阿美施工安全手册.doc

SAUDI ARAMCO CONSTRUCTION SAFETY MANUAL PREFACE Dhahran Saudi Arabia February 1993 The purpose of the Saudi Aramco Construction Safety Manual CSM is to prevent injury loss of life and damage to assets This is the fourth revision of the CSM Since its 1974 introduction the Construction Safety Manual has provided safety criteria for all construction work performed by Saudi Aramco and its contractors Many of the requirements in this manual detail the need for Saudi Aramco services or equipment Where references indicate that certain equipment fall protection safety shoes etc should be provided or services rendered bio monitoring etc the intent is that contractors must provide equivalent equipment or services as approved by Saudi Aramco from their own resources The construction industry functions in a dynamically changing work environment in which updating of equipment and standards is a continuous process resulting from changes in operating variables regulatory requirements and safety practices Although this manual has been updated to reflect the latest Saudi Aramco and construction industry practices as time goes on there may be a need to consider new procedures standards or operating conditions Such new developments including potential conflicts with existing provisions should be referred to the Loss Prevention Department for resolution The Loss Prevention Department will issue interim revisions or updates where appropriate Good loss prevention is an integral part of good project management For our projects and maintenance programs to proceed safely all Saudi Aramco and contractor personnel involved in construction activities whether management or line employees need to understand and follow the provisions in this Manual Only with the active commitment of everyone can we ensure that Saudi Aramco maintains the safest possible work environment A G AL GHANIM Senior Vice President Engineering and Project Management February 1993 Construction Safety Manual Table of ContentsPage i February 1993 Table Of ContentsPage ii I Administration 1 1 0 SAUDI ARAMCO LOSS PREVENTION POLICY AND PROGRAM 2 1 1Loss Prevention Policy Implementation 2 1 1 1Compliance With Construction Requirements 2 1 1 2Operating Standards and Instructions 2 1 1 3Personal Protection 2 1 1 4Inspection 2 1 1 5Education and Training 3 1 1 6Motivation and Recognition 3 1 1 7Job Placement 3 1 1 8Response to Accidental Occurrences 3 1 1 9Contractor Safety 3 1 1 10Off The Job Safety 3 1 1 11Traffic Safety 3 1 1 12Accountability 4 1 1 13Compliance Reviews 4 1 2Saudi Aramco Loss Prevention Requirements For Contractors 4 1 2 1Non Compliance 4 1 2 2Assistance 4 1 2 3Standards and Instructions 5 1 3Contractor s Loss Prevention Program 5 1 3 1Written Program 5 1 3 2Hazard Identification Plan 6 1 3 3Safety Supervisor 6 1 3 4Safety Discussion 6 2 0 SAUDI ARAMCO LOSS PREVENTION DEPARTMENT SERVICES 7 2 1Loss Prevention Program 7 2 2Program Management Services 8 2 3Program Maintenance Services 9 