Handbook
March 23, 2022 | Author: Anonymous | Category: N/A
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Pipe Line Company
Safety Handbook
2006
Health, Environment & Safety Chevron Pipe Line Company
Safety Handbook Revised September 2006
Emergency Information Immediate Notification Procedure
http://cpl.chevron.com/ emergencyresponse/
Emergency Hotline Contact Number
(877) 863-5196 This number is ONLY for CPL internal calls
Ambulance, Police or Fire Department
911
CPL Security Issues
CPL Security Advisor 281-684-4194
In Case of a Motor Vehicle Accident
Call your supervisor first or the Emergency Hotline For emergency situations and/or injuries call 911 immediately
Copyright 2006 This handbook contains confidential and proprietary information of Chevron Corp. Any use of this manual without authorization from Chevron and/or its affiliates is prohibited. The Safe Practices Handbook was written by the Chevron Pipe Line Company, Health, Environment, and Safety Team in Houston. It was published by the BRES Global Information Design and Consulting Team in Houston. Publication is available on alternative media at: http://www.chevron.com/pipelinecsm/documents/SafetyHandbook.pdf
Chevron Pipe Line Company
Safe Practices Handbook Acknowledgment This Safe Practices Handbook has been prepared with your personal safety and well-being in mind. You are expected to read, understand it and follow these practices as you perform your daily work assignments. If you have any questions about the meaning or intent of any of the practices in this handbook, you may ask your supervisor or contact the CPL HES staff for more information. After you read, understand and agree to follow the practices listed here, please fill out and sign this form, detach this “Acknowledgment” and return it to your supervisor. This document will be retained. I have read, understood, and agree to abide by the health, environment and safety practices contained herein. Name (Print): ___________________________________ Please check as appropriate: ❏ Employee ❏ Contractor CAI / ID number / Company name: _________________ ______________________________________________ Date: __________________________________________ Signature: ______________________________________ Comments: If you have any suggestions for updates or improvements to this handbook, we’d like to hear them. Please email your comments to the senior safety specialists or acknowledge understanding of the handbook via Knowledge Planet (CPL Safety Handbook).
Blank
Preface It is the intent of Chevron Pipe Line Company (CPL) to read and use this handbook to comply with our corporate Policy 530, “Health, Environment and Safety” and to abide by all applicable government laws and regulations, as well as internationally accepted industry best practices. To this end, all levels of the organization are responsible for taking all practical measures to ensure that the design, installation, operation, and maintenance of CPL facilities and equipment, are in accordance with the information contained here. That’s why it’s important that you read the handbook in its entirety and make these safety practices part of your day-to-day behavior at Chevron Pipe Line Company.
Rebecca B. Roberts President, CPL
Contents 1.0 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2.0 General Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.1 Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.1.1 Team Leader . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.1.2 Employee. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2.1.3 Contractor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2.1.4 Short-Service Employees (SSE). . . . . . . . . . . . . 7 2.1.5 Visitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.2 Incident Reporting and Analysis . . . . . . . . . . . . . . . . . 8 2.3 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2.3.1 New Employee Orientation. . . . . . . . . . . . . . . . 8 2.3.2 HES Required Training . . . . . . . . . . . . . . . . . . . 9 2.3.3 Job Safety Analysis (JSA) . . . . . . . . . . . . . . . . . . 9 2.4 Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.5 Food and Beverage . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.6 Smoking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.7 Alcohol and Drugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.8 Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 2.9 Discipline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.0 Personal Protective Equipment (PPE). . . . . . . . . . . . . . . . 14 3.1 Mandatory PPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 3.2 Field Work Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3.3 Protective Clothing – General . . . . . . . . . . . . . . . . . . 16 3.4 Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 3.5 Eyes and Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 3.6 Hearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 3.7 Respiratory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 3.8 Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 3.9 Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 3.10 Fall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 4.0 Common Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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4.1 Slip, Trip, and Fall Prevention (walking hazards) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 4.2 Stairways and Elevated Work Surfaces . . . . . . . . . . 26 4.3 Ladders and Scaffolds . . . . . . . . . . . . . . . . . . . . . . . . . 27 4.3.1 Ladders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 4.3.1.1 Portable 4.3.1.2 Positioning a Ladder Straight 4.3.1.3 Positioning Step 4.3.1.4 Permanently Fixed Ladders 4.3.2 Scaffolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 4.4 Worker Safe Guards . . . . . . . . . . . . . . . . . . . . . . . . . . 30 4.5 Grinding Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 4.6 Tools Maintenance and Use . . . . . . . . . . . . . . . . . . . . 31 4.7 Equipment/Machinery in Motion . . . . . . . . . . . . . . . 34 4.7.1 Centrifuge Machines . . . . . . . . . . . . . . . . . . . . 34 4.7.2 Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 4.7.3 Engines/Turbines . . . . . . . . . . . . . . . . . . . . . . . 35 4.7.4 Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 4.8 Pocket Knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 5.0 Safe Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 5.1 Safety Meetings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 5.2 Safety Signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 5.3 Behavior Based Safety Process, Inspections or Audits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 5.4 Permit to Work (PTW) Systems. . . . . . . . . . . . . . . . . 38 5.5 Materials Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 5.5.1 Handling Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . 39 5.5.2 Tractor Loader/Backhoe Unit Operation. . . . 40 5.5.3 Powered Industrial Truck (PIT or Forklift) Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 5.5.4 Cranes and Hoisting, Cables and Slings. . . . . 43 5.5.4.1 Inspection Criteria 5.5.4.2 Capacity Chart 5.6 Hazardous Materials and Substances. . . . . . . . . . . . 49 5.6.1 General Principles . . . . . . . . . . . . . . . . . . . . . . 49
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5.7
5.8
5.9
5.10
5.11
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5.6.2 Safety Color Coding. . . . . . . . . . . . . . . . . . . . . 50 5.6.3 Storing Flammable Liquids . . . . . . . . . . . . . . . 50 5.6.4 Corrosive Chemicals . . . . . . . . . . . . . . . . . . . . 51 5.6.5 Solvents and Cleaning Agents . . . . . . . . . . . . . 51 5.6.6 Using Tools Around Chemicals and Gases . . 52 Hazards Communication (HAZCOM) . . . . . . . . . . . 53 5.7.1 List of Chemicals . . . . . . . . . . . . . . . . . . . . . . . 53 5.7.2 Material Safety Data Sheet (MSDS) . . . . . . . . 53 5.7.3 Material Labeling . . . . . . . . . . . . . . . . . . . . . . . 54 Excavation, Trenching and Shoring . . . . . . . . . . . . . 57 5.8.1 Soil type and Site Preparation. . . . . . . . . . . . . 57 5.8.2 Worker Protection . . . . . . . . . . . . . . . . . . . . . . 58 5.8.3 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 5.8.4 Permit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Gas Testing and Analysis . . . . . . . . . . . . . . . . . . . . . . 59 5.9.1 Plan the Gas Tests. . . . . . . . . . . . . . . . . . . . . . . 59 5.9.2 Calibrating and Maintaining Gas Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . 59 5.9.3 Verify Instrument Performance Before Gas Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 5.9.4 Review Precautions . . . . . . . . . . . . . . . . . . . . . 60 5.9.5 Conduct Gas Tests . . . . . . . . . . . . . . . . . . . . . . 60 5.9.6 Interpret Gas Test Readings. . . . . . . . . . . . . . . 61 Confined Spaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 5.10.1 Workplace Evaluation . . . . . . . . . . . . . . . . . . . 62 5.10.2 Pre-Entry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 5.10.3 Working in a Non-Permit Required Confined Space. . . . . . . . . . . . . . . . . . . . . . . . . 63 5.10.4 Confined Space Entry Using Forced-Air Ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 5.10.5 Permit-Required Confined Space Entry . . . . 64 Lockout/Tagout (LOTO) . . . . . . . . . . . . . . . . . . . . . . . 64 5.11.1 Energy Sources . . . . . . . . . . . . . . . . . . . . . . . . . 64 5.11.2 Equipment Specific Procedure (ESP) Sheet . 65 5.11.3 Normal Equipment Isolation . . . . . . . . . . . . . 66 5.11.4 Shift Change . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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5.12 Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 5.12.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 5.12.2 Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 5.12.3 Extension Cords . . . . . . . . . . . . . . . . . . . . . . . 69 5.12.4 Electrical Power Tools . . . . . . . . . . . . . . . . . . 70 5.12.5 Static Electricity . . . . . . . . . . . . . . . . . . . . . . . 71 5.12.6 Sampling and Gauging . . . . . . . . . . . . . . . . . 72 5.12.7 Electrical Fuses and Circuit Breakers . . . . . 72 5.12.8 Explosion-Proof Electrical Equipment . . . . 73 5.12.9 Batteries and Standby Generators . . . . . . . . 73 5.12.10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 74 5.13 Hot Work Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 5.13.1 Hot Work Permits . . . . . . . . . . . . . . . . . . . . . 74 5.13.2 Area Preparation . . . . . . . . . . . . . . . . . . . . . . 76 5.13.3 Fire Watch . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 5.14 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 5.14.1 General Precautions . . . . . . . . . . . . . . . . . . . 78 5.14.2 Minimizing Electric Shock from Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . 79 5.14.3 Welding in or Near Tanks or on Pipelines That Contained or Have Contained Hydrocarbons . . . . . . . . . . . . . . . . . . . . . . . . 80 5.14.4 Hot Tapping . . . . . . . . . . . . . . . . . . . . . . . . . 82 5.14.5 Compressed Gas Cylinders. . . . . . . . . . . . . . 82 5.14.5.1 Oxygen and Acetylene 5.14.5.2 Compressed Air 5.14.5.3 Natural Gas 6.0 Pipeline Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 6.1 General Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 6.1.1 DOT Pipeline Safety Regulations . . . . . . . . . . 90 6.1.2 Work on Existing Pipelines . . . . . . . . . . . . . . . 90 6.1.3 LOTO (5.11) and Blinding Procedure . . . . . . 92 6.1.4 Valves, Piping and Tubing . . . . . . . . . . . . . . . . 93 6.1.4.1 Block Valves
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6.1.4.2 Check Valves 6.1.4.3 Pressure Relief (Safety) Valves 6.1.4.4 Valve Actuation 6.1.4.5 Pressure Gauges 6.1.5 Scraper Traps . . . . . . . . . . . . . . . . . . . . . . . . . . 95 6.1.6 Engine and Motor Operation . . . . . . . . . . . . . 95 6.2 Tank Gauging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 6.2.1 Ascending and Descending Tanks . . . . . . . . . 96 6.2.2 Tank Top Safety . . . . . . . . . . . . . . . . . . . . . . . . 96 6.2.3 Gauging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 6.2.4 Static Electricity . . . . . . . . . . . . . . . . . . . . . . . . 97 6.2.5 Sampling and Gauging . . . . . . . . . . . . . . . . . . 97 6.2.6 Tank Dike Maintenance. . . . . . . . . . . . . . . . . . 97 6.3 Tank and Vessel Cleaning . . . . . . . . . . . . . . . . . . . . . . 98 6.3.1 General Precautions . . . . . . . . . . . . . . . . . . . . . 98 6.3.2 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 6.3.2.1 Light Inside Tanks 6.3.2.2 Personal Protective Equipment 6.3.2.3 Atmospheric Monitoring Equipment 6.3.2.4 Ventilating Fan or Exhauster 6.3.3 Cleaning Procedures . . . . . . . . . . . . . . . . . . . . 99 6.3.3.1 Prepare the Area 6.3.3.2 Cold Repair Work 6.3.3.3 Hot Repair Work 7.0 Transportation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 7.1 Motor Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 7.1.1 Vehicle Operation. . . . . . . . . . . . . . . . . . . . . . 102 7.1.2 Driver Responsibility . . . . . . . . . . . . . . . . . . . 102 7.1.3 Safe Driving Principles . . . . . . . . . . . . . . . . . 103 7.1.3.1 Inspecting Vehicles 7.1.3.2 Backing 7.1.3.3 Turning 7.1.3.4 Following 7.1.3.5 Parking 7.1.3.6 Loading and Unloading v
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7.1.3.7 Use of Cellular Phones While Driving 7.1.3.8 Transporting Tools and Other Materials 7.1.4 Breakdowns. . . . . . . . . . . . . . . . . . . . . . . . . . . 107 7.1.5 Trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 7.1.6 Commercial Driver’s License . . . . . . . . . . . . 110 7.1.7 Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 7.2 Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 7.2.1 Marine Travel (Boat Transportation). . . . . . 110 7.2.2 Personal Flotation Devices . . . . . . . . . . . . . . 112 7.2.3 Swing Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . 113 7.2.4 Personnel Baskets . . . . . . . . . . . . . . . . . . . . . . 115 7.3 Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 7.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 7.3.2 Helicopter Travel . . . . . . . . . . . . . . . . . . . . . . 116 7.3.2.1 Arrival at Departure Points 7.3.2.2 Embarking and Disembarking Aircraft 7.3.2.3 Pilot-in-Command 7.3.2.4 Special Rules for the Sikorsky S-76 7.3.2.5 In Flight 7.3.2.6 Miscellaneous Rules 7.3.3 Fixed Wing Aircraft . . . . . . . . . . . . . . . . . . . . 121 8.0 Ergonomics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 8.1 Musculoskeletal Injuries and Cumulative Trauma Disorders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 8.2 Alternative Work Breaks. . . . . . . . . . . . . . . . . . . . . . 122 8.3 Workstation Design. . . . . . . . . . . . . . . . . . . . . . . . . . 122 8.4 Work Habits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 8.4.1 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 8.4.2 Back Injury – Low Back Pain . . . . . . . . . . . . 123 8.5 Exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 9.0 Office Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 9.1 Computer Workstations . . . . . . . . . . . . . . . . . . . . . . 126
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9.2 9.3 9.4 9.5 9.6 9.7
Floors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Aisles and Stairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Office Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . 128 Material Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Fire Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
10.0 Emergency Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 10.1 Work Site Fire Emergencies . . . . . . . . . . . . . . . . . . . 130 10.2 Emergency Response Plans . . . . . . . . . . . . . . . . . . . . 131 10.3 Emergency Drills . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 11.0 First Aid and CPR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 11.1 First Aid Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 133 11.1.1 First Aid Kits . . . . . . . . . . . . . . . . . . . . . . . . 133 11.1.2 Eye Wash and Safety Showers . . . . . . . . . . 133 11.2 Basic First Aid Steps . . . . . . . . . . . . . . . . . . . . . . . . . 134 11.2.1 Artificial Respiration. . . . . . . . . . . . . . . . . . 134 11.2.2 Cardiopulmonary Resuscitation (CPR) . . 135 11.2.3 Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 11.2.3.1 Arterial 11.2.3.2 Venous 11.2.4 Burns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 11.2.4.1 Thermal 11.2.4.2 Chemical 11.2.4.3 Electrical 11.2.5 Thermal Stress . . . . . . . . . . . . . . . . . . . . . . . 138 11.2.5.1 Heat Stroke/Heat Prostration 11.2.5.2 Heat Exhaustion 11.2.5.3 Frostbite 11.2.5.4 Hypothermia 11.2.6 Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 11.2.7 Fractures. . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 11.2.8 Foreign Body in an Eye. . . . . . . . . . . . . . . . 141 11.2.9 Choking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 11.2.10 Snake and Insect Bites. . . . . . . . . . . . . . . . . 142
