exposed to temperatures exceeding 350°F.

The scaffold builder is responsible for developing a plan to safely use the scaffold located in high temperature locations.

Special attention must be given when scaffolds are utilized during turnarounds or equipment downtime. Before startup, scaffolding must be surveyed to ensure it is not located near hot equipment.

Requirements for Specialty Scaffolds

Step Guideline

1 The following scaffolds pose a higher risk to scaffold builders and users and are considered Specialty Scaffolds:

a. Scaffold greater than 125 feet (38 m) in height

b. Hanging or using process piping, equipment or structure as main load-bearing support

c. Cantilever or bridge design

d. Scaffold with a height to base width ratio of >3:1

e. Scaffold intended for services exceeding the normal load limit or used as an anchor point for rigging activities

f. Constructed in close proximity to live electrical sources or vehicle accessway (roads/railway)

g. Erected on loose fill or recently disturbed soil

h. Scaffolds with complex configuration involving vessel internal, uses special components (e.g. trusses or beams), enclosed (with large tarp or covering that would be subject to wind loading) or on questionable foundation

i. Suspension scaffolds hung on or by cables such as Spyders, window washing scaffolds, etc.


Rev. 12, 04/16 of 31


Requirements for Specialty Scaffolds, Continued

Step Guideline

2 Specialty scaffolds require additional design and review criteria due to the risks associated with them. The scaffold company is responsible for ensuring that the design meets federal regulations, scaffold industry safety standards and manufacturer guidelines.

3 In addition to the design, specialty scaffolds may require certain experience or training qualifications for the scaffold builders involved in the erection and dismantling. The Scaffold Company Site Management will have a written process in place that specifies the criteria used to evaluate, designate and clearly identify Competent Specialty Scaffold Builders (CSSBs) at the plant. The process must document criteria and responsibilities for a Lead CSSB. Lead CSSB must have extensive knowledge, training and work experience. The Scaffold Company must maintain a current roster of CSSBs. The CSSBs will meet the following minimum requirements:

• Hold current NCCER Scaffold Builder Plus Certification

• Have completed Scaffold Company’s CSSB evaluation process

• Be designated by Scaffold Company Site Management as a CSSB

• CSSB must be identified on certification card as per CSS-11400

4 All specialty scaffolds require an erection/dismantling plan available at the job site for the scaffold builders to refer to. This plan typically consists of a sketch that shows the proper sequence for erection and dismantling, erection notes and special precautions.

5 There are specific design and erection requirements for specialty scaffolds depending on the type. Refer to Attachment 8 for these detailed requirements.

Scaffold Management During Turnarounds

Step Guideline

1 During Turnarounds, a risk-based decision process must be used to manage scaffolds to ensure:

Scaffolds needed for work activities are erected in a timely manner

Access to critical process valves is maintained during shutdown and startup

Access to bleeders required for hydrocarbon freeing or dry-out are accessible

http://ishareteam2.na.xom.com/sites/chemmbta23/Sub02/Manuals%20Central/Contractor%20-%20Contractor%20Safety/CSS-11400.pdf


Rev. 12, 04/16 of 31


Scaffold Management During Turnarounds, Continued

Step Guideline

1 Continued

Egress from process areas is maintained

Unit lighting needed for shutdown and start-up activities is maintained

2 The Shutdown/Startup (SD/SU) TA Scaffold tagging system is used to ensure proper review, communication and agreement between Mechanical and Process on the location, erection and dismantling of scaffolds that will be left standing during the SD/SU phases of the turnaround.

3 During the pre-turnaround phase, T/A Mechanical Representatives will meet with Process Representatives to discuss and review the type, number and locations of scaffolds that will remain standing during the SD/SU activities.

Mechanical will propose a list of scaffolds that need to remain standing during these time periods.

Process will identify any critical valves, bleeders, egress paths or unit lighting that could be affected by the scaffolds.

Erection techniques such as extra wide bays, alternate bracing in lieu of cross bracing, etc. should be considered to ensure adequate access to process equipment.

Proximity to high temperature process equipment that will be started up must also be considered when determining scaffolds that will remain up during the start-up phase (refer to Scaffold Erection/Dismantling section of this standard).

4 After review and agreement of the scaffolds that can remain standing during SD/SU, a "SD/SU TA Scaffold tag" will be completed and attached to each individual scaffold. (Refer to Attachment 7, SD/SU TA Scaffold Tag.) The tag requires the following review and sign-off responsibilities by Mechanical and Process:

Process Technician issuing permit for scaffold shall review access to valves, egress from area, lighting in regards to impact of the scaffold on shutdown and startup. If acceptable, then sign tag.