3 0 ACCIDENT INVESTIGATION ANALYSIS AND REPORTING 10 3 1Reports Required by Saudi Aramco 10 3 2Accident Investigation 11 3 2 1Responsibilities for Investigation 11 3 2 1 1Supervisor Safety Representative 11 3 2 1 2Project Manager 11 3 3Cases to be Investigated 12 3 4Accident Investigation Guidelines 12 3 5Accident Analysis 12 3 5 1Classification 12 4 0 RESPONSIBILITIES FOR SAFETY 16 4 1Contractor Senior Management 16 4 2Design Engineer 16 4 3Contractor s Safety Officer 16 4 4Construction Manager Superintendent 17 4 5Site Safety Supervisor 18 4 6Equipment Manager Supervisor 18 4 7Engineer Supervisor 18 4 8Foreman 18 February 1993 Table Of ContentsPage iii 4 9Worker 19 5 0 EMERGENCY PROCEDURES 20 5 1Action to be Taken 20 5 2Contact After Office Hours 20 5 3Help in an Emergency 20 6 0 SAFETY TRAINING 22 6 1Safety Training for Supervisors 22 6 2Safety Training for Workmen 22 6 2 1Integrated Practices 22 6 2 2Specialized Training 22 6 2 3Use of Persuasion 23 6 2 4Course Requirements 23 6 3Scope of Training 24 6 3 1Safety Training Topics For Supervisors 25 6 3 2Induction Safety Topics For Workmen 27 7 0 SITE PLANNING AND HOUSEKEEPING 28 7 1Initial Planning 28 7 1 1Hazard Identification Plan 28 7 1 2Loss Prevention Program 29 7 1 3Protection of Employees and Equipment 29 7 1 4Transportation 29 7 1 5Lifting Equipment 29 7 1 6Demolition 29 7 1 7Excavations 29 7 1 8Scaffolding 29 7 2Site Layout 30 7 2 1Site Accommodation 30 7 2 2Adequate Access Roads 30 7 2 3Project Sign 30 7 2 4Safe Means of Access and Egress 31 7 2 5Parking Facilities 31 7 2 6Drainage 31 7 2 7Vehicle Heavy Equipment Paths On Site Vs Pedestrian Paths 31 7 2 8Sand 31 7 2 9Fire Prevention 31 7 2 10Site Illumination 31 7 3Storage Areas 31 7 4Welfare Facilities 32 7 5Good Housekeeping 33 7 6Construction Sites and Materials Storage Yards 33 8 0 FIRST AID 36 8 1Provision of First Aid Facilities 36 8 2First Aid Attendants 37 8 3First Aid Facilities At Work Site 38 8 4Labor And Workmen Law 40 9 0 PERSONAL PROTECTIVE EQUIPMENT 42 9 1Head Protection 43 9 2Eye and Face Protection 43 February 1993 Table Of ContentsPage iv 9 2 1Eye Protection from Impact 44 9 2 2Eye Protection from Radiant Energies 44 9 2 3Face Protection 44 9 3Hand Protection 44 9 4Foot Protection 44 9 5Hearing Protection 45 9 5 1Ear Plugs 45 9 5 2Ear Muffs 45 9 6Fall Restraining Arresting Devices 45 10 0BREATHING APPARATUS 52 10 1Selection of Equipment 52 10 1 1Requirements For Use 53 10 1 2Misuse 53 10 1 3Hazardous Substances 54 10 1 4Contaminants 54 10 2Respiratory Protective Devices 54 10 2 1Air Purifying Respirators 54 10 2 1 1 Gas Masks 54 10 2 1 2 Chemical Cartridge Respirators 55 10 2 1 3 Particulate Filter Respirators Dust Respirators 55 10 2 2Supplied Air Respirators 55 10 2 2 1 Air Line Respirators 55 10 2 2 2 Abrasive Blasting Respirators 56 10 2 2 3 Air Supplied Suits 56 10 2 3Self Contained Breathing Apparatus SCBA 56 10 3Training 57 10 4Safety Precautions 57 10 4 1Air Compressors 57 11 0FIRE PREVENTION 60 11 1Before the