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12.0 Fire Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 12.1 Fire Triangle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 12.2 Fire Classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 12.3 Fire Suppression Equipment . . . . . . . . . . . . . . . . . . 145 12.3.1 Fire Protection Equipment. . . . . . . . . . . . . 145 12.3.2 Inspection and Maintenance of Fixed Fire Extinguishing Systems . . . . . . . . . . . . . . . . 145 12.3.3 Portable Fire Extinguishers . . . . . . . . . . . . 146 12.3.4 Wheeled Fire Extinguishers . . . . . . . . . . . . 147 12.3.5 Fire Water Systems . . . . . . . . . . . . . . . . . . . 147 13.0 Occupational Health . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 13.1 Work Environment Hazards . . . . . . . . . . . . . . . . . . 149 13.1.1 Chemical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 13.1.2 Physical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 13.1.3 Dusts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 13.2 Monitoring Exposures. . . . . . . . . . . . . . . . . . . . . . . . 158 13.3 Bloodborne Pathogens . . . . . . . . . . . . . . . . . . . . . . . 159 14.0 Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 14.1 Waste Management. . . . . . . . . . . . . . . . . . . . . . . . . . 160 14.1.1 Hazardous . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 14.2 Regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 14.2.1 Clean Air Act . . . . . . . . . . . . . . . . . . . . . . . . . 161 14.2.2 Clean Water Act . . . . . . . . . . . . . . . . . . . . . . 161 14.2.3 Resource Conservation and Recovery Act RCRA . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 14.2.4 Comprehensive Environmental Response, Compensation and Liability Act CERCLA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 14.2.5 Superfund Amendment and Reauthorization Act (SARA Title III) . . . . . . . . . . . . . . . . . . . 161 14.2.6 Occupational Safety and Health Act (OSHA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 14.2.7 Toxic Substances Control Act (TSCA) . . . . 162 14.2.8 Hazardous Materials Transportation Act . . 163 14.2.9 Safe Drinking Water Act. . . . . . . . . . . . . . . . 163 Safe Practices Handbook – 2006 viii
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 A. Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 B. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 C. Safe Work Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . 167 D. Excavations Checklist . . . . . . . . . . . . . . . . . . . . . . . . 168 E. Confined Space Checklist . . . . . . . . . . . . . . . . . . . . . 169 F. LOTO Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 G. Hot Work Permit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
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1.0
Introduction
Chevron Pipe Line Company (CPL) is committed to the principles of Chevron’s Policy 530, for “Health, Environment and Safety.” We follow the Operational Excellence (OE) Management System and our conduct is guided by the Tenet Principles. This Handbook has been given to you to: • Provide general guidelines and rules for conducting company business in a safe manner. • Verify compliance with various Occupational Safety and Health Administration (OSHA) and Department of Transportation (DOT) requirements as well as many other applicable regulations. The information contained here applies to all personnel and visitors, company- or contractor-related, engaged in or on any CPL activity or in any company owned, operated or maintained pipelines or facilities. Remember:
Stop Work Authority It is your Responsibility You have the Authority Zero is Attainable Your ideas and concerns are important. We always comply with the Tenets of Operational Excellence shown on the following page. As an employee or contractor for Chevron, you are responsible and authorized to stop any work that does not comply with these tenets, and there will be no repercussions to you. That is our commitment to you. Chevron Pipe Line Company
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CPL Tenets and Principles We believe all incidents are preventable. ✔
Do it safely or not at all
✔
There is always time to do it right
✔
When in doubt, find out
Always: 1. Operate within design or environmental limits. 2. Operate in a safe and controlled condition 3. Ensure safety devices are in place and functioning. 4. Follow safe work practices and procedures. 5. Meet or exceed customers' requirements. 6. Maintain integrity of dedicated systems. 7. Comply with all applicable rules and regulations. 8. Address abnormal conditions. 9. Follow written procedures for high risk or unusual situations. 10. Involve the right people in decisions that affect procedures and equipment.
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Chevron Pipe Line Company
Safe Performance Self-Assessment Before beginning any activity/task/job, after an incident or near miss, any unusual circumstances:
Assess the risk What could go wrong? What is the worst thing that could happen if something does go wrong?
Analyze how to reduce the risk Do I have all the necessary training and knowledge to do the job safely? Do I have all the proper tools and personal protective equipment?
Act to ensure safe operations Take necessary action to make sure the job is done safely! Follow written procedures! Ask for assistance, if needed!
Do not proceed unless everything is safe! For Everyone • Every Day • All the Time
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2.0
General Rules Accidents can and must be prevented.
Safety is a necessary part of an efficient operation. Compliance shall not be compromised for convenience, production or expediency.
✓ Shutdown Authorization: In cases of imminent danger, personnel are authorized and expected to order work stoppage, shut down facilities, and activate firefighting and life-safety systems as required to prevent injuries or catastrophic loss. Employees shall notify as soon as possible their team leader (and the site supervisor if appropriate) when such action is taken. ✓ Electronic equipment may be considered a risk (as a source of ignition) or security threat in certain areas, therefore the use of: Cell phones, photographic or film cameras (digital or not, with flash, light or without it) or similar devices, is restricted and not allowed without a permit.
2.1 Responsibilities Employees, contractors and/or visitors shall:
•
Be familiar with and abide by the: § Tenet Principles for CPL
§ rules and practices contained in this handbook § posted safety regulations in the workplace
§ written and oral company instructions to perform their jobs safely
•
4
Comply with all applicable country, federal and state regulations as applicable
Chevron Pipe Line Company
•
Consult their team leader before proceeding with a job if there is any question regarding job safety or regulatory requirements
2.1.1 Team Leader
• §
§
§
§
§
Develop operating rules and procedures consistent with our Policy 530 regarding Health, Environment and Safety. Ensure that:
•
Emergency procedures (e.g., station bills, pre-fire plans, emergency response plans, evacuation routes, etc.) are posted and that personnel are familiar with them.
•
Visitors, contractors, and/or new personnel: u
are briefed on appropriate emergency procedures on their arrival
u
have an HES initial orientation before starting work
u
contractors who will perform work shall receive a safety handbook returning its acknowledgement.
Provide instruction and guidance to ensure that employees and contractors follow proper work procedures; including any additional assistance to new employees and/or visitors. Communicate with and join employees regarding LPS activities (e.g., LPOs, LI, NLIs and status of an investigation if a loss is occurred, JSAs, etc.). Inspect tools, equipment, and working conditions to determine that there are no obvious or hidden safety hazards, or people performing unsafe acts. Encourage and enforce (if necessary) the rules and regulations that apply to the operation.
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§
Maintain workplace conditions by: 1. Periodically auditing facilities for potential hazards 2. Eliminating or mitigating hazards that present an unacceptable level of risk 3. Listening to employee feedback regarding workplace conditions
2.1.2 Employee §
§
§
Periodically check the equipment, tools and work area for possible safety hazards and inform the team leader of any unsafe conditions. Be prepared for emergency situations, locating safety showers, fire protection equipment, evacuation route, rally point, respiratory equipment and first aid equipment before you begin working, and make sure that the equipment is in good working order. Whenever necessary, participate and support LPS activities, including investigation processes.
2.1.3 Contractor §
§
§
§
6
Ensure that personnel assigned to work at Chevron locations are fit for duty and that they are physically capable of performing all aspects of their jobs. Conduct operations in a manner that constitutes no potential hazard to the employees, property, or the environment. Provide and maintain all required PPE, safety equipment, and instrumentation necessary to perform their work effectively, efficiently and safely. Have a designated safety representative at each job site responsible for all safety-related activities. On small or low-risk projects, the person in charge of the job may designate a qualified crewmember to contractor’s work. In any case, contractor safety
Chevron Pipe Line Company
§ §
§ §
personnel must periodically make visits to Chevron locations where their personnel are working. Bring any observed, unsafe conditions to the attention of a Chevron representative. Provide the designated Chevron Pipe Line representative with reports of hazards presented by the contractor’s work or identified during the contractor’s work. Have written safety programs and procedures, as required or needed. Conduct appropriate industrial hygiene monitoring and, if requested, provide copies of the results to CPL.
2.1.4 Short-Service Employees (SSE): Note: An SSE is an individual who has been employed by contractor or subcontractor for less than six months or has been in a like job by contractor for less than six months. §
§
No one-person crew may be staffed by an SSE. Only one SSE is allowed on a two-to-four person crew and on crews of five persons or more. No more than 20 percent may be SSEs. Contractor shall notify team leader and clearly identify any SSEs on its crews. A qualified mentor must be assigned to each SSE to monitor the SSE job performance. Exceptions to the SSE policy may be made only with Company’s prior approval.
2.1.5 Visitor § § § § §
Sign in when entering, boarding or leaving any CPL-owned site Follow instructions for the facility you are visiting Adhere to the safety practices contained in this handbook Wear your security ID at all times Never be alone on premises Safe Practices Handbook – 2006
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2.2 Incident Reporting and Analysis
•
Report to your team leader and/or Chevron representative immediately:
§ all accidents (e.g., on-the-job injury/illness, spill, fire, etc.) § near-misses
§ all motor vehicle incidents occurring at or affecting the worksite or its employees, visitors or contractors
•
Promptly investigate and analyze the reported events with your team to determine the root cause, and formulate immediate corrective and preventive measures. Depending on the nature of the incident, assistance from other departments may be warranted.
•
Data collection and investigation will begin within 24 hours
2.3 Training
•
Personnel must be trained in the proper use of equipment and safe performance of their jobs.
•
Documentation of past training must be kept at the work location.
•
Any questions or concerns regarding your training shall be expressed to your team leader.
2.3.1 New Employee Orientation §
The team leader is responsible for: • orientation which will take place the first day on the job • enrolling the new employee in the first available session regarding HES procedures
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Chevron Pipe Line Company
2.3.2 HES Required Training Many of the activities summarized here are not allowed until the employee has taken specific training, such as, but not limited to: §
confined spaces entry
§ lockout/tagout (LOTO)
§ heavy equipment operation (e.g., forklift, crane
operation, etc.)
§ first aid response § etc.
2.3.3 Job Safety Analysis (JSA)
§ Every task that is not covered by a procedure or activity
must have a JSA before the activity is performed. Employees must be trained and aware of the potential risks involved with the operation.
§ JSA must be documented and available to consult at the
work location.
2.4 Housekeeping
•
Good housekeeping improves safety and efficiency. Keep tools, equipment, facilities and your work area clean and orderly. Before waste accumulates, dispose of it in compliance with local regulations.
•
When not in use, store hand tools in bins or toolboxes with sharp edges facing inward. Return tools and work equipment to the place provided for them.
• • •
Maintain tools and work equipment in good condition. Store heavy equipment and heavy tools on low shelves. Discard any tools that cannot be maintained in good condition, and request replacements through your team leader.
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•
Keep access clear to walkways, exits and firefighting equipment. Exits shall be kept free of obstructions. Work areas, walkways, and stairways shall be kept free of slipping/tripping hazards.
•
Keep all company vehicles free of trash, oily rags, and other debris.
•
Clean up spills immediately. Use barricades to secure the area, if necessary.
2.5 Food and Beverage
•
Food or drink shall not be kept or consumed in areas where possible contamination is present. Use only designated areas.
2.6 Smoking
•
Smoke in designated “smoking areas” only. When in doubt, please ask!
•
Safety matches are the only type of matches permitted on a CPL work site. Carrying strike-anywhere or lighters on company premises is prohibited.
•
Disposable butane lighters are not permitted at any field locations. Any lighter carried on company premises must have enclosed flint, steel, and operating mechanisms to prevent accidental lighting and sparking.
2.7 Alcohol and Drugs
•
10
Employees shall notify their supervisors when they are taking medication, (prescription or nonprescription), that might affect job performance.
Chevron Pipe Line Company
•
Prescription drugs brought onto Chevron facilities must be in the container in which they were originally dispensed and must be prescribed for that employee. The employee's team leader must be notified of the presence or use of any prescription drugs that may impair an employee's judgment or performance.
•
The illegal use, possession, distribution, purchase, or sale of any controlled substance by any person while on CPL premises, engaged in CPL business, or while operating equipment is prohibited.
•
Personnel assigned to a position which is deemed “safety-sensitive” are required to maintain a blood alcohol concentration (BAC) of 0.00 percent at all times while on duty or driving a company-owned or rented vehicle.
•
CPL reserves the right to conduct or require an alcohol or controlled substance screening test on any person who is on premises or operating CPL equipment, engaging in CPL business, or applying for employment. Prior consent must be obtained from any person who is to be screened.
•
Mandatory screening will occur when:
§ alcohol or drugs are suspected to be a contributory cause to an incident
§ an individual’s behavior is such that excessive alcohol or drug influence is suspected
§ a driver is involved in a motor vehicle crash or the driver’s vehicle was hit by another vehicle
•
DOT Drug Testing Regulations
§ All personnel who perform operations, maintenance or emergency response functions
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required by DOT regulations have been deemed by the DOT to be “safety sensitive.” All safety sensitive employees are subject to part 199 of the DOT drug testing regulations, which includes random drug testing
§ Random and “for cause” drug testing may be requested in accordance with DOT regulations, the CPL Anti-Drug Plan, and Chevron Corporation drug-abuse prevention policies
2.8 Security
•
If the security staff is unavailable to conduct a search, the supervisor must have another supervisor present to witness the search. In all cases, the supervisor must inform the department manager before a search is conducted.
•
Without prior announcement, company-authorized representatives may search any person, vehicle, and personal items of anyone entering, working at, or exiting from any controlled company work area.