Process FLS shall verify quality assessment was made by signing the tag.

Mechanical FLS shall verify agreement with Process and need for scaffold during shutdown and startup and shall sign tag.

These tags must remain on the scaffolds throughout the duration of the T/A to identify the scaffolds approved to remain standing during SD/SU.


Rev. 12, 04/16 of 31


Mobile Scaffolds

Step Guideline

1 The maximum work level height of mobile scaffolds must not exceed two times the smallest base dimension.

2 The minimum platform width for any work level must not be less than 20 inches.

3 Surface must be level.

4 All casters and vertical members will be secured with pins or bolts of sufficient strength to prevent separation of the stacked joints.

5 All scaffold casters must be provided with positive wheel locks and/or swivel locks to prevent movement.

6 Attachable ladders must be supported with brackets and braces to prevent separation or sagging.

7 Before moving the scaffold, the following steps must be followed:

• Ensure no one is on the scaffold.

• Remove or secure all tools or materials.

• Unlock the wheels.

• Ensure the path of travel is clear of other personnel and equipment.

Suspension Scaffolds

Single Point (Spider Staging) and Two Point (Swinging) Suspension Scaffolds:

NOTE: The primary aspects of suspension scaffold safety are contained in Attachment 4, Suspension Scaffold Pre-job Safety Checklist.

Step Guideline

Approval of Contract Companies

1 Prior to being placed on the Approved Supplier List, contract companies that will perform suspended scaffold work must:

1. Pass a Technical Review (completed by Contractor Safety Coordinator)

2. Receive approval of the contract by the Joint Safe Operations Committee (JSOC) (reference SSS-0060) with input from Technical Reviewer



Rev. 12, 04/16 of 31


Suspension Scaffolds Continued

Rigging and Safety Procedures

Step Guideline

2 In preparing equipment for operation, the contractor will ensure the following:

• Brackets attaching platform to rigging equipment meet design and certification requirements.

• All required inspections have been completed as specified by the manufacturer and OSHA. Inspections shall occur before delivery to the jobsite and as the components are being erected.

• Pre-operational test has been performed, witnessed, and documented as required by the manufacturer.

• Identify the wind speed limitations of the equipment.

3 Contractor working from these scaffolds must confirm the following safety items before using single point or two-point suspension scaffolds at the ExxonMobil Baytown Complex:

• Harnesses, lifelines, and supporting cables have been inspected by qualified personnel and are in good working order.

• OSHA approved hoisting equipment has been tested and approved.

• Each person working with suspension scaffold equipment rigging is outfitted with a safety harness and an independent safety line and anchor point that is in good condition and free from defects.

• The following requirements for support rigging design, fabrication, and inspection have been met and accepted by ExxonMobil Field Representative:

Design and fabrication has been approved by a licensed professional engineer.

Copies of the support rigging design have been submitted to the ExxonMobil Field Representative.

Documented certification that fabrication of the support rigging assembly and all components has been performed per design and by qualified welders, and that Nondestructive Testing (NDT) inspections have been satisfactorily completed, and have been submitted to the ExxonMobil Field Representative.


Rev. 12, 04/16 of 31


Suspension Scaffolds Continued

Rigging and Safety Procedures, Continued

Step Guideline

3 Continued

Attachment 5, Certification of Support Rigging has been completed by supplying requested information.

Certification that a weight test has been performed on lift baskets and hoisting equipment and that the equipment meets or exceeds OSHA capacity requirements has been submitted to the ExxonMobil Field Representative.

Lift baskets and hoist have been tested and listed by a nationally recognized laboratory.

Documented certification that a pre-operational load test has been performed on the installed suspension scaffold assembly, and that the assembly meets or exceeds OSHA capacity requirements, has been provided to the ExxonMobil Field Representative.

NOTE: Roof hooks and other support rigging components must be rated four times the maximum intended load.

• Suspension lines have been inspected by qualified personnel, and will support 6 times the intended load.

• Suspension lines, rigging, and safety tieback lines have been properly assembled, spaced, and installed by qualified personnel.

• Rigging will support a load of 2 tons.

• Persons using the equipment are certified to use the equipment properly, and are knowledgeable of applicable local, state, and federal regulations pertaining to scaffold general safety and health provisions, and personal protective and lifesaving equipment.

• Roof irons, rollers, hooks, clamps, and other support rigging components are constructed of wrought iron, mild steel, or other equivalent material, are of OSHA approved size and design, and are securely installed and anchored to the fixed equipment structural support.

• Platform of two point suspension scaffolds is between 20-inches and 36-inches wide and securely fastened to the hangers by U-bolts or other equivalent means.