Job Starts 60 11 2Layout 61 11 3Equipment Protection 61 11 4Control of Ignition Sources 62 11 5Flammable Liquids 62 11 5 1Storage 62 11 5 2Handling of Flammable Liquids 63 11 5 3Ventilation 63 11 6Combustible Materials 63 11 7Housekeeping 63 11 8Emergency Equipment 63 11 8 1Water Type Fire Extinguisher 64 11 8 2Carbon Dioxide Type Extinguisher 64 11 8 3Dry Chemical Type Extinguisher 64 11 8 4Pressurized Water 64 11 9Reporting a Fire 65 11 10End of Shift Checks 65 12 0RADIO COMMUNICATIONS 67 12 1Equipment 68 12 1 1Remote Control Unit 68 12 2Safe Operation 68 12 3Radio Phrases 68 February 1993 Table Of ContentsPage v 12 4Phonetic Alphabet 69 12 5International Communications Union Agreement 70 12 5 1Monitoring of Circuits 71 12 5 2Secrecy Act 71 12 5 3Penalties 71 12 6Message Priorities for Company Operations 71 12 7Distress Messages 73 12 7 1MAYDAY 73 12 7 2Urgency Signal 74 12 7 3Priority Traffic 75 13 0 TRANSPORTATION 76 13 1Driver Requirements 76 13 2Driver s Responsibilities 76 13 3Motor Vehicle Regulations Saudi Arab Government and Saudi Aramco 78 13 4Vehicle Condition 78 13 5Driver Training 80 13 6Enforcement of Safe Driving Practices 80 13 7Action Taken After a Saudi Aramco Motor Vehicle Accident 81 13 7 1Emergencies 81 13 7 2Remain at Scene 81 13 8Passenger Seating and Seat Belts 82 13 9Desert Driving 82 13 9 1Stay With Vehicle 82 13 9 2Sand Tires 82 13 10Vehicle Admittance to Restricted Areas 83 13 11Operation of Motor Vehicles Within Saudi Aramco Communities 83 13 11 1 Seat Belts 83 13 11 2 Traffic Regulations 83 14 0 AIRCRAFT OPERATION 84 14 1General Operating Responsibilities 84 14 1 1Captain Pilot 84 14 1 2Camp Supervisors 84 14 2Passenger Briefing Instructions General All Aircraft Types 85 14 3Transportation of Dangerous Goods 86 14 4Hours of Operation for Single Engine Helicopters 86 14 5General Precautions for Helicopters 86 14 5 1Life Vests 86 February 1993 Table Of ContentsPage vi II General And Civil 87 1 0 WORK PERMIT SYSTEM 88 1 1Definitions 88 1 1 1Restricted Areas 88 1 1 2Issuer Operation Supervisors 89 1 1 3Receiver Authorized Craftsmen 89 1 1 4Work Permit 89 1 2Issuance and Approval 89 1 2 1Power Distribution Department Clearances 90 1 3Precautions 90 1 3 1Checklist 90 1 3 2Clear Area 90 1 3 3Work Stoppage 90 1 4Handling of Issued Work Permit 90 1 5Closing Out and Filing the Permit 91 1 6Certification 91 1 712 Rules on Work Permit Procedure 91 1 8Hold Tags and Multiple Lockouts 91 2 0 EXCAVATIONS TRENCHING AND SHORING 96 2 1Before Work Starts 99 2 2Work Permit 99 2 2 1Excavation near Saudi Telephone Cables 99 2 3Underground Obstructions 100 2 4General Precautions 100 2 4 1Shoring Protective Systems 100 2 4 2Personnel Protection 100 2 4 3Inspection 101 2 4 4Clearance 101 2 4 5Mechanical Excavator 101 2 4 6Walkways 101 2 5Access and Egress 101 2 6Hazardous Atmospheres and Materials 101 2 6 1Ventilation101 2 6 1 1Hazardous Atmospheres 102 2 6 1 2Emergency Rescue Equipment 102 2 6 2Exhaust Gases 103 2 6 3Organic Lead 103 2 7Edge