•
When appropriate, items discovered through an inspection may be taken into custody and turned over to the appropriate local law enforcement agency. Failure to comply with any of the above shall result in disciplinary actions, which may include dismissal.
2.9 Discipline Disciplinary action, including discharge, will be taken for disregard or violation of safety instructions or practices as follows:
•
12
any violations will result in disciplinary action up to and including termination
Chevron Pipe Line Company
•
failure to maintain fitness for duty will result in disciplinary action up to and including termination
•
to deviate from safety instructions will be cause for disciplinary action up to and including termination
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3.0
Personal Protective Equipment (PPE)
PPE is an essential element in protecting employees from work place hazards and on-the-job injuries. All PPE shall meet standards established by recognized governmental and/or industry groups.
3.1 Mandatory PPE
•
All employees, contractors, and visitors must wear the following protective equipment when working in areas other than offices, parking areas or change rooms unless wearing the PPE causes an additional risk, which will have to be validated by the team leader: § fire-resistant clothing § hard hats
§ steel-toed footwear § safety glasses
Additional protection may be required depending on the hazards (as indicated by the team leader, signs or procedures); this equipment includes, but is not limited to the following: § safety glasses § hard hats
§ respirators
§ goggles (grinding, chemical, brazing, or cutting)
§ face shields (splash and welding), gloves, welders’ jacket, pants, arm protectors as appropriate, life jackets, full body harness, etc.
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Chevron Pipe Line Company
PPE shall be furnished by the employer (Chevron or contractor) as required and at no charge to the employee or visitor. It is the employee's responsibility to maintain it in a safe and sanitary condition, as well as follow the manufacturers' recommended instructions or applicable procedures for cleaning, maintenance, use and replacement.
3.2 Field Work Clothing
•
Employees are encouraged to wear natural or nonmelting fibers such as cotton or wool as general clothing or under their Fire Resistant Clothing (FRC). Kermel, Kevlar (PBI Gold or equivalent), and Nomex III are all acceptable materials for protection against flash fires. For other fire resistant clothing materials check with your safety specialists. If clothing (including shoes) becomes contaminated with a potentially hazardous (flammable or toxic) material it should be: § immediately removed to prevent skin irritation and/or possible ignition
§ changed in a well-ventilated area, and the person should take a shower if necessary
§ not worn again until it has been properly cleaned
•
FRC shall be worn by all persons working in or around any of CPL-owned or operated facilities and/or pipelines, which contain hydrocarbons or electrical equipment, but not limited to: § any of the operations units and fenced in areas § pump stations and valve locations
§ maintenance areas, truck racks, and tank farms § electrical switchgear areas
§ rectifier checks, and valve manifold areas
•
Personnel may travel between designated facility entrances/parking areas and their work locations
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without wearing FRC, provided they use the roadways on the most direct path to their work locations. FRC is not required in offices and machine shops.
•
FRC shall be worn in the appropriate manner to maximize protection:
§ must cover the entire body from the neck to the ankles
§ should be worn as an outer garment, unless a Tyvek suit is required for the operation (you may also wear layered clothing underneath as needed for personal warmth)
§ may not be modified, such as, long sleeves rolled up, zippers left down or shirts/jackets unbuttoned
3.3 Protective Clothing - General
•
The wearing of loose or ragged clothing must be avoided when working around moving machinery because it can get caught in machinery, moving belts, etc. Long shirt tails must be tucked in trousers. Clothing (including shoes) that becomes contaminated with a potentially hazardous (flammable or toxic) material should be removed immediately to prevent skin irritation and possible ignition. Change such clothing in a well ventilated area and take a shower if necessary. Do not wear the clothing again until it has been properly cleaned. Hair long enough to be potentially hazardous while working around moving machinery or rotating tools and equipment shall be secured. Hair styles that make it impossible to wear a hard hat properly are not permitted. Except in office jobs, rings and other jewelry (except watches) should be removed while at work.
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Chevron Pipe Line Company
3.4 Head
•
Hard hats shall be worn by all personnel V-Guard at all work locations and along the rightShock Guard of-way, except in offices or when an employee is riding in an enclosed vehicle. Hard hats must be nonmetallic (non-conductive or ‘dielectric’) and meet ANSI Z89.1, Class A and B requirements.
•
Electricians and other employees who could be exposed to electrical hazards should use dielectric or nonmetallic accessories (such as liners and chin straps) only.
•
For situations during welding operations where the welder must work in a head-down position, and where there are no overhead hazards, the team leader shall have discretion to allow an exception to the hard hat requirement. These situations occur mainly in welding on the underside of pipelines when the welder’s attempts to keep the hard hat on can create a hazard. All other welding operations require a hard hat to be worn in combination with a welding shield.
•
Do not alter hard hats in anyway that could reduce its dielectric or impact qualities. This includes drilling of any hole, carving, etching, painting, etc. Do not place objects between the liner and the shell while wearing the hat.
•
Employees should replace liners periodically and replace the hat when it becomes damaged or brittle. It is recommended that liners be replaced at least every six months, and hats at least every two years.
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3.5 Eyes and Face
18
•
All safety glasses or face shields must meet ANSI Z87.1 standards, and its primary intention is to protect where a potential eye hazard exists.
•
For prescription safety glasses, the company will pay 100 percent of the cost of frames and lenses. When an employee requires prescription lenses, the employee must furnish an up-to-date prescription (within one year). The employee pays for the examination and fitting. The company will provide up to two pairs of safety glasses per year, one clear and one tinted. The tinted lenses may only be gray, green or rose depending on the employee’s preference.
•
Contact lenses provide no protection to the eye and should be worn with other eye protection. They should not be worn in high-dust conditions or in the presence of irritating vapors or smoke.
•
Advise your team leader if you routinely wear any type of contact lenses. This information may be needed during a medical emergency. Also advise your team leader if you wear contact lenses due to surgical removal of your natural lenses. Carry some form of medical alert identification at all times. Wear chemical goggles over implanted contact lenses in areas where eye protection is required.
•
Do not wear “hard” contact lenses when you are working in a contaminated atmosphere with a supplied air respirator unless they are gas-permeable lenses (OSHA 1910.134) (e) (5ii). Air passing over non-gaspermeable lenses may severely dry the eyes and cause severe pain. “Soft” contact lenses are permitted.
Chevron Pipe Line Company
•
Safety glasses are not safety goggles. Use goggles to protect against hazards that may enter your eye from the sides. Do not depend on safety glasses for this protection. There are two primary types of goggles, impact and chemical.
•
Impact-type goggles shall be worn during activities involving flying or falling objects or particles such as: § chipping, cutting, or breaking stone, brick and concrete
§ using hammers, chisels or other steel hand tools § scraping paint or scale from wood or metal surfaces
§ using a wire brush to clean threads, fittings or metal and wood surfaces
§ grinding on abrasive wheels (even when a glass or plastic guard is provided) § using compressed air for cleaning purposes to clean or blow out debris
•
Splash-proof chemical goggles and face shields shall be worn when handling potentially hazardous chemical liquids and solids or in any other operation where the eyes may be exposed to potentially hazardous chemicals.
•
Never wear face shields alone as eye protection. Use face shields in addition to eye protection to protect the face and neck from flying particles, sprays of chemicals, splashes of molten metal and from hot solutions.
•
Welding, brazing, soldering or cutting operations require the use of shaded lenses. Use the following table to select the proper shaded lens for welding:
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Welding Operation
Minimum Shade Number
Shield metal-arc welding, up to 5/32" electrodes.............. 10 Shield metal-arc welding, 3/16 to 1/4" electrodes............. 12 Shield metal-arc welding, over 1/4" electrodes..................14 Gas metal-arc welding (nonferrous)..................................11 Gas metal-arc welding (ferrous)........................................ 12 Gas tungsten-arc welding................................................... 12 Atomic hydrogen welding.................................................. 12 Carbon arc welding............................................................ 14 Torch soldering..................................................................... 2 Torch blazing................................................................. 3 or 4 Light cutting, up to 1"................................................... 3 or 4 Medium cutting, 1 to 6"................................................ 4 or 5 Heavy cutting, over 6"................................................... 5 or 6 Gas welding (light), up to 1/8"..................................... 4 or 5 Gas welding (medium), 1/8 to 1/2".............................. 5 or 6 Gas welding (heavy), over 1/2"..................................... 6 or 8
•
20
Abrasive blasting and sandblasting require a hood designed specifically for this purpose. The hood should have appropriate eye and face protection: forced-air ventilation for the operator, and appropriate airpurifying respirators for others who may be exposed.
Chevron Pipe Line Company
3.6 Hearing
•
Hearing protection shall be worn by all workers exposed to 8-hour, time-weighted average (TWA) noise levels of 85 dB or above to prevent hearing loss. This may require wearing a combination of hearing protection devices (for example, earplugs and ear muffs).
•
CPL shall identify high noise areas and post appropriate warning signs so appropriate actions can be taken. Employees should report suspected highnoise areas to their safety specialist.
•
The warning signs will be posted at entrances indicating that hearing protection is required.
•
Also, use hearing protection whenever you're exposed to mobile noise sources such as power tools and equipment or during venting operations.
3.7 Respiratory
•
Respiratory equipment is required in any situation with at least one of the following conditions: § whenever the job needs to be performed in an oxygen-deficient area
§ in an area that contains hazardous concentrations of toxic contaminants
•
Prior to being approved for the use of respiratory equipment, employees shall: § have medical clearance from the company physician
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§ receive the required training (selection, use, care, maintenance and limitations of the equipment) § be fit-tested as appropriate for the respirator model he/she will be wearing
22
•
The type of respiratory protection equipment used will depend on the type of respiratory hazard, such as dust, chemical, vapor or paint respirators for protection during exposures to specified concentrations of these contaminants.
•
Use self-contained breathing apparatus or supplied air respirators when the atmosphere is immediately hazardous to life or health (for example, excessive concentrations of C02 or H2S). Breathing air shall meet at least the requirements of the specification for Grade “D” breathing air.
•
All respirators shall be examined prior to use. Employees shall clean, disinfect, and properly store respirators after each use, unless this responsibility is assigned to others. Additionally, respiratory protective equipment must be inspected monthly and prior to each use. Maintain a written inspection record with each piece of equipment.
•
Employees and contractors who may be required to wear respiratory protection, either in their normal duties or under emergency conditions, shall not be permitted to have beards, mustaches or sideburns in the facial area contacted by the mask. A tight face-tomask seal is required for the safe use of all types of respiratory protective equipment.
•
Employees who must wear prescription glasses, and whose normal duties require them to wear full-facepiece respiratory protection, will be provided with units designed for use with glasses.
Chevron Pipe Line Company
•
Employees who wear prescription glasses and who are required to wear full-face-piece respiratory protection should remove their glasses only in emergencies if they can see well enough to function without them; if not, positive-pressure units designed for use with glasses will be made available to them.
3.8 Hand
•
Employees shall wear appropriate hand protection when performing operations that expose the fingers and hands to cuts, scrapes, bruises, burns, and chemicals. Examples of appropriate hand protection include:
§ insulated or heat-resistant gloves when handling steam hose, or when performing other duties in which regular work gloves do not afford burn protection § leather or leather-palmed gloves when handling wire rope § cloth gloves when handling pipe, and rubber gloves approved for electrical work
§ chemical-resistant gloves when handling acids, caustics, caustic soda, etc.
§ hydrocarbon resistant gloves when using hydrocarbon-based solvents, cleaning agents, or chemicals The company will supply proper gloves, taking into account the type of work being performed and the types of chemicals that may be involved. Use extra caution when wearing gloves where there is a possibility of catching them in moving equipment; ask your supervisor, it may be better not to wear them.
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3.9 Foot
•
Foot protection is required whenever risk of falling objects is present. Field personnel are required to wear steel-toed footwear when working in areas outside of the office setting.
•
Acceptable footwear must comply with the following: § steel-toed
§ provide ankle coverage
§ have a notched heel that prevents slippage when climbing ladders § oil-resistant soles
•
Visitors (non-company personnel) to the field may not need to comply with CPL steel-toed footwear policy provided that they are accompanied by a CPL employee and do not participate in work activities that could result in a foot injury.
3.10Fall
•
Fall protection shall be used in certain situations. These include, but are not limited to: § open-sided floors, floor openings, catwalks, or platforms elevated six (6) feet or higher where handrails or barricades are not provided § working over water when personal flotation devices (PFDs) are not used.
•
24
Personal fall arrest systems consist of anchor points, connectors, and a full-body harness. They may also include a shock absorbing lanyard, deceleration device, lifeline, or suitable combination of these.
Chevron Pipe Line Company
•
Employees shall use fall protection devices where they are installed. Fall protection rescue equipment and personnel trained in its use will also have to be available at the job site.
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4.0
Common Hazards
On many occasions, accidents occur in places or during operations and activities that we take for granted. This section includes a few of those that are more frequent.
4.1 Slip, Trip, and Fall Prevention (Walking Hazards)
•
Watch your step while walking about the job to avoid tripping, stumbling, slipping and similar hazards.
•
Be aware that weather conditions such as ice, water, or mud can create or aggravate existing hazardous situations.
• •
Use the walks, stile and stairs provided.
• •
Avoid jumping from elevated places.
Remove or repair tripping or slipping hazards as they are found. Do not take shortcuts, such as walking up or down earthen banks or berms if stiles and walkways have been installed for your use.
4.2 Stairways and Elevated Work Surfaces
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•
Employees shall use available stairways, walkways and handrails.
•
Employees shall not climb onto vessels, tank roofs, etc. without safeguards (planking, scaffolds, etc.).
•
Working from any surface more than six feet above adjacent floor or ground requires guard rails or the use of fall protection.
•
Stairways having four or more risers shall have handrails.
Chevron Pipe Line Company
•
Where guard rails are installed, toe-boards shall be provided if a person can pass beneath the open sides or where falling materials can create a hazard.
•
Openings in floors into which a person can accidentally step or fall shall be covered, continuously attended, or protected by barricades or standard hand railings.
•
Employees shall avoid carrying loads that extend above eye level or otherwise obstruct vision when on stairways or elevated work surfaces.
4.3 Ladders and Scaffolds
•
Shall be examined for defects before each use. Defective equipment shall be removed from service and reported to the appropriate supervisor.
•
Wooden ladders shall not be painted. Paint hides cracks and other damage.
•
Always face a ladder when ascending or descending it. Both hands should be free to grip the ladder firmly.