• On open sides, scaffolds have been equipped with top rails (36-inches to 42-inches high), mid rails, and toe boards (4-inches high).


Rev. 12, 04/16 of 31


Suspension Scaffolds, Continued

Step Guideline

Rigging and Safety Procedures, Continued

3 Continued

• Cage or basket of a single point suspension scaffold has been fully enclosed on all sides with top rails, mid-rails, and toe boards that conform with above.

4 Inspect the support structure on which suspension scaffolds are being used to ensure condition is adequate to support the suspension scaffold at the rated load with support rigging.

5 After inspection, complete Attachment 4, Suspension Scaffold Pre-job Safety Checklist.

6 ExxonMobil Field Representative confirms Attachment 4, Suspension Scaffold Pre-job Safety Checklist, has been completed.

• Forward a copy to the appropriate contract Administrator for retention in the Contractor's records.

7 When the workers leave the job site, lower to the ground and tie off the scaffold.

NOTE: Fiber ropes are not permitted where acid solutions are used unless the ropes have been acid proofed.

8 On suspension scaffolds designed for a working load of 500 pounds, ensure no more than 2 workers work at one time.

9 On scaffolds with a working load of 750 pounds, ensure no more than 3 workers work at one time.

10 Ensure the following additional safety requirements for single point suspension scaffolds are followed:

• Electric arc welding is not to be performed unless special precautions are followed and a nonconductor connection (insulated hook, etc.) is provided to eliminate a possible ground.

NOTE: Accidental contact between the electrical holder and the scaffold frame could cause the hoisting cable to serve as a ground wire.

• When sand blasting or water blasting, protect the suspension cable with a temporary cover.

• Ensure supporting cable is straight for its entire length and operator does not sway the basket or fix the cable to any intermediate points to change the original path of travel.


Rev. 12, 04/16 of 31



Regular Inspection and Service

Step Guideline

Daily Inspection

NOTE: ExxonMobil requires regular inspection and

service for several components of the powered platform and accessory equipment.

11 Perform daily visual inspection on the following equipment to ensure equipment is in good working condition:

• Wire rope

• Wire rope guide

• Tension holder

• Wire rope level wind system

• Transmission

• Overload shutoff

• Motor control switch

• Air hoist motor

• Air hoist oiler and filter

• Wire rope drum and automatic emergency brake

12 Follow manufacturer's recommended daily inspection procedures for this equipment.

13 Each day before a single point suspension scaffold is used, raise the scaffold about 1 foot from the ground and check brake operations before using.

30-Day Inspection

14 Perform a 30-day inspection on the following equipment:

• Wire rope

• Wire rope level wind system

• Transmission

• Overload shutoff

• Motor control switch

• Air hoist motor

• Air hoist oiler and filter

• Wire rope drum and automatic emergency brake


Rev. 12, 04/16 of 31



Regular Inspection and Service, Continued

Step Guideline

30-Day Inspection, Continued

15 Certify all equipment has been inspected according to the manufacturer's recommended 30-day inspection procedures and submit a written certification of the inspection results to the ExxonMobil Field Representative.

16 Use Attachment 6, 30-Day Equipment Inspection Checklist to certify

inspections.

17 Ensure any piece of equipment that shows signs of damage or excessive wear is not used.

18 Contractor follows the manufacturer's servicing guidelines for the equipment.

Tank Builder's Scaffolds

Special Purpose Scaffolding used During Tank Fabrication or Repair

Step Guideline

When Used 1 Tank Builder's Scaffolding is used for erection, fabrication or repair of tanks. The scaffolding consists of metal brackets and other components welded to the shell wall of the tank. Wood planking is used for the work deck and wire rope is used for the guard rail system.

Requirements for Installation and Use

2 Any Tank Builder's Scaffolding must be designed and erected per engineered drawings that have been approved by a professional engineer.

3 Clips welded to the tank shell that will support the scaffolding will be dye penetrate tested to ensure they will hold the load intended.

4 The Scaffold Use Tagging and Scaffold Shift Inspection Tagging Systems described on previous pages of this standard must be used.

5 The maximum distance between brackets to which scaffolding and guardrail supports are attached must be no more than 10 feet 6 inches.

6 Synthetic rope is not allowed for guard rail or safety lines.

7 If the distance between the innermost edge of the scaffold platform and the curved plate structure of the tank shell is greater than 12 inches, taut wire rope must be installed to reduce any open space to less than 12 inches.