Protection Markers and Fixed Lighting 103 2 8Roads Streets and Sidewalks 103 2 9Backfilling 103 2 10Borrow Pits 103 3 0 DEMOLITION 124 3 1Before Work Starts 125 3 1 1Responsible Supervisor 125 3 1 2Original Drawings 125 3 1 3Disconnections 125 3 1 4Adjacent Structures and Public Areas 125 3 1 5Barricades Signs 125 3 2Method of Demolition 125 February 1993 Table Of ContentsPage vii 3 2 1Demolition of Equipment Containing PCB Polychlorinated Biphenyl ASKAREL 126 3 2 2Demolition Of Buildings With Asbestos Insulation Materials 126 3 3Stability During Demolition 126 3 4Working Place Clearance 126 3 4 1Access 126 3 4 2Glass Removal 126 3 5Structural Steel Removal 127 3 6Tanks Vessels and Pipe Work Explosion Prevention 127 3 6 1Welding and Hot Cutting 127 3 6 2Cold Cutting 127 3 6 3Steaming and Ventilation 127 3 6 4Residue Cleaning 127 3 7Protective Clothing and Equipment 127 3 8Mechanical Equipment Guards 128 4 0 ASBESTOS AND OTHER FIBERS 129 4 1Types of Asbestos 129 4 2Health Risks 129 4 3Before Work Starts 130 4 3 1Air Sampling 130 4 3 2Job Details130 4 3 3Chest X rays 130 4 4Storage and Transportation 130 4 5Work Area 131 4 6Handling and Use 131 4 6 1Wetting Ventilation 131 4 6 2Cutting 131 4 6 3Protective Equipment 131 4 7Protective Clothing 132 4 7 1Types 132 4 7 2Contamination 132 4 7 3Review 132 4 8Respiratory Equipment 132 4 8 1Type 132 4 8 2Use 132 4 8 3Care 133 4 9Washing and Changing Facilities 133 4 10Disposal of Waste Asbestos Materials Clothing 133 4 11Cleanliness of Work Areas and Equipment 133 5 0 WELDING CUTTING AND BRAZING 134 5 1Gas Welding Oxy Acetylene Equipment and Use 134 5 1 1Gases 134 5 1 2Color Coding of Cylinders 135 5 1 3Storage Of Cylinders 135 5 1 4Handling of Cylinders 136 5 1 5Inspecting Equipment 137 5 1 6Faults 139 5 1 7Fuel Gas and Oxygen Manifolds 140 5 2Electric Arc Welding 140 5 2 1Voltage 140 5 2 2Welding Connections 141 February 1993 Table Of ContentsPage viii 5 3Protective Measures 142 5 4Welding and Cutting Tanks Vessels and Drums 144 5 5Confined Spaces 144 5 6Personnel Protection 145 5 7Health Hazards 145 5 7 1Radiant Energy 145 5 7 2Respiratory Effects 146 6 0 EXPLOSIVE MATERIALS 148 7 0 PILING OPERATIONS 149 7 1Before Work Starts 149 7 1 1Cranes 150 7 1 2Pile Gates 150 7 1 3Inspection 150 7 1 4Wedges 150 7 1 5Timber Block 150 7 1 6Ground Support 151 7 2Driving Piles 151 7 2 1Pitching 151 7 2 2Driving 151 7 3Pile Extraction 151 7 4General Precautions 152 8 0 ROADWORKS 153 8 1General 153 8 2Street and Road Construction Excavations and Maintenance Traffic Controls 154 9 0 WORKING PLACES LADDERS AND SCAFFOLDING 155 9 1Working Places General 156 9 1 1Falls 156 9 1 2Access and Egress 156 9 1 3Lighting 156 9 1 4Prevention of Falls 156 9 1 5Ramps 156 9 1 6Falling Material 157 9 1 7Hot Surfaces 157 9 1 8Slipping and Tripping 157 9 1 9Roof Work 157 9 1 10Insecure Structures 157 9 1 11Work Over Water 158 9 2Ladders and Stepladders 158 9 2 1Selection 158 9 2 2Condition 159 9 2 3Position 159 9 2 4Use 160 9 2 5Stepladders 