•
Tools should be carried in a belt or should be raised and lowered by rope. (Make sure no one is standing below the tools as they're being transported).
•
Fiberglass ladders shall be used for electric equipment installations, repair or maintenance work.
4.3.1 Ladders 4.3.1.1 Portable
•
Employees shall only use portable ladders that have labels showing that the ladders conform to appropriate ANSI standards.
•
Metal ladders shall not be used for electrical equipment installations, repair or maintenance work where they may contact electrical conductors. Special non-conductive ladders (approved wooden, fiberglass, etc.) may be used.
•
A ladder shall not be used in a horizontal position as a walkway or scaffold.
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•
Portable ladders shall be equipped with safety feet to prevent slippage.
• •
Not more than one person shall be on the ladder.
•
Employees shall not stand or sit on the top two steps of a stepladder.
•
When two people are carrying a ladder, grasp it near both ends. Exercise caution when approaching doorways and corners.
•
A folding step ladder shall not be used in a straight closed position.
Employees shall not lean from a ladder to reach work, the ladder shall be repositioned.
4.3.1.2 Positioning a Ladder Straight
•
Set the portable ladder base at the correct angle. A rule of thumb: The distance from the foot of the ladder to the object it will lean against should be one-fourth the required height.
3 1/2 foot minimum lashed, clamped, or otherwise secured to structure ladder
1/4 height In other words, the feet of (working length) of ladder a 12-foot-long ladder should be placed about 2-1/8 feet away from the base of the object (12 ft ladder - 3-1/2 = 8.5 = working length = 8.5/4 = 2-1/8).
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•
Straight and extension ladders shall extend 3-1/2 feet beyond the top resting point when used for climbing onto a platform.
•
If this is not possible, a helper should hold the base of the ladder in position during use. Whenever possible, securely fasten the ladder at the top to prevent slipping.
Chevron Pipe Line Company
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Based on the nominal length of the extension ladder, each section of a multi-section ladder shall overlap the adjacent section by at least the number of feet stated below: Nominal Length of Overlap Ladder (Feet) (Feet) Less than or equal to 36 3 37-48 4 49-60 5
Set a portable ladder on a firm base. Fully extend the legs and lock the cross braces into place. Have someone help steady the ladder. Do not use the ladder if all its feet are not firmly contacting the ground.
overlap
4.3.1.3 Positioning Step
•
4.3.1.4 Permanently Fixed 4.3.1.4 Ladders
•
May vary from vertical to 75 degrees from horizontal and shall have a toe clearance of at least seven inches between the ladder and the surface behind the ladder.
•
Shall be securely fastened at the top, bottom, and intermediate points, as required.
•
Shall not be climbed longer than 20 feet unless it is equipped with a cage or the employee uses a fall protection device.
•
Construct scaffolds with provided handrails, midrails, toe boards, and all other items specified in the Chevron Safety in Design Manual.
4.3.2 Scaffolds
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A few safety tips while using a scaffold, do not: • walk under it while people are on it. • work off it during a strong wind. • place it in front of a door without locking/blocking the door closed or posting a guard. • leave tools or materials on it.
4.4 Worker Safeguards
•
Do not get inside guardrails or barriers while the equipment is in operation. Guardrails around operating equipment are placed there for your protection.
•
Follow all appropriate requirements regarding excavations to prevent someone or something from falling into one. Provide barricades as required.
•
Install temporary guards whenever portions of handrails have been removed to facilitate the handling of material. Reinstall permanent handrails immediately after the need for the opening has ended.
•
Make sure machine guards, such as those over belts and chains, are in place whenever equipment is readied for operation. Keep long hair, sleeves and shirt tails away from running equipment.
•
High-temperature surfaces (those that will cause burns if contacted) shall be clearly identified, insulated and/or guarded.
•
Apply lockout/tagout (LOTO) procedures on any setup or maintenance work.
4.5 Grinding Wheels
•
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When using or working near a grinding wheel, wear goggles or safety glasses and a full-face shield.
Chevron Pipe Line Company
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Do not operate the grinder unless it has a safety guard and is properly adjusted.
•
Grinders are considered an ignition source. Obtain a hot-work permit before operating grinders in a restricted area (i.e., an electrically-classified area).
•
Do not use the side of a grinding wheel to grind unless the wheel is designed for that purpose.
•
Use an appropriate wheel when grinding aluminum, rather than wheels designed for ferrous metals.
•
Inspect safety guards frequently to ensure that proper distances are maintained.
•
The work rest for a grinder shall be no more than 1/4 inch from the wheel and the tongue guard no more than 1/8 inch from the wheel.
•
Do not attempt to adjust the guards while the wheel is in motion. Make sure it is unplugged (with plug within reach) before making any adjustments or repairs.
•
Inspect the grinding wheel before each use for signs of possible cracking or other damage. Replace all defective wheels immediately.
•
Grinding wheels should never be used on Asbestos Containing Materials (ACM) unless retrofitted to an approved HEPA vacuum system.
4.6 Tools Maintenance and Use
•
Inspect all tools before using them to determine if they are the proper size and in good condition. If they are not in good condition, let your team leader know. Do not use defective or damaged tools.
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32
•
Keep tool surfaces and handles clean and free of excess oil to prevent slipping and glancing.
•
Tools shall be used only for the purpose for which they are designed. Use the right tool for the job.
•
Keep tools in a safe place and not in overhead areas or on ladders. Do not carry screwdrivers or other sharp objects in a pants pocket, use an approved tool pouch or equivalent to carry tools.
•
Upon completion of a job, clean tools and return them to the tool box or storage area.
•
Make sure wrenches have a good bite before applying pressure. An employee shall ensure they are in a safe and stable position before applying pressure to a tool handle, to avoid losing balance or falling if the tool should slip.
•
Brace yourself and place your body in the proper position so that you will not fall in case the tool slips. Also provide sufficient clearance for your hands and fingers in case the tool slips.
•
Keep chisels, axes and similar tools sharp for safety and efficiency.
•
Frequently inspect driving faces of hammers, chisels, bars, and similar tools for mushroom heads, broken faces and other defects. Discard defective tools. Use a tool holder when using driving tools, striking chisels, punches, rods, stakes, etc., to prevent hand injuries. Eye protection shall be worn when striking tools are used.
Chevron Pipe Line Company
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“Mushroomed” or expanded heads of impact tools such as chisels and sledge hammers shall be dressed (filed off) as needed.
•
Ball peen hammers and sledge hammers shall be used in conjunction with striking tools (e.g., chisels, punches, rods, stakes, etc.). The use of claw hammers is prohibited.
• • •
A hammer shall not be struck against another hammer.
•
Adjustable crescent wrenches shall not be used if a box or open-end wrench of the correct size is available.
•
Jaws on adjustable crescent wrenches shall be tightened around fitting/nut and the force applied on the side with the stationary jaw.
•
Local regulations may restrict or prohibit the use of wrench extensions or “cheaters.” (e.g., CA-OSHA regulations state: “When a pipe wrench extension is used, the maximum length of the extension shall be two times the length of the pipe wrench handle. The extension shall be constructed of steel pipe of such a diameter to snugly fit the pipe wrench handle, and cover the full length of the pipe wrench handle. The force exerted on the wrench shall not exceed the manufacturer's rated breaking strength of the wrench.”)
•
Tools not bolted, tied or secured in some manner shall be removed from locations where they could fall on employees below.
•
Handles of sledges, hammers, mauls and the like shall be securely wedged into the heads. Wooden handles
Files shall be equipped with handles. Wrenches shall be pulled instead of pushed when possible.
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shall not be painted because paint causes handles to be slick and hides cracks and other defects. Cracked or split handles shall be replaced; they shall not be taped.
4.7 Equipment / Machinery in Motion
•
The following safety precautions shall be observed when working around rotating machinery:
§ follow proper LOTO procedures for any type of equipment § do not wipe any moving part while it is in motion
§ keep rags away from moving machinery; don't let them protrude from your pockets § rotating machinery consists primarily of compressors, engines, turbines and pumps. Rotating machinery is dangerous because of the high speeds and pressures used in its operation. Repairs shall not be initiated until the fuel supply is shut off and the starting circuits disconnected, locked out, and tagged
4.7.1 Centrifuge Machines §
§ §
Centrifuge machines shall be equipped with guards Centrifuge machines shall be operated with the tops closed. Pneumatically operated machines shall be operated at manufacturer's recommended pressures.
4.7.2 Compressors § §
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Before starting repairs, the suction and discharge valves shall be closed and the pressure bled off. Compressor alarms and shutdowns shall be tested periodically.
Chevron Pipe Line Company
4.7.3 Engines and Turbines § §
§
§
§
§
Pressurized lines shall be bled off. When turbines are shut down for maintenance or service, air or gas supply to the auxiliary lube oil pump shall be shut off to prevent accidental operation (where applicable). Engines shall be located in well ventilated areas and as far away as practical from headers, separators, and oil storage tanks. Air starters shall be used instead of gas starters where practical; however, if gas starters are used, exhaust piping shall be securely anchored and vented to a safe location. Means shall be provided to vent unused gas or liquid accumulation trapped between the starter and the starter valve after it is closed. Before activating the gas starter, the integrity of the vent line shall be checked. Portable internal combustion engines with engine mounted fuel tanks shall be shut down and allowed to cool before refueling. Exceptions shall be approved by local supervision. When cranking engines using a rope starter, employees shall not wrap the rope around their hands or wrist. The starting rope shall be equipped with a pull handle.
4.7.4 Pumps §
§ §
Prior to initiating repairs or maintenance, the pump shall be shut down, isolated, and the internal pressure bled down. Main electrical disconnects and valves shall be locked out and tagged prior to initiating work. A pressure relief valve shall be part of the discharge manifold on every power-driven pump, with the exception of centrifugal pumps. It shall be placed ahead of the first valve on the discharge line. Relief valve
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§
outlets shall be vented to a safe location or discharged back into the pump suction. When discharge extensions (vents) are necessary, they shall be securely anchored. If it is necessary to tighten packing glands while pumps are in operation, use extreme caution.
4.8 Pocket Knives
•
36
Personnel are allowed to carry pocket knives; however, they are not allowed to use them while working. USE THE APPROPRIATE TOOLS FOR THE JOB. POCKET KNIVES ARE NOT APPROPRIATE TOOLS.
Chevron Pipe Line Company
5.0
Safe Practices
5.1 Safety Meetings Pre-job or pre-startup meetings shall be conducted to review all safety procedures, restrictions, guidelines, permits, JSA’s and concerns before starting with the activity.
5.2 Safety Signs
• Safety signs are usually posted where dangers are present. Heed all warning signs (such as those regarding PPE, “Danger”, “Road Closed”, “Keep Out”, etc.) and safety guards.
•
Never remove, move or change warning signs, safety guards or equipment without company authorization.
•
Warning signs, safety guards or equipment are provided for your protection - don't ignore them!
5.3 Behavior Based Safety Process, Inspections or Audits All personnel are expected to participate in a behavior based safety process which shall include training to observe co-workers for “safe” and “at risk” performance and provide feedback after completion of the observation.
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Contractor companies may have their own program. Any employee or visitor may approach the work area to perform a safety observation, inspection or audit. The job will continue as scheduled and everybody is encouraged to participate if allowed by the operation and requested by the observer. The team will be expecting feedback from the observations as soon as practical, in order to improve the overall safety of the process.
5.4 Permit to Work (PTW) Systems CPL has instituted permit systems to authorize and approve, in writing, various types of work activities. The permit specifies the location and type of work to be performed and also certifies that hazards have been evaluated by a qualified person and that all necessary protective measures have been specified and implemented. ✓ Please review and follow the Safe Work Permit checklists in the Appendix section. Safe Work Permits are required for:
•
High-risk operations: § hot work
§ confined space entry § lockout/tagout § excavations
•
Non-routine maintenance work:
§ pipeline repair or replacement
§ tank or vessel maintenance and/or repair (except inspections) § hot taps
§ overhauling of equipment (pumps, compressors) § site remediation projects
§ any other work that is hazardous or unusual, such as:
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Chevron Pipe Line Company
• working from heights where personal fall protection is required • overhead activities involving rigging in a congested area or over piping or equipment in service • work activities requiring respiratory protective equipment • unbolting, disconnecting, opening or removal of any line, process piping, equipment or system that has been in service • unflanging or removal of heads, isolating blinds, blind flanges, man ways, process piping or equipment that has been in service • working on electrical equipment over 600 V • removal of process valves and relief valves • any maintenance work done by contractors • construction work (includes the installation of new equipment and the modification of existing equipment)
5.5 Materials Handling 5.5.1 Handling Pipe § § § § §
Designate a leader if working in a team of two or more persons. Team will follow his/her directions. Wear gloves and other appropriate PPE when handling pipe. Make sure stops to hold pipe from rolling are in place before moving pipe on a rack. Roll pipe away from, rather than toward you, to reduce the possibility of it rolling on your toes. Use a tether for loads above your head to help control pipe. The person in charge is responsible to determine if pipe contains Asbestos Containing Material (ACM) and ensure proper handling.
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Do not hold pipe on the end with your fingers inside, if the end comes in contact with another object your fingers could be injured.
5.5.2 Tractor Loader/Backhoe Unit Operation §
Inspect the backhoe equipment before operating it. Give special consideration to: • Installing step plates or other devices that provide suitable footing for the operator when moving between the backhoe and tractor seats. • Installing an engine “kill” switch in an explosionproof housing near the backhoe controls to provide a fast means of “killing” the engine in an emergency.
§
• Modifying the exhaust system to minimize the possibility of igniting petroleum vapors or dry vegetation. The backhoe should be equipped with: • lights on the front and back of the tractor suitable for use with the backhoe • an easily accessible dry-chemical fire extinguisher on the tractor
§
• a rollover protection device. • a noise device that beeps when the vehicle is backing. Inspect the trailer used to haul the backhoe to make certain it complies with prevailing motor vehicle codes. In addition, install the following: • expanded metal or other suitable material to provide a non-skid surface on the trailer bed for tractor wheels • side rails to aid in preventing the unit from slipping off the trailer during loading or unloading
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Chevron Pipe Line Company
• a hydraulic control, or other device, to control the rate of tilting during loading or unloading (if applicable) § §
§
• adequate loading ramps, if required Maintain the tractor unit in a safe operating condition. Be thoroughly familiar with the manufacturer's instructions regarding maintenance, operation and safety precautions. Take the following precautions during the operation of this equipment: • Only the operator is allowed on the equipment. • Do not make mechanical adjustments while the unit is in motion. Do not repair hydraulic hoses while they are under pressure (e.g., loader bucket raised, backhoe raised, or engine running). • Rest loader and backhoe buckets on the ground and set the brakes when the unit is left temporarily. If the unit is left unattended for a longer period, turn off the engine; place the transmission in “park”, and remove the key from the ignition. • Have the operator check for clearance before moving the unit. Keep co-workers and bystanders clear of the unit while it is in operation and while loading or unloading on the trailer. • Drive at a speed that allows you to maintain control of the vehicle and ensure the safety of yourself and others.