Rev. 12, 04/16 of 31


Tank Builder's Scaffolds, Continued

Special Purpose Scaffolding used During Tank Fabrication or Repair, Continued

Step Guideline

Requirements for Installation and Use, Continued

8 Approved scaffold planks of rough full-dimensioned 2 inch x 12 inch Douglas Fir or Southern Yellow Pine of Select Structural Grade must be used.

9 Guardrails must be constructed of a taut wire rope, and must be supported by angle irons attached to brackets welded to the steel plates. These guardrails must comply with OSHA standards. Guardrail supports must be located at no greater than 10 feet 6 inch intervals.

10 Falling object protection including tool lanyards and screens or netting must be incorporated into the scaffold where personnel will pass underneath. See SSS-4101, Overhead Work Safety Precautions.

11 Not more than three employees shall occupy a 10 feet 6 inch span of scaffold planking at any time.

** End of Site Safety Standard **



Rev. 12, 04/16 of 31

Attachment 1

Scaffold Use Tags

Scaffold contractors must supply and hang tags per the above specifications.


Rev. 12, 04/16 of 31

Scaffold Inspection Checklist

Ask yourself the following questions to help check that the scaffold has not been altered significantly since it was last inspected and approved for use.

Inspection Required Each Work Shift

That The Scaffold Is Used

No. Safety Check

1 . Does scaffold tag state that the scaffold is safe to use?

2 . Does the scaffold appear level?

3 . Does the footing appear secure?

4 . If it is a rolling scaffold, are the wheels locked?

5 . Do scaffold legs appear to be rigid and straight?

6 . Is bracing connected and are railings in place?

7 . Does the ladder appear secure?

8 . Are people protected from falling objects?

9. Are decking boards and toe boards in place and secure?

A “no” answer to any item above equals a safety concern. In the event of a safety concern, contact your Supervisor before using the scaffold.

(see reverse)

Scaffold Inspection

Inspection Required Each Work Shift That The Scaffold Is

Used

Print Name Date 6am-6pm

Days

6pm-6am Nights

Spot Check

1. For T/A: Check Either Day or Night Box (times will vary) 2. Evening Shift (e.g. 4-12): Check Night Box 3. Spot Check: Inspection Of A Partial Area Of A Large Scaffold (good for

inspected area only)

Attachment 2

Scaffold Inspection Tag

Scaffold Inspection Tag

Material #49001340242X Front of (Tan) Tag Back of (Tan) Tag


Rev. 12, 04/16 of 31

Attachment 3

Fall Protection Required Sign


Rev. 12, 04/16 of 31

Attachment 4

Suspension Scaffold Pre-job Safety Checklist

Structure Location/Description:

Fixed Equipment:

Unit:

Type of Rigging:

NOTE: Contractor is responsible for performing daily inspection of equipment.

NOTE: If the rigging equipment is removed from the tank, it must be retested.

At a minimum, the contractor will confirm the following: Initial

1. Harnesses have been inspected and are in good working order. _______

2. Lifelines and supporting cable have been inspected and are in good working order.

_______

3. OSHA approved hoisting equipment has been tested and approved. _______

4. Lifelines and safety harnesses are in place at the work site. _______

5. Support rigging and components have been designed, fabricated, and inspected. Certification has been provided to ExxonMobil using Attachment 2 or equivalent.

_______

6. Current 30-day inspection of equipment has been performed and documentation and certification of the inspection have been provided to ExxonMobil, using Attachment 1 or equivalent.

_______

7. Suspension line has been inspected for proper assembly, spacing, and installation and will support a load of at least 2 tons.

_______

8. All personnel working with the equipment are trained and have knowledge of OSHA regulations regarding suspension scaffolding and personal protective equipment.

_______

9. Roof irons, rollers, hooks, and clamps are securely installed and anchored to fixed equipment structural support.

_______

10. Roll ID: # # # # _______

11. Structural supports for the contractor's rigging are adequate. _______

Contractor Company Name

Foreman Signature Date


Rev. 12, 04/16 of 31

Attachment 4, Continued

Suspension Scaffold Pre-job Safety Checklist

ExxonMobil Field Representative will verify the following: Initial

1. Support rigging design, fabrication, and testing certification has been received.

_______

2. Lift basket and hoisting equipment capacities have been verified to meet OSHA requirements.

_______

3. Pre-operational load tests of the scaffold assembly have been performed per procedure and witnessed by the ExxonMobil Field Representative. A copy has been sent to the appropriate Contract Administrator.