162 9 2 6General 162 9 3Scaffolding Components 163 9 4Requirements Common to All Scaffolding 168 9 4 1Foundations 168 9 4 2Posts 168 9 4 3Runners 169 February 1993 Table Of ContentsPage ix 9 4 4Bearers 169 9 4 5Board Bearers 169 9 4 6Bracing 170 9 4 7Ties 170 9 4 8Platform Units 171 9 4 9Guardrail Systems and Toeboards 172 9 4 10Access 172 9 4 11Scaffold Ladders 172 9 4 11 1 Portable Straight and Extension Ladders 173 9 4 11 2 Vertical Ladder 173 9 4 12Workmanship 174 9 4 13Inspections 174 9 5Fabricated Tubular Frame and System Scaffolding 174 9 6Tube and Coupler Scaffolds 176 9 6 1Independent Tied Scaffold 176 9 6 2Light Duty Tube and Coupler Scaffolds 176 9 6 2 1Design Loading and Dimensions 176 9 6 2 2Platform 177 9 6 2 3Limitations 177 9 6 3 Medium Duty Tube and Coupler Scaffold 177 9 6 3 1Design Loading and Dimensions 177 9 6 3 2Platform 177 9 6 3 3Limitations 178 9 6 3 4Bearers 178 9 6 4Heavy Duty Tube and Coupler Scaffolds 178 9 6 4 1Design Loading and Dimensions 178 9 6 4 2Platform 178 9 6 4 3Limitations 178 9 6 4 4Bearers 179 9 7Free Standing Tower Scaffolds 179 9 7 1General Requirements 179 9 7 2Design Loading and Dimensions 179 9 7 3Runners and Bearers 179 9 7 4Bracing 179 9 7 5Ties 179 9 7 6Platform 180 9 7 7Access 180 9 7 8Limitations 180 9 8Mobile Tower Scaffolds 180 9 8 1Foundations 180 9 8 2Operation 181 9 8 3Limitations 181 9 9Scaffolds for Tanks and Vessels 181 9 9 1Bracket Scaffolds 181 9 10Special Scaffolds 182 9 11Scaffold Terminology 182 10 0 HAND TOOLS AND POWER TOOLS 193 10 1Hand Tools General 194 10 1 1Quality 194 10 1 2Cleanliness 194 10 1 3Repair and Storage 194 10 1 4Selection 194 February 1993 Table Of ContentsPage x 10 1 5Electrical Risks 194 10 2Individual Hand Tools Precautions 194 10 2 1Screwdrivers 194 10 2 2Hammer 195 10 2 3Chisels 195 10 2 4Picks and Shovels 195 10 2 5Spanners and Wrenches 195 10 2 6Pipe Wrenches 195 10 2 7Pliers 196 10 2 8Jacks 196 10 2 9Hacksaws 196 10 2 10 Hand saws 196 10 3Power Tools General 196 10 3 1Quality 196 10 3 2Repair and Storage 197 10 4Pneumatic Tools 197 10 4 1General 197 10 4 2Individual Tools Precautions 198 10 4 2 1 Jack Hammer and Concrete Breakers 198 10 4 2 2 Rock Drill 198 10 4 2 3 Grinding Machine 198 10 5Cartridge Operated Tools 203 10 5 1General 203 10 5 2Storage 203 10 5 3Selection and Training of Personnel 203 10 5 4Personal Protective Equipment 204 10 5 5Issue and Returns 204 10 5 6Work Permits 204 10 5 7Use 204 10 5 8Maintenance and Repair 206 10 6Electrically Operated Tools 207 10 6 1General 207 10 6 2Maintenance and Storage 208 10 6 3Personal Protective Equipment 208 10 6 4Individual Tools Precautions 209 10 6 4 1 Grinders 209 10 6 4 2 Drills 209 10 6 4 3 Saws 209 10 6 4 4 Radial Saws 210 11 0 PAINTS AND COATINGS 220 11 1Flammability Hazards of Coating Materials 220 11 1 1Flammable Materials 220 11 1 2Flash Point Definition 220 11 1 3Flammable Explosive Limits Definition 220 11 1 4Fire Precautions 221 11 2Health Hazards Associated With Paints 221 11 2 1Toxic Materials 