5.5.3 Powered Industrial Truck (PIT or Forklift) Operations §
No employee who is currently unqualified may operate a forklift truck. Each forklift truck operator must re-qualify at least every two years.
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§
§
§
§
Before a forklift truck may be operated the first time during a shift, the forklift operator must complete an inspection checklist. Keep a copy of the checklist for three years. To prevent unexpected movement of the vehicle, do not unload any truck or cargo trailer that is not secured. As a minimum, set the brake and place chocks under the wheels of the vehicle. Any employee who is working near a forklift truck must notify the operator of his/her activities. Each employee must be careful to avoid entering the path of a moving forklift truck. Guidelines for safe forklift operation: • use seat belts • report any damage or problems that occur to a forklift during a shift • don’t jump from an overturning forklift. Stay with the truck. Hold on firmly. Lean in the opposite direction of the overturn • use extreme caution on grades and ramps • on grades, tilt the load back and raise it only as far as needed to clear the road surface • don’t raise or lower the forks while the forklift is moving • don’t handle loads that are heavier than the weight capacity of the forklift • operate the forklift at a speed that will permit it to be stopped safely • slow down and sound the horn at locations where vision is obstructed • look toward the travel path and keep a clear view of it
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Chevron Pipe Line Company
• don’t allow passengers to ride on forklift trucks unless a seat is provided • when dismounting from forklifts, set the parking brake, lower the forks or mast, and neutralize the controls • don’t drive up to anyone standing in front of a bench or other fixed object • don’t use a forklift to elevate workers who are standing on the forks • elevate a worker on a platform only when the vehicle is directly below the work area • whenever a truck is used to elevate personnel, secure the elevating platform to the mast or forks of the forklift • use a restraining means such as rails, chains, or a full-body harness with a lanyard or deceleration device for the worker(s) on the platform • don’t drive to another location with the work platform elevated or with people on it
5.5.4 Cranes and Hoisting, Cables and Slings §
§
§
Cranes are machines used to lift, swing, and lower heavy objects or loads. Cranes shall be properly operated and maintained in accordance with manufacturer's guidelines and applicable regulations. Only qualified (certified and carry the certification on their person) personnel who are familiar with the equipment shall operate cranes and hoisting equipment. Only qualified (certified and carry the certification on their person) rigger who are familiar rigging shall rig load for hoisting. Safe Practices Handbook – 2006
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§
§ §
§
§
Check that the capacity of the equipment can support the weight of the material to be lifted. Operators must ensure that safe working capacities are posted on cranes, and that these capacities are not exceeded. Cranes shall be certified annually. Crane components (booms, cables, rigging, slings, shackles, fittings, fastenings, foundation mountings, control cables, etc.) and safety devices, shall be examined and determined to be functioning properly by the crane operator each day before starting operations. All cranes shall have a pre-operation checklist performed by the operator prior to use. The checklist can be a manufacturer or vendor check list. The examination shall include, but not be limited to, a visual examination for: • cracked welds • cable defects • bent braces • sheave condition • deformed or broken hooks • load indicators • stops • evidence of overloading • excessive wear • sharp bends • knots • equipment damage or any other defects In addition to these “before-use” inspections, Maintenance-related inspections shall be made on cranes and their cables and any other lifting devices. Records of these periodic inspections shall be maintained.
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Chevron Pipe Line Company
§
§ § § §
§
§
§
§
§
§
The crane operator shall not operate the crane until persons involved have been instructed as to the work to be performed. Employees shall be clear of a load before it is picked up or landed and must remain clear at all times. Employees shall not stand/pass under suspended loads. Cranes shall not be operated in adverse weather conditions (lightning storm, high winds, rain, etc.). The operator of a truck-mounted crane shall check truck positioning and anchoring prior to use. The wheels shall be chocked to prevent the truck from moving. If the truck is so equipped, maxi brakes shall be set. Outriggers shall be properly used and positioned when available. Outriggers shall not be used in the place of wheel chocks. Wire rope and wire rope slings shall be lubricated to protect against wear and corrosion. Slings must be inspected before each use. Chain and fabric slings shall have an identifier indicating manufacturer, load rating, and date placed in service. This identifier shall not be removed. Slings must be inspected before each use. Lifting accessories (chains, slings, etc) should be stored away from direct contact with adverse weather and conditions when not in use. Slings must be inspected before each use. Boom angle indicators shall be permanently attached to the boom to show the operating radius. The rated load capacity/boom angle of the crane shall not be exceeded. The crane operator shall check the load chart, confirm boom length with chart, and establish load weight and maximum operating radius or corresponding minimum boom angle.
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§
§
§
Practice extreme care when operating or working around equipment such as portable cranes, power shovels, and forklifts. Do not ride on equipment except in seats provided for that purpose. If you are operating equipment and cannot see the load from your position, you must have the assistance of a co-worker and use the appropriate crane hand signals. For cranes with a lifting capacity of three tons or greater, a properly trained signalman shall work with the crane operator. Standard signals shall be used. Normally, all signals shall be given by the signalman, but the operator shall obey any emergency stop signal given by anyone. CRANE SIGNALS HOIST
LOWER
STOP
EMERGENCY
SWING
TRAVEL
RAISE BOOM
LOWER BOOM
STOP
MOVE SLOWLY
TELESCOPING BOOMS EXTEND BOOM
§ § § §
46
RETRACT BOOM
DOC EVERYTHING
Taglines shall be used when it is necessary to control the load. During operation, at least three wraps of cable shall be maintained on the drum at all times. During operation, at least three wraps of cable shall be maintained on the drum at all times. Never stand at, near, or in line with a rope or cable that is under strain or within a loop that could tighten.
Chevron Pipe Line Company
§ § § § §
§
Employees shall wear gloves and appropriate PPE when handling wire rope slings. Boom stops shall be provided on crane booms to prevent the possibility of overtopping the boom. Platforms, walkways, steps, handholds, guardrails, and toe boards shall be provided on cranes where necessary. Crane hooks shall not be used without safety bolts or latches. The crane boom shall be kept in the cradle when not in use. The operator shall properly secure the crane and boom before going off duty or when shutting down operations. Minimum required clearances from overhead highvoltage lines shall be maintained in all directions: Line Voltage Minimum Required (Phase to Phase) Clearance (Feet) < 50k 75k - 125k
10 11 13
125k - 175k 175k - 250k 250k - 370k 370k - 550k 550k - 1000k
15 17 21 27 42
50k - 75k
Except where electrical distribution and transmission lines have been de-energized and visibly grounded on both sides of the work area, or where insulating barriers not a part of or an attachment to the crane have been erected to prevent physical contact with the lines.
In transit with no load and boom lowered, the following minimum clearances shall be maintained: Line Voltage Minimum Required (Phase to Phase) Clearance (Feet)
§
< 50k
4
50k - 345k 345k - 750k
10 16
When working in areas with power lines: • the area of the work and paths of equipment travel shall be surveyed to identify locations of all overhead power lines
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• a person shall be assigned to observe the operation of the equipment and power lines • high voltage proximity alarms should be mounted on the crane boom 5.5.4.1 Inspection Criteria
Lifting equipment presenting any of the following conditions shall be immediately removed from working area and replaced as needed. Examples of Wire Rope Sling Abuse
Acid Damage
Heat Damage
Broken Wires
Cuts
Worn Wires Cuts & Tensile Damage
Corroded
Abrasion Damage
Bird Caging Face Cuts
Punctures & Snags
Tensile Breaks
Kinked and Crushed
Worn and Deformed Attachments Illegible or Missing Tag
Taken from the World Wide Web http://www.lift-all.com/PDF/WebSlings/WebSlingGeneral.pdf
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Chevron Pipe Line Company
5.5.4.2 Capacity Chart HOW ANGLES EFFECT SLING STRESS 1. Divide the total load to be lifted by the number of legs to be used. (This provides the load per leg if the lift wher being made with all the legs lifting vertically.) 2. Determine the angle between the legs of the sling and the verticle. 3. Then, MULTIPLY the load per leg by the LOAD FACTOR for the leg angle being used (from the table at right) to compute the ACTUAL LOAD on each leg for this lift and angle. NOTE: THE ACTUAL LOAD MUST NOT EXCEED THE RATED SLING CAPACITY.
LEG ANGLE
LOAD
(Degrees)
FACTOR
0 5 10 15 20 25 30 35 40 45 50 55 60
1.000 1.003 1.015 1.035 1.064 1.103 1.154 1.220 1.305 1.414 1.555 1.743 2.000
5.6 Hazardous Materials and Substances 5.6.1 General Principles §
§
§
§
§
Be certain of the properties of every substance you handle and take every precaution as directed. Know the protective equipment you need to wear. Consult your team leader and the Material Safety Data Sheet (MSDS) if you're ever in doubt. Employees should be aware of how chemicals and substances can contact the body and how that contact can be prevented. Handle all chemicals with caution. Avoid contact with the skin or eyes, and never put them in or near your mouth. Be sure to wash carefully after working with petroleum or chemicals. Many of these materials will not cause immediate burns but will irritate your skin if they are contacted repeatedly and not washed off thoroughly. Don't wear clothing or shoes contaminated with petroleum or chemicals; take a shower and put on clean clothing. If you find evidence of chemical spills - such as a visible fume or vapor cloud or a strong odor or eye irritation notify your team leader. If you suspect that you or a
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co-worker are reacting to a chemical exposure and have any symptoms - such as dizziness, headache, irritated nose, throat or eyes, coughing or nausea seek medical help and notify your team leader as soon as possible.
5.6.2 Safety Color Coding Color-coding provides a uniform system of identifying corrosive and toxic chemicals, hazardous equipment or conditions, and emergency safety equipment.
5.6.3 Storing Flammable Liquids §
§
§
§
§
50
Use only safetyrated metal containers for flammable liquids as required by DOT regulations.
Automatic Closing Flame Arrestor
Vent Cap
Spout Small Storage Container
Large Storage Container
Large Dispensing Container
Store flammable liquids in designated cabinets and areas only; away from heat sources, electrical apparatus and other sources of ignition. Label all containers. Samples or other liquids with flash points less than 100 degrees Fahrenheit should not be stored inside of laboratories. Store them in a separate building in flammable materials storage cabinets provided for that purpose. Do not carry gasoline or other flammable liquids in the trunk of company vehicles. Flammable liquids may be transported in the bed of company trucks if they are in proper containers that are securely fastened to the bed. Gasoline or other flammable material shall be transported only in approved DOT (metal) safety containers.
Chevron Pipe Line Company
§
§
Bonding and grounding procedures shall be followed during the transfer/collection of flammable liquids into portable containers to prevent ignition from static electricity. Plastic buckets do not conduct or dissipate static electrical charges and therefore shall not be used to collect flammable liquids, e.g., condensate samples, oil samples, etc.
5.6.4 Corrosive Chemicals §
§
Before using corrosive chemicals, note the location of emergency showers and eye wash facilities, as well as other nearby water sources. Take every precaution to avoid direct contact with corrosive chemicals. These chemicals may cause severe burns or poisoning. If you do come into contact with corrosive chemicals, immediately remove any contaminated clothing and flush the affected parts with running water. Eyes should be washed for at least 15 minutes; skin may need to be washed for 30 minutes to remove all traces of the chemical. After washing, consult a physician to see if further medical treatment is needed.
5.6.5 Solvents and Cleaning Agents
§ Gasoline, distillate, condensate or any other similar flammable materials shall not be used for cleaning purposes (skin, clothing or machinery). It is a fire hazard and could cause flesh burns. §
The following may be approved by local management for use as cleaning agents if proper PPE is used: • diesel fuel • kerosene • stoddard solvent or equivalent • cold water cleaners (solvents or detergent base)
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§
§
§ §
§
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Carbon disulfide, carbon tetrachloride, benzene, and halogenated solvents shall not be used as degreasers or cleaning agents. Stoddard solvent or equivalent, kerosene, or cutting agents shall be used for the purpose of shakeouts (cuts). Cleaning agents shall not be heated or used on hot surfaces or near flames. Rags that have been used with cleaning agents shall be placed in designated covered metal containers until they can be properly cleaned or disposed of. Skin contact with solvent liquids or inhalation of vapors shall be avoided. Nitrile, neoprene, or other suitable gloves shall be used to protect hands when using petroleum based solvents and cleaning agents. If a cleaning agent or solvent comes in contact with the skin, the affected area shall be cleaned with soap and water and a lotion applied to replace the natural body oils. Areas where cleaning solvents are used shall be well ventilated. Employees shall review cleaning agent container labels to determine if contents are acceptable for the intended use. Acceptable solvents shall be those listed in this section. Non-petroleum based products should be substituted where practical in parts washers. Fusible links on parts washers shall not be bypassed, disabled, or altered.
5.6.6 Using Tools Around Chemicals and Gases § §
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Handle tools with caution when working around acid, caustic substances or other hazardous chemicals. Be careful not to drop tools where they may cause chemicals to splash.
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§
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Thoroughly clean all tools after working with hazardous chemicals. If the tools become heavily contaminated while working, wash them at once. Avoid using rope slings or lines near corrosive chemicals. If you must use a rope sling or line in this environment, carefully check it for wear after you're done and tag it identifying the hazard before returning it to the tool storage area.
5.7 Hazardous Communication (HAZCOM) 5.7.1 List of Chemicals The company maintains an inventory or index of all chemicals used at each facility. This index, the Chemical Inventory, is available at each facility and from your team leader.
5.7.2 Material Safety Data Sheet (MSDS) §
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The MSDS must be made available to each employee for review prior to handling hazardous chemicals. It contains precautions for handling, requirements for protective clothing, and a 24hour emergency number to reach the manufacturer who can tell you what to do in an emergency. Each facility must have its set of MSDS’s for the chemicals normally used at that location. Contact your local safety specialist before bringing any new chemicals onto company property. An MSDS must accompany each chemical brought onto the work site regardless of how long it will be used there. The MSDS must be obtained from the manufacturer and reviewed for possible health hazards and handling concerns. Safe Practices Handbook – 2006
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Chemicals that will be used or stored routinely at the location must be added to the chemical inventory for that location.