_______

ExxonMobil Field Representative Signature

Date


Rev. 12, 04/16 of 31

Attachment 5

Certification of Support Rigging

1. Description of lift baskets and support rigging components:

Component No. Description

_____________

_____________

_____________

_____________

_____________

2. Design of lift baskets and support rigging components has been approved by a licensed professional engineer. List the applicable drawing numbers (including engineer's name and seal number) below:

Drawing No. Engineer's Name Seal Number

_______________ _____________

_______________ _____________

_______________ _____________

_______________ _____________

_______________ _____________

3. Components have been fabricated and inspected per design:

Contractor __________________________________________ Signature Date

4. Reviewed:

ExxonMobil Field Representative ________________________ Signature Date


Rev. 12, 04/16 of 31

Attachment 6

30-Day Equipment Suspension Scaffold Inspection Checklist

Contractor will confirm qualified personnel have performed the 30-day inspection on the following equipment:

NOTE: Detailed 30-day inspection procedures are provided by the equipment manufacturer.

Initial

1. Wire rope has been inspected for corrosion, abrasion, scrubbing, flattening, crushing, and penning; replaced if damaged.

______

2. Tension holder rollers have been inspected for deep grooves and flat spots. ______

3. Wire rope drum has been inspected for signs of damage. ______

4. Automatic emergency brake has been inspected to ensure brake disc moves freely; brake plate, bearing housing seal, and locknut are in place and secure.

______

5. Drum base of wire rope level wind system has been inspected for signs of damage. Pivot pins have been inspected for wear and are secured with snap rings. Tilt control assembly resists tilting of the drums.

______

6. Transmission oil level has been inspected and topped off with oil, if necessary. Teeth on bronze gear have been inspected for wear and gear replaced, if necessary.

______

7. Overload shutoff has been inspected and lifts the staging with the rated working load shown on the load rating plate.

______

8. Motor control switch has been inspected and turns the drum in both up and down directions. Handle and control assembly are properly secured and are not damaged.

______

9. Fasteners on the air hoist motor are secure; the housing is not damaged. Air hoses are properly secured and not damaged.

______

10. Air hoist filter has been cleaned and o-rings lubricated. ______

11. Air hoist oiler has been inspected and oil flow is 3 to 4 drops per minute. ______

Contractor

Signature Date


Rev. 12, 04/16 of 31

Attachment 7

Shutdown/Startup Turnaround Scaffold Tag

These tags are available by special order and are kept by the T/A & Majors Department


Rev. 12, 04/16 of 31

Attachment 8 – Requirements for Specialty Scaffolds

Type of Specialty Scaffold

Scaffold Company Design Criteria Work Crew

Requirements

Scaffold greater than 125 feet in height

Engineered with PE Stamp CSSB leads work crew

2nd

CSSB inspects

Hanging or supported by piping or equipment

If typical plan applies consult w/ Owner’s Engineer for written approval to use support

CSSB leads work crew

2nd

CSSB inspects

If outside scope of typical plan: Engineered with PE Stamp and consult w/ Owner’s

Engineer for written approval to use support

Cantilever or bridge design If typical plan applies use it CSSB leads work crew

2nd

CSSB inspects If more complex than typical plan Engineered with PE Stamp

Scaffold with a height to base width ratio of > 3:1

If typical applies use it CSSB leads work crew

2nd

CSSB inspects Engineered with PE Stamp

Scaffold intended for services exceeding the

normal load limit or for any used as an anchor point

for rigging activities

If typical plan applies use it


2nd

CSSB inspects If weight exceeds typical – Lead CSSB can

design if within standard component capacity otherwise use Engineered with PE Stamp

Constructed in close proximity to live electrical

sources or vehicle access-way (roads/railway)

Roads – Approval from Process FLS required

Railroads – Approval from Area Rail Management Group required

Electrical – Approval from Site Electrical Group required

For Roads & Railroads a CSSB leads the work

crew

For scaffolds near electrical sources,

Electrically Qualified Personnel may be

required – CSSB leads crew

Erected on loose fill or recently disturbed soil

Consult with Lead CSSB if simple

If complex Engineered with PE Stamp


2nd

CSSB inspects

Scaffolds with complex scaffold configuration

vessel internals, special components, enclosed or

on questionable foundation

Vessel Internals – If typical plan use it, if complex Engineered w/ Stamp and review by ExxonMobil (Use SRLs no ladder cages)

Special Components – Lead CSSB to consult w/ Engineer as needed

Enclosed – Lead CSSB to consult w/ Engineer as needed

Foundation issues – Lead CSSB to consult with Engineer as needed


2nd

CSSB inspects

Suspension Scaffolds See requirements in Suspension Scaffold section of SSS-4130

Work Crew trained by Vendor of the equipment

and led by CSSB

2nd

CSSB inspects

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