221 11 2 2Dermatitic Materials 222 11 2 3Prevention of Health Hazards 222 11 3Ventilation in Confined Spaces 222 11 4Surface Preparation 223 11 4 1Abrasive Blast Cleaning 224 February 1993 Table Of ContentsPage xi 11 4 2Hydroblast and Steam Cleaning 224 11 4 3Hand and Power Tool Cleaning 224 11 4 4Chemical Cleaning 225 11 4 5General Safety in Surface Preparation 225 11 5Personal Protective Equipment 226 11 6Paint Application 228 11 6 1Paint Materials 228 11 6 2General Safety In Paint Application 228 11 7Scaffolding and Ladders 229 11 8Tarring Operations 229 11 9General Safety for Paints and Coatings 229 12 0 CONCRETE CONCRETE FORMS AND SHORING 232 12 1General 232 12 2Reinforcing Steel 232 12 3Bulk Concrete Handling 232 12 4Concrete Placement 232 12 4 1Concrete Mixers 232 12 4 2Guardrails 232 12 4 3Bull Floats 232 12 4 4Powered Concrete Trowels 233 12 4 5Concrete Buggies 233 12 4 6Pumpcrete Systems 233 12 4 7Concrete Buckets 233 12 4 8Discharging on Slope 233 12 4 9Back Up Man Truck Spotter 233 12 4 10 Pneumatic Hose 233 12 5Vertical Shoring 233 12 5 1General Requirements 233 12 5 2Tubular Welded Frame Shoring 234 12 6Forms and Shoring 234 12 6 1General Provisions 234 12 6 2Vertical Slip Forms 235 12 6 3Tube and Coupler Shoring 235 12 6 4Single Post Shores 236 February 1993 Table Of ContentsPage xii III Mechanical Equipment And Materials 237 1 0 CRANES AND LIFTING EQUIPMENT 238 1 1Competent Person 239 1 2Saudi Aramco Crane Operations General Requirements 239 1 3Saudi Aramco Crane Operator Qualifications 240 1 4Special Crane Operating Procedures 240 1 5Effect of Wind Speeds on Crane Operations 240 1 6Overhead Power Lines 240 2 0 SLINGS AND LIFTING GEAR RIGGING 245 2 1 Safe Working Load SWL 245 2 2 Chain Slings 246 2 2 1Grades 246 2 2 2Repairs 246 2 3Wire Rope Slings 246 2 4Synthetic Webbing Slings 247 2 4 1Removal from Service 247 2 4 2Repaired Slings 247 2 5Synthetic and Natural Fiber Rope Slings 248 2 6Care of Slings 249 2 7Hooks 249 2 8Spreader Bars 250 2 9Eyebolts And Safety Hoist Rings 250 2 10Shackles 251 2 11Rigger 251 3 0 MECHANICAL EQUIPMENT 257 3 1Operators 258 3 1 1Qualifications 258 3 1 2Licensing Requirements 258 3 2Machinery Guards 259 3 2 1Multi Piece Tire Rims and Locking Rings 259 3 3General Requirements 259 3 4Compressors 260 3 5Concrete Mixers and Batching Plants 261 3 6Dumpers and Dump Trucks 262 3 7Excavators 263 3 8Fork Lift Trucks 264 3 9Generators 265 3 10Graders Dozers Scrapers Loaders And Miniloaders 266 3 11Woodworking Machinery 266 4 0 MATERIALS HANDLING 268 4 1Planning 268 4 2Machine Transport 269 4 2 1Dumpers 269 4 2 2Tractors and Trailers 270 4 2 3Conveyor Belts and Monorails 270 4 2 4Concrete Pumps 270 4 3Site Stores 270 4 4Manual Handling 271 February 1993 Table Of ContentsPage xiii IV Electrical And Radiation 275 1 0 ELECTRICITY 276 1 1Voltage 277 1 2Temporary Installations 277 1 3Hand Tools and Lighting 278 1 4Work on Live Equipment 279 1 5Overhead and Underground Cables 280 1 6Overhead Power Transmission and Dist