5.7.3 Material Labeling Any container containing chemicals must be labeled with the name of the substance and any hazards associated with it, regardless of the size of the container. There are three main systems of hazard warning labels that you are likely to encounter within the company: Department of Transportation (DOT) The following is a partial listing of the more commonly encountered DOT labels. DOT labels are required when vehicles are used to transport hazardous: • Explosive - A substance that will ignite with a violent reaction and can cause massive destruction. • Non-Flammable Gas - A compressed gas that will not readily burn and is not poisonous. It is hazardous because it is under pressure and/or it can suffocate a person within a confined space. • Flammable Gas - A gas that, at ambient temperature and pressure, forms a flammable mixture with air at a concentration of 13 percent by volume or less. • Poison Gas - Gases such as chlorine and anhydrous ammonia that are poisonous to humans or animals when inhaled.
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EXPLOSIVES
NON-FLAMMABLE GAS
FLAMMABLE GAS
POISON GAS
• Flammable Liquid - Any liquid having a flash point below 100°F FLAMMABLE (37.8°C), except any mixture having LIQUID components with flash points of 100°F (37.8°C) or higher, the total of which make up 99 percent or more of the total volume of the mixture. • Flammable Solid - A solid, other than a blasting agent or explosive, FLAMMABLE SOLID that is liable to cause fire through friction, absorption of moisture, spontaneous chemical change, or retained heat from manufacturing or processing, or that can be ignited readily and when ignited burns so vigorously and persistently as to create a serious hazard. • Oxidizer and Oxidizing Agent - A substance that yields oxygen readily to stimulate the combustion (oxidation) of organic matter.
OXIDIZER
• Poison - A substance that is harmful to human health. Toxic. Poison
• Radioactive - Material that emits radioactive particles or rays, such as many of the materials used in well RADIOACTIVE logging and/or for industrial radiography. The type of placard used relates to the amount of radioactive material stored in the vehicle or container. • Corrosive - Causes visible destruction of irreversible alterations in living tissue by chemical action at the site of contact. Causes a severe corrosion rate in steel.
CORROSIVE
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The Hazardous Material Identification System (HMIS®) HMIS is a registered trademark of the National Paint & Coating Association. The code numbers, on a scale of 0 for no hazard to 4 for high hazard, for degree of health hazard, flammability, reactivity, and recommended personal protective equipment (PPE) are written on the label at the time the label is placed into service. The numbers on the following figure were created solely for illustration purposes. Substance Identity (same as shown on MSDS) HMIS ®
Identify Product Blue Red Yellow PERSONAL PROTECTION RATINGS:
4-Extreme, 3-High, 2-Moderate, 1-Slight 0-No significant hazard
Health Hazards (Immediate & Delayed Target Organ Effects)
ABC Chemical Company 1234 Main Street Anywhere, ST 00123
The National Fire Protection Association System (NFPA) The NFPA System is used in industrial plant and storage locations to provide information for fire fighting and emergency response personnel. The code numbers, on a scale of 0 for no hazard to 4 for high hazard, for degree of health hazard, fire hazard, reactivity, and special hazard are written on the label at the time the label is placed into service. The numbers on the following figure were created solely for illustration purposes.
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Red Health Hazard:
4 Deadly 3 Extreme Danger 2 Hazardous 1 Slightly Hazardous 0 Normal Material
Fire Hazard:
3
1
3
Blue Specific Hazard:
Oxidizer OX Acid Acid Alkali ALK Corrosive COR Use No Water W Radioactive
Flash Points 4 Below 73°F (boiling pt. below 100°F) 3 Below 73°F (boiling pt. at/above 100°F) and/or at/above 73°F - not exceeding 100°F
ACID
Yellow
Reactivity:
4 May Detonate 3 Shock and heat may detonate 2 Violent chemical change 1 Unstable if heated 0 Stable
White
5.8 Excavation, Trenching and Shoring ✓ Please review and follow the checklist related to this activity in Appendix D.
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An excavation is any man-made cut, cavity or depression in the earth’s surface formed by earth removal.
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Notify the appropriate state, regional and/or local 'onecall service' at least 48 hours before any excavation (unless the excavation work itself is an emergency) to notify other pipeline and utility companies.
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Consult the team leader and check station maps and line atlas sheets to locate possible hazards such as underground conduit, electric cables and gas or oil lines.
5.8.1 Soil Type and Site Preparation §
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The Person-In-Charge (PIC) will inspect the work area around the proposed excavation site prior to commencing excavation activities to identify and alleviate any hazardous conditions and obtain information to request any state or local permits. Employees who work in and around excavations and trenches shall be trained in the hazards associated with this work and the correct work practices.
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The competent person or PE (registered professional engineer) shall determine: • if sloping, benching or shoring is required to protect against cave-ins • the need for PPE and specify the means of escape for employees • certify any shoring devices to be used on site
5.8.2 Worker Protection §
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When personnel are working in the trench, the distance from the work area to an escape ramp must not be greater than 25 feet laterally. For example, ladders or ramps shall be placed so that no person will have to move or be moved more than 25 feet to exit the trench. If employees may be expected to cross over the trench from one side to the other, a platform with standard handrails and guards must be installed.
Any trench or excavation left open at night or left unattended for any reason must be surrounded with some form of barrier identifying the existence of a hazard, such as a tape barrier that reads, “Danger Excavation Work in Progress.” § If employees are working in the trench, the atmosphere inside the trench must be monitored for any hazards to employees, such as oxygen deficiencies, or flammable or combustible vapor build-up. The results of the monitoring must be documented.
5.8.3 Inspection §
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The trench must be inspected before each shift by the competent person. In addition to that, competent person inspections are required after any rain or if there may be suspected movement of the trench walls. All inspections must be documented.
Chevron Pipe Line Company
5.8.4 Permit All excavations require an Excavation Permit. For all excavations involving entry, a competent person is required to conduct soil tests and determine the type of protective system to be used to protect workers. The competent person is a person who is capable of identifying existing and predictable hazards, soil types in the surroundings and working conditions that are hazardous to employees, and is authorized to take prompt corrective measures.
5.9 Gas Testing and Analysis ✓ Review the HES-209 procedure for more information.
5.9.1 Plan the Gas Tests §
The PIC identifies hazardous substances or conditions that may be present and require gas testing such as: • oxygen deficiency or enrichment • flammable gas or vapor • toxic airborne concentrations of benzene • hydrogen sulfide
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• carbon monoxide • carbon dioxide The gas testing plan includes at a minimum: • gases to be tested • frequency of the testing • acceptable limits
5.9.2 Calibrating and Maintaining Gas Detectors §
The Qualified Calibrator must calibrate and maintain the equipment according to the manufacturer’s guidelines. In general, calibrate equipment at nearly the same conditions (temperature, relative humidity, etc.) as test conditions.
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§
Calibration results and routine maintenance must be documented.
5.9.3 Verify Instrument Performance Before Gas Testing §
The Qualified Gas Tester must do a physical check of the instrument, and verify gas sensor performance, before using it to measure the atmosphere. This must be performed on every work shift, or before each use, if not used on every shift. Refer to the manufacturer’s instructions as necessary to ensure understanding.
5.9.4 Review Precautions §
Review the warnings and cautionary statements in the manufacturer’s instructions. These vary depending upon the manufacturer and the type of sensor being used. Here are some of the warnings that may apply: • oxygen deficient atmospheres will cause erroneous low LEL readings • oxygen enriched atmospheres will cause erroneous low LEL readings • recharge battery only in a non-hazardous atmosphere • do not draw liquid into the sampling probe • only zero the instrument in clean air
5.9.5 Conduct Gas Tests §
Test the atmospheric hazards specified by the Hot Work Permit, Confined Space Entry Permit, Excavation Work Permit, Job Site Safety Plan or other gas testing plan. Test the required gases in the following order: 1. oxygen 2. flammable gas 3. toxic vapors
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WARNING: If oxygen levels are outside acceptable limits, flammability and toxic levels may not be accurate. Use extreme caution. Acceptable levels are listed on the Hot Work Permit, Confined Space Entry Permit, Excavation Work Permit, or Gas Testing Plan and Results form. If tests indicate that oxygen deficiency or enrichment, flammable gas, or toxic vapors exist, the tests should be stopped and the space ventilated until subsequent tests indicate the space is safe.
5.9.6 Interpret Gas Test Readings §
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When an alarm sounds, everyone inside the area must immediately exit and the reason for the alarm must be determined. The Qualified Gas Tester is responsible for ensuring all occupants exit immediately. On most instruments with digital displays, an alarm sounds when unacceptable flammable and/or toxic levels are detected. Some instruments have low level alarms and high level alarms for flammable and/or toxic concentrations. An alarm also sounds when unacceptably low and high oxygen levels are detected. On older flammable gas testing instruments with analog displays (i.e., needles on a continuous scale), the Qualified Gas Tester must observe the needle constantly. The final resting place on the scale may not be as important as the movement to the resting place. If the needle moves to a high reading and then falls back near zero, the atmosphere may have high flammable levels. Leave the area, remove the test probe, purge it with fresh air, and then re-test. If the needle goes upscale and then falls near zero again, the area is unsafe for entry or hot work. Whenever the results of any follow-up tests differ significantly from the initial tests, more frequent tests must be taken. If the subsequent readings do not return to the initial levels, the cause for the change must be determined.
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The Qualified Gas Tester or any other person must stop the job whenever gas testing indicates that a hazardous condition exists that could endanger workers. Workers must leave the area until the situation has been corrected and proper precautions have been taken.
5.10 Confined Spaces ✓ Review and follow the checklist related to this activity in Appendix E. ✓ Review the HES-211 procedure for more information.
5.10.1 Workplace Evaluation §
A confined space is a space that: • is large enough and configured such that an employee can bodily enter and perform assigned work • has limited or restricted means of entry or exit (for example; tanks, vessels, silos, storage bins, hoppers, vaults, or pits
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• is not designed for continuous employee human occupancy Examples of equipment that may be confined spaces are: • external floating roof tanks • below grade valve boxes or sumps or working platforms • vessels, separators, and tanks (entered by a man-way) • pig or scraper traps • pits • tank cars/trucks • internal floating roof tanks • pontoons of floating roofs • footing excavations and bell bottom pier holes
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§
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There are three types of confined space: non-permit confined space, confined space entry using forced air ventilation and permit required confined space. All confined spaces require a Confined Space Entry Permit. The PIC and the person conducting the work determine the type of confined space and which sections of the permit must be completed. No one shall enter a permit-required confined space unless a Confined Space Entry Permit has been completed, approved and posted. Only trained employees are allowed to perform work involving any confined space entry. Employees assigned to permit required confined space operations shall be trained in safe entry and emergency procedures and be periodically retrained as an entrant, entry supervisor, attendant, or rescue team member. Persons conducting non-entry and entry rescue must be trained according to OSHA requirements. Attendants must be trained in cardiopulmonary resuscitation, bloodborne pathogens, and first aid.
5.10.2 Pre-Entry The atmosphere in the confined space shall be tested for oxygen deficiency, flammability, and toxicity before entry and continuously monitored (uninterrupted) as feasible throughout the confined space operation.
5.10.3 Working in a Non-Permit Required Confined Space A Non-Permit Confined Space is a confined space that does not contain, or, with respect to atmospheric hazards, does not have the potential to contain any hazard capable of causing death or serious physical harm.
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5.10.4 Confined Space Entry Using Forced-Air Ventilation Confined space entry using forced air ventilation occurs when forced air (local and/or general) is used to control unacceptable atmospheric hazards.
5.10.5 Permit-Required Confined Space Entry A permit required confined space is a confined space that has one or more of the following characteristics: • contains or has a potential to contain a hazardous atmosphere • contains a material that has the potential to engulf an entrant • has an internal configuration that could trap or cause asphyxiation • contains a recognized health/safety hazard
5.11 Lockout/Tagout (LOTO) ✓ Review and follow the checklist related to this activity in Appendix F. ✓ Review the HES-203 procedure for more information.
5.11.1 Energy Sources §
There are several energy sources, all of them may be locked and tagged. The list includes: • electricity • hydraulic • pneumatic • chemical • thermal • gravity • etc.
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5.11.2 Equipment Specific Procedure (ESP) Sheet §
An ESP Sheet must exist for each piece of equipment that needs to be isolated and released for regular or maintenance work. To complete the ESP Sheet, the PIC (CPL employee) shall: 1. identify each piece of equipment and/or system to be maintained, serviced, or repaired, including equipment number and location 2. identify other equipment that must be shut down, isolated, locked and tagged out, and energy dissipated 3. identify all actual and potential sources of energy, all potential sources of energy reaccumulation and the hazards of these energy sources for the equipment 4. identify all energy control devices that will be needed to secure the piece of equipment and/or pipeline system to be maintained, serviced or repaired 5. make a simple sketch of the equipment or system being isolated, showing blinds, valves, switches, etc. used for isolation 6. identify the normal shut down procedure(s) to be used or document the steps to shutdown the equipment or pipeline system 7. document the steps required to isolate each energy source and the means for isolating or dissipating the stored or accumulating energy 8. document the steps required to secure (lockout/tagout) each energy source 9. document the steps to verify continued isolation 10. document the steps to restoring equipment or system to service
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11. sign the document 12. submit the ESP Sheet to be reviewed by another field team member with equal or greater qualifications for final review 13. the team leader will also review the ESP and sign it 14. review the ESP Sheet with all the persons who will be working on the equipment or pipeline system and obtain their agreement on the procedure. This would usually be done at the safety/training meeting in preparation for the job 15. the PIC then signs on the line indicating that affected employees have been notified
5.11.3 Normal Equipment Isolation
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Normal equipment isolation is initiated when person(s) servicing or maintaining equipment or piping system places their own personal lock and tag on the energy isolating devices. This covers most situations where the work is in one location where the one PIC can directly account for all isolations and work that is going on.
5.11.4 Shift Change §
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The exiting PIC or Principal Authorized employees ensure the incoming people fully understand the work to be performed under this Equipment Isolation procedure by having a procedure review meeting. The entering workers review the permits and sign the Equipment Specific Procedure Sheet indicating they have read, understood and visually verified that all equipment on the Equipment Specific Procedure Sheet is still locked out and tagged out. For maintenance activities that will last for more than one day (tank repair; compressor repair) the entering workers review the permits and sign the Equipment Specific Procedure Sheet indicating they have read, understood and visually verified that all equipment
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on the Equipment Specific Procedure Sheet is still locked out and tagged out.
5.12 Electrical Safety 5.12.1 General
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Work on electrical equipment and systems shall be performed only by qualified persons. Qualified persons are those who have training in avoiding the electrical hazards of working on or near exposed, energized parts. Work on electrical equipment and systems greater than 600 volts requires the use of special PPE and procedures. Electrical switchgear shall be labeled to identify the equipment it controls. Follow all applicable LOTO procedures before working on electrical equipment to ensure that power cannot be accidentally restored. When working on a motor or circuit, the supply switch or circuit breaker must be open and locked and the switch must be properly tagged (i.e., “Danger - Do Not Close Switch”) to warn others that someone is working on the equipment. After completing the tagout, doublecheck to be sure that the circuit is de-energized and that it cannot be re-energized by someone else. After disconnecting the power source and before touching any connections, ground high-voltage points. Exercise extreme care not to touch electrical equipment while standing in water, on metal floors, on damp concrete or other well-grounded surfaces. Hands, footwear, and clothing shall be dry when any energized electrical equipment is handled.
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Employees should not wear rings or watches, or carry keys, lighters, or similar metallic objects while working on electrical systems, unless the metallic objects are rendered nonconductive by covering, wrapping, or other insulating means. Where required, use fiberglass or other non-conductive material made for electrical work. Employees shall avoid being near switch boxes, pumping units, or other electrically operated equipment during an electrical storm. Interlocks shall not be made inoperative by removal, modification, or destruction. Properly sized overload protection (fuses and/or circuit breakers) shall be provided to protect the circuit's maximum current carrying capacity. As an example, a 30-amp fuse shall not be used on a 20-amp circuit. A fuse puller shall be used to remove fuses. Fuse pullers shall be kept clean and dry to prevent a conductive film from forming on the surface of a puller. Substitutes for fuses are prohibited. Electrical connections to ground shall not be made to a gas pipe, steam pipe, dry pipe sprinkler systems, or lightning protection system. Water shall not be used on electrical equipment fires. When possible, electrical equipment shall be de-energized before attempting to extinguish an incipient stage fire. The National Electrical Code (NEC) and/or the American Petroleum Institute (API) RP-500, Recommended Practices for Classification of Locations for Electrical Installations at Petroleum Facilities, shall be followed in the installation and operation of electrical systems.
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5.12.2 Lighting
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Lighting shall be installed as appropriate for the location. Portable lights used in potentially hazardous locations shall be either explosion-proof flashlights or other types of portable lights approved for potentially hazardous atmospheres. The outside globe and guard on portable hand lights shall be maintained and be in place during use. Portable lights and extension cords shall be kept in good repair. They shall be checked for damaged or worn insulation and cracked or broken protective globes. When changing a broken/burned out light bulb, the circuit shall be de-energized. Any fixture designed for protective glass globes and metal guards shall have the globes and guards in place before the light is used. Stationary light fixtures that are low enough that they could be contacted during normal activities, either directly or by an item held by hand shall have protective covers or guards installed.
5.12.3 Extension Cords §
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Lighting shall be installed as appropriate for the location. Portable lights used in potentially hazardous locations shall be either explosion-proof flashlights or other types of portable lights approved for potentially hazardous atmospheres. Make all other electrical connections permanent installations by proper construction methods. Use extension cords for temporary use only. Extension cords shall be the appropriate length. Cords shall not be connected to extend the length. Use extension cords with the appropriate voltage and amperage rating for the job.
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Extension cords shall be of a three-wire grounded type and free of splices. Depending on the location and intended use, they also shall be equipped at each end with either explosion-proof or non-explosion-proof three-wire, grounded receptacles and plugs (but not with one of each). Do not use “hybrid,” ungrounded or external ground wire extension cords. Never repair a damaged cord with electrical tape. Prevent cords from contacting oil, hot surfaces and chemicals. Extension cords shall not be fastened with staples or otherwise hung in a fashion that could damage the outer jacket or insulation. Do not hang cords over nails or other sharp edges, or place them where vehicles may run over them. Extension cords shall be protected from damage when in use (e.g., vehicular traffic, falling objects, etc.). Extension cords attached to equipment shall not be used for raising and lowering the equipment. Rope or line shall be used instead. Do not use twist-lock cords for portable tools.
5.12.4 Electrical Power Tools
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Portable electrical tools and equipment shall be UL listed, double insulated tools or be grounded through a third wire in the cord. The ground wire connection shall not be defeated. Electrical tools and equipment with damaged or inadequate insulation, defective cords, etc. shall be removed from service until repaired. Taped splices in cords are not considered properly repaired and shall not be used. The power supply source shall be disconnected before repairs or services are performed on power tools. Where there is danger of explosion or fire, pneumatic (air-operated) power tools should be used. Chevron Pipe Line Company
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Outlets that are not a part of a permanent building or structure supplying power to portable electrical tools that may be used in a wet location or construction site, shall have ground fault circuit interrupter (GFCI) protection.
5.12.5 Static Electricity
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Do not “splash fill” tanks storing hydrocarbon products. Overhead fill lines should have downspouts extending to the bottom of the tank. Any filter screen should be placed well forward of the outlet to allow the induced static electrical charge to dissipate before it reaches the tank. Transport vehicles shall be bonded through a bare metal surface to the designated location on the loading facility. Bond nozzles to the tank if steam or water is used to clean hydrocarbon (crude products, etc.) storage tanks and separators. Sandblasting nozzles shall be bonded electrically to the item being blasted. Before transfer/collection of flammable liquids, dispensing containers or process equipment shall be properly grounded and bonded to a receiving container. The illustration below shows one method of bonding and grounding a metal dispensing drum and a metal receiving container. NO SMOKING
FLAMMABLE
Grounding rod (buried 8-feet deep)
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5.12.6 Sampling and Gauging §
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Metal tanks are grounded through contact with the earth. When using conductive (metal) tapes or containers to gauge or sample metal tanks, the tape or container shall be held in continuous contact with the tank hatch or tap. Use only natural fiber lines (such as hemp or cotton) to lower conductive items into either metal or nonmetal tanks. Do not suspend buckets equipped with plastic or wooden handle grips from a nipple or valve to collect a sample or to drain a line; the plastic or wood grip prevents the bucket from being bonded to the valve, and static electrical charges cannot be drained away. Use metal cans with metal grips or static discharge connections for this purpose. Never use plastic. Do not pour hydrocarbon products from one container to another without bonding both containers, whether by direct contact of both containers or via a bonding wire. There's one exception to this rule: If one of the containers is completely made of a non-conducting material (such as a glass sample bottle or plastic drum), then bonding is neither needed nor possible.
5.12.7 Electrical Fuses and Circuit Breakers §
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Do not change lights or fuses when circuits are energized, unless you are a qualified electrician. Only authorized personnel shall remove or change highvoltage fuses. Do not bridge fuses or circumvent the normal operation of circuit breakers. Do not replace blown fuses with fuses having higher amperage or lower voltage rating. To maintain proper circuit protection, replace it with a similar fuse. Always use a fuse puller to remove fuses.
Chevron Pipe Line Company
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When operating circuit breakers, stand to one side and use a firm, swift, positive action to open or close the circuit. If a circuit breaker continues to trip out, this is indicative of an abnormal situation. Locate the cause of the problem. Under no circumstances shall the breaker be held manually or by some other physical means; this could cause an electrical fire.
5.12.8 Explosion-Proof Electrical Equipment
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Electrical equipment in electrically classified areas shall meet the National Electrical Code (NEC) and/or the American Petroleum Institute (API) RP-500, Recommended Practices for Classification of Locations for Electrical Installations at Petroleum Facilities, for such installations. Explosion-proof equipment shall be maintained in good condition to retain its original integrity and the ability to perform effectively. Explosion-proof caps, covers, boxes, etc. shall be secured and seated to maintain the integrity of the system. To prevent the migration of gases in electrical conduit, EYS seals shall be poured and maintained in accordance with the requirements.
5.12.9 Batteries and Standby Generators
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Batteries are generally used as backup power. They contain acid and may emit gases when being charged. In certain mixtures, these gases may constitute an explosion hazard. Provide adequate ventilation for such batteries. Sealed batteries are preferred and are recommended for backup use. Treat batteries carefully. A shorting battery can produce electrical sparking and considerable heat. Wear protective chemical goggles and gloves when working on and around batteries.
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Standby generators, where installed, are used to provide emergency power and generally are hooked up in a way to prevent overloading. The power available from a standby generator is limited. For generators that start automatically, post a sign on the generator that reads “Caution, this equipment starts automatically.” Do not overload a generator. Never add additional loads without checking a generator's capacity. Maintain at least two feet of clearance around all sides of generators. Do not store combustible or flammable materials near generators.
5.12.10 Maintenance
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The covers and all bolts on electrical equipment shall be reinstalled and tightened upon the completion of work. Defective appliances, lines/cords, electrical equipment, etc. shall be taken out of service, tagged, and reported to your team leader.
5.13 Hot Work Areas 5.13.1 Hot Work Permits ✓ Review and follow the checklist related to this activity in Appendix G. §
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A Hot Work Permit shall be issued in specified areas where any source of ignition is used and the potential for flammable or combustible materials is present. A source of ignition includes: welding, cutting, burning with a torch, grinding, smoking, sandblasting, spray painting, breaking concrete, use of internal combustion engines, personal electronic devices (cellular phones, pagers, computers, etc.), and operation of motor vehicles.
Chevron Pipe Line Company
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On jobs lasting more than one day, hot work permits shall be reviewed each day so that any situation change can be evaluated. A new hot work permit must be issued any time work is suspended and the area is vacated (this is done to ensure that conditions have not changed during a crew's absence). Inform new personnel of the entire scope of the operation, especially during a crew change. Before introducing an ignition source, test the atmosphere with a gas detector. Note that the atmosphere of a normally “safe” area may change due to wind direction and vent locations. Before welding/cutting work is authorized and started: • Designate the person in charge to be responsible for issuing any hot work permits that may be required.
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• Discuss with the team leader, operating personnel, welder and any contractors, the nature of the work to be done and all possible hazards. As long as a known ignition source is present in a hot work permit area: • The person in charge or a qualified company representative must remain on site until the work is completed. If the scope of the operation is too spread out or involves too many people for one company representative to adequately supervise it, a second company representative also must be on hand to assist. • All company representatives and contract personnel shall continually be alert for changing conditions in the area that might increase the possibility of fire. Any changing conditions noticed in the area shall be thoroughly discussed with all those concerned.
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• If the hot work permit area is a confined space, at least one employee must stand by on the outside, ready to give prompt assistance in case of emergency.
5.13.2 Area Preparation §
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Minimize ignition source exposure time in hot work areas by welding materials together outside of the area and bringing them to the installation site to complete final tie-in welds. Do not weld or cut if there is work in progress where vessels, lines or fittings containing hydrocarbons are opened to the atmosphere and are not continuously gas-tested. A closed valve or check valve should not be considered a means of positive shut off from the atmosphere or from connecting vessels or lines. Use blind plates, skillets, or similar devices for this purpose, and gas test to make sure the atmosphere is safe. Before moving any heavy loads around or other equipment containing hydrocarbons: • Stop all welding, cutting, or other operations that involve ignition sources.
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• Shut in and/or bleed off the affected equipment. Do not operate valves while welding/cutting equipment and other known ignition sources are in operation around hydrocarbon-producing wells and equipment on stream. As required by the hot work permit, check pressured vessels to keep pressure below that of the relief valve set pressure and the rupture disk bursting pressure. Do not bleed off pressure in line, fitting, vessels, and other operating equipment to the atmosphere until: • The person in charge says it is safe to begin the procedure. • Known ignition sources in the area have been eliminated.
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• All conditions of the hot work permit have been met.
5.13.3 Fire Watch
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Establish a Fire Watch before starting work on jobs requiring ignition sources in hot work permit areas. The Fire Watch may be either a company or contract employee whose only duty will be that of fire watch. The fire watch will: • Have a fire extinguisher on the site near the work to be done, where it will be readily accessible in a fire situation with adequate backup extinguishers strategically located. • When available, have at least one fire hose reel ready to operate if required. • Know how to properly operate the fire extinguisher and other fire equipment. • Flush or plug and test (with a detector) all drains in the area when welding is to be done, since gas vapors may collect in these areas. • Remove rags, scrap wood, oil spills, rope, canvas, mud sacks, etc. from areas where slag may fall, before work commences. If wood cannot be removed, thoroughly wet it down with water and continually observe it for fire. • Continually observe the work in progress for fire or other hazardous conditions that may arise. • Observe where hot slag and sparks are falling to ensure that they are not falling on combustible materials. • Cool or guard hot surfaces to keep personnel from coming in contact with them. • Establish a hot work shutdown procedure, should an emergency arise.
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• Thoroughly wash down and observe the area for 30 minutes after welding operations are suspended or completed to be certain no fire hazard is present. • Fire watch training must include hands-on defensive firefighting at a minimum, utilizing a portable fire extinguisher. Training certification shall be maintained. Fire watch training requirements are noted in HES Procedure 205, Appendix C.
5.14 Welding 5.14.1 General Precautions §
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Consult the welding procedure to determine which welding methods are appropriate for repairs and new construction jobs. Follow hot-work permit and fire watch procedures before beginning welding. Remember, only the PIC can authorize welding to begin. The welder should point out any concerns to this person. Never weld where gas detectors read above 10 percent of the Lower Explosive Limit (LEL). Comply with the safe practices outlined for working with pressurized cylinders. In addition, observe the following precautions: • Inspect equipment to see that it is in proper operating condition. If a backfire has occurred and has reached the hose, the hose may have become unsafe; the entire length should be tested to verify that the cutting torch has not become clogged. If hose is clogged discard and replace before proceeding. • Do not hang torches from the regulators attached to the cylinder. • Do not let hot slag fall on combustible materials, hoses or on the cylinder.
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• Do not let hoses come in contact with hot steam lines or solvents. • Release the hose pressure and close the cylinder valves when work is interrupted for a longer period (such as mealtime). • Do not leave a pilot flame burning at the tip of the torch during interruption of operations. • Follow limitations on the amount of tape allowed on welding hoses (four inches of tape per 12 inches of hose). • Close the valves if left unattended. § When working in an elevated position, protect workers and materials below. § § § §
Provide a pan or screen to keep hot metal, electrode stubs, hot metal slag, etc., from falling below. Provide toe boards when working from scaffolding under which workers may be passing or working. Restrict access to the area below the work site. Instruct the welder's helper to act as a lookout since goggles or a helmet often obscures the welder’s vision. The welder's helper will: • Eliminate tripping hazards and maintain good housekeeping in the work area. • Watch for and warn the welder of any fire or other potentially dangerous situation.
5.14.2 Minimizing Electric Shock from Arc Welding §
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Cables must be of sufficient size to avoid overheating. The insulation must be in good condition and there should be no loose connections. Never weld on any line or equipment until it has been connected to the ground connection of the welding machine. Never pull or disconnect a ground line while the arc is in use.
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Never let the live metal parts of the welding circuit touch damp skin or clothing. Ventilate confined spaces (in accordance with the safe entry procedure) and have assistance readily available. Toxic or non-toxic vapors, gases, and fumes may accumulate in the work area during welding operations.
5.14.3 Welding in or Near Tanks or on Pipelines that that Contained or Have Contained Hydrocarbons
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Inspect the line or tank. The team leader or person in charge and welder will eliminate the possibility of a flashback in one section being transmitted to another section. If the line is not being used at the time of the welding, this can be done by blinding off or isolating the section to be welded on. Gas test to verify the level of hydrocarbons present. Determine the minimum wall thickness with an ultrasonic testing device. Reduce line pressure as much as practical for spot welding, welding patches, sleeves, hot-tap connections, etc. Refer to the welding procedure for more information. Do not weld on a hydrocarbon pipeline unless adequate flow is present (greater than one cubic foot per second), the line is full and under positive pressure with a means of safely relieving pressure build-ups away from the work site, or the line is “gas free.” Flush lines with water where practical. Turn off any cathodic protection rectifiers connected to the line at each side of the tie-in. Install a bond wire before cutting apart the line.
Plugs § Check plugs for tightness, and monitor the open end of the line for gas vapors (with a combustible gas indicator) just before welding. The area should be “flashed” with a torch prior to welding. 80
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Do not jar or move the line until welding is complete to avoid loosening the plug. Start welding as soon as the plug is in place and complete the job without any interruptions.
Dry Ice § Follow the precautions below if dry ice (solid carbon dioxide) is used to seal off small amounts of petroleum fluids and dilute flammable vapors in the pipeline. §
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Do not use dry ice in a line where there is a likelihood of a significant accumulation of petroleum fluid or expansion of vapors. It does not form a true plug. Be prepared to weld when the line freezes. Do not plug the line and then leave for a prolonged period (such as mealtime). Always check the ice plug before welding. Avoid pounding or jarring the pipe in the plug area. Because the pipe is now much more brittle and the impact strength is reduced at low temperatures, it could break. Avoid contact of dry ice with your bare skin. Do not carry it within the passenger section of any vehicle. If it is necessary to use the trunk section of an automobile, prop the trunk lid partially open. Ventilate bell holes when using dry ice. Although carbon dioxide is a non-toxic gas, it is heavier than air and, in large quantities, could cause suffocation due to oxygen deficiency.
Vents § If necessary, mechanically install a vent in the pipe to carry off liquids or vapors that may accumulate behind the plug. Locate the vent a safe distance from the welding and make it long enough to carry vapors and liquids to a safe spot (generally 50 to 200 feet away).
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Bell Holes § Construct bell holes with ample dimensions to permit easy access and escape and to allow the welder freedom of movement. Consult trenching access and shoring procedures and confined space procedures. §
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Test the bell hole with a combustible gas and oxygen meter, as explained in the confined space entry procedure. A standby shall be available to help the welder out of the bell hole should an emergency arise. Maintain a close fire watch over the welder - a welder's vision is restricted while welding. If there may be danger of gas in low spots, keep the welding machine in an elevated location upwind from the bell hole.
5.14.4 Hot Tapping
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Tapping a pipeline is a specialized operation and shall not be done without an adequate, overall comprehensive plan. Some general guidelines include: • Make bell holes for hot-tap welding large enough to allow easy access to those who must work in the hole. • Thoroughly check any adjacent fittings for leaks and safe condition. • Check working conditions before welding.
5.14.5 Compressed Gas Cylinders §
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Cylinders of any compressed gas may be dangerous because they can be under several thousand pounds of pressure. If a cylinder falls or the valve nipple breaks, the rapidly escaping gas may convert the cylinder into a projectile.
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Cylinders shall never be used for any purpose other than to contain gas for which the cylinder was designed. Empty cylinders shall be marked or labeled "EMPTY." Valves shall be tightly closed and the valve protection caps replaced.
Handling § When it is necessary to move compressed gas cylinders, a cart or other mechanical device especially designed for that purpose shall be used. Cylinders may also be rolled on the bottom edge, but never dragged. § §
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Cylinder valves shall be kept closed with the valve protection cap in place during handling. Cylinders to be transported shall be loaded and secured in an upright position, unless specifically designed for horizontal service. When transporting cylinders in a vehicle, secure the cylinders to the vehicle so they cannot move or fall while the vehicle is moving. Keep cylinders of different types of gases separated as much as possible to avoid grabbing the wrong one off the vehicle and to reduce the possibility of an accident or reaction should two cylinders be leaking slightly. Cylinders shall never be dropped or allowed to strike each other violently. Do not use ropes or chains to lift a cylinder and do not lift it by its cap. Cylinders handled by hoisting equipment shall be carried in a cradle or similar device and care taken to prevent their being dropped. Valve protection caps shall never be used for lifting the cylinder.
Use § Never use cylinders that have been defaced or had suppliers’ identification information (labels, tags,
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decals, etc.) removed. The color of a cylinder cannot be relied upon to indicate a particular gas. Do not attempt to mix two gases in one cylinder or transfer gas from one cylinder to another. Use regulators, gauges, hoses, etc. only for the particular gas(es) for which they are specified. Do not “mix and match” these appliances with cylinders containing gases that have different properties. Use properly fitted and recommended wrenches with cylinder valve accessories. A cylinder of compressed gas shall never be used without a pressure-reducing regulator attached to the cylinder valve. The cylinder valve shall always be closed before attempting to stop leaks. Routinely soap-test manifolds, gauges, hoses and fittings to disclose leaks. Do not attempt to repair valves or plugs on a leaking gas cylinder; such cylinders shall not be used. Notify the supplier for assistance. Keep cylinder valves closed and protector caps in place at all times, except when the cylinder is in use. Open cylinder valves slowly with the hose end of the valve pointing away from personnel. Never “force'” a cylinder valve open; if it doesn't open in a normal fashion, set it aside and notify the supplier. Never leave cylinder valves open when they are not being used. When you finish a job or take a break, close the cylinder valves and release the regulator adjusting screw to relieve the pressure on the hose. Coil the hoses near or on top of the cylinders, but do not wrap them around the cylinder. Never use cylinders for purposes they were not designed for, such as rollers or supports.
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Sparks, molten metal, electrical currents, excessive heat, or flames shall not be permitted to come in contact with the cylinder or attachments. This includes propane or acetylene torches and space heaters. Oil or grease shall never be used as a lubricant on valves or attachments to oxygen cylinders, since oil and oxygen under pressure can be a fire hazard. Also, oxygen regulators shall not be handled with oily or greasy hands or gloves. Threads on a regulator or union shall correspond to those on the cylinder valve outlet. Connections shall not be forced.
Examination § Compressed gas cylinders shall bear all markings and be hydrostatically tested as required by U.S. Department of Transportation (DOT) regulations. § §
Cylinders shall be examined for signs of corrosion or other damage. Leaky or damaged cylinders shall be reported and taken out of service immediately. They shall be removed to a safe location and observed until safely depressurized. They shall be marked or labeled “DAMAGED.”
Storage § Store cylinders in shaded, well-ventilated areas away from flammable substances (oil, gasoline, waste, etc.). Post “No Smoking” and “Caution - Flammable Gas” signs on all cylinders. Secure them with chains or rope, in an upright position, with valves closed and caps in place. Separate empty cylinders from full cylinders and label them when empty. §
Oxygen cylinders shall not be stored within 20 feet of fuel gas cylinders or combustible/flammable materials (especially oil or grease), unless protected by a noncombustible barrier at least 5 feet high having a fire resistant rating of at least one-half hour.
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Compressed gas cylinders shall not be accepted from the supplier unless they are properly labeled and have protective valve caps in place.
5.14.5.1 Oxygen and Acetylene
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Do not store oxygen and acetylene together. Keep them separated by 20 feet or by a five-foot-high fire wall.
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Always use and store acetylene cylinders in an upright position (valve end up) to prevent the acetone (a stabilizing agent) from draining into the valves or fittings. Without acetone present to stabilize the acetylene, it can explode.
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Never use acetylene at a hose pressure in excess of 15 pounds per square inch (gauge). Above 15 psig, acetylene is extremely unstable, and can explode.
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Do not allow oxygen to come in contact with oil or grease; it can cause an explosion and fire. Never lubricate or allow oil or grease to get on oxygen connections; use only those types of fittings that do not require lubrication.
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Never use oxygen as a substitute for compressed air. Be aware that oxygen connections for hoses and regulators have right-hand threads. Acetylene and cutting gas connections have left-hand threads.
5.14.5.2 Compressed Air
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Compressed air may be dangerous if not used correctly. Never point an open air hose at another person. Never use it to blow dirt from clothing. Compressed air can penetrate the blood stream without breaking the skin. The resulting air bubbles are extremely painful, and may cause death.
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Wear goggles if the use of compressed air stirs up dust and flying particles.
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Direct pressure equipment such as grease guns and spray paint guns away from the body and other personnel in the area.
Chevron Pipe Line Company
5.14.5.3 Natural Gas
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Never use natural gas to power pneumatic tools.
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The use of compressed air or oxygen in a gas system is prohibited. The use of natural gas in a compressed air or inert gas system is also prohibited. Nitrogen shall be the only gas used as an alternate source in both natural gas and compressed air systems.
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Use natural gas only as fuel for internal combustion machines or to power pumps, pneumatic controls or starters. Use only in areas free of other combustion sources. Any other use of natural gas requires prior approval by the team leader.
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Do not vent or exhaust natural gas to confined areas, enclosures or other areas where gas can be trapped.
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Never use rubber hose for supply or exhaust lines for natural gas powered equipment.
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Natural gas, from safety devices and vent stacks, shall not be allowed to vent into a building or beneath a floor or platform. Discharge vents to atmosphere shall be firmly secured.
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Where located on a building, vent piping shall be above the eave to prevent vent gas entry into the building. Drain or weep holes in the vent line shall not be located inside a building.
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Before venting gas lines, instrumentation lines, scrubbers, drip pots, etc., the person performing the work shall determine that the area is free of ignition sources.
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Natural gas used inside enclosures for instrumentation, e.g., back pressure valves and level controllers, etc. shall be vented outside.
Natural gas as a pressure source shall only be used in equipment designed for its use, including, but not limited to, gas starters, gas operated pumps, valve actuators, centrifuges, and instrument systems.
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In cleaning and/or maintaining any natural gas fuel system on field or plant equipment such as treaters, line heaters, furnaces, etc., care shall be taken to remove any possible source of ignition. When working in/on a hot/cold fire box, fuel lines to the pilot and main burners shall be disconnected or blinded to prevent accidental gas flow into the fire box. Automatic fuel shutoff valves shall not be depended upon to isolate the gas system.
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Before inserting a torch to light a pilot or burner in a heater or treater, all manual valves shall be closed for a reasonable length of time (minimum 5 minutes) to purge the fire box of potentially explosive mixtures. Fuel systems for fired equipment shall never be turned on without a pilot light or torch in the fire box. Precautions shall be taken so employees are not in line (path) with a possible flame flashback. Employees should wear appropriate face shields when manually lighting fired equipment.
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When lighting or firing a steam generator, employees shall remain away from the air intake (vortex) so as not to be in the path of a possible flame flashback.
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The vent lines from atmospheric storage tanks/vessels shall be checked for reduced flow or flow stoppage when excessive gas pressure is noted in the storage tanks/vessels. The vent system shall be cleaned if it becomes plugged.
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Where necessary, gas vent lines shall be equipped with flame arrestors, pressure-vacuum relief valves, or an equivalent device to prevent flame flashback from the end of the vent line to the tank/vessel.
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Flame arrestors shall be installed and maintained according to manufacturer's specifications.
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Thief hatch covers shall be kept closed except during the collection of samples or the gauging of tanks/vessels.
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Flapping thief hatch covers shall be reported to the immediate supervisor so that action can be taken to reduce the gas pressure in the tanks/vessels. The gaskets on the tank/vessel hatch covers shall be maintained in good condition to prevent gas from escaping.
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Gas vent lines shall be installed to prevent fluid from accumulating and being trapped in the lines.
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When an ice plug develops in a gas manifold or a gas line, the upstream and downstream pressures shall be equalized and reduced to the lowest pressure possible. Sufficient time shall be allowed for the ice plug to melt. If possible, free water should be drained and properly disposed of.
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Natural gas used at some locations may be purchased from an oil-producing lease and may not have been odorized for domestic use. Extra precautions should be taken at these locations, as natural gas itself does not have a detectable odor. Delivery lines and equipment lines should be checked periodically for leaks.
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6.0
Pipeline Operations
6.1 General Rules 6.1.1 DOT Pipeline Safety Regulations §
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The Federal Department of Transportation or an affiliated state agency (such as the Texas Railroad Commission or the California State Fire Marshall) primarily regulates CPL’s operations. The regulations covering pipeline operations are contained in 49 CFR, parts 190-199. The regulations are performance oriented; they tell pipeline companies what must be accomplished rather than how to accomplish it. These regulations require pipeline companies to prepare operating and maintenance manuals detailing how they will complete all operations, maintenance and emergency response functions necessary for the safe operation of their pipeline. Requirements contained in these manuals have the same legal standing as law. These manuals are reviewed for accuracy and completeness during inspections by the DOT. Records also are checked to ensure all required maintenance inspections are being performed and documented. If any deficiencies are found in the manuals or record keeping, civil penalties may be issued. The primary procedures required for compliance with these regulations are contained in various manuals including the operations manuals, emergency response plans, Maintenance and Inspection Manual and the HES Procedures Manual. For more information contact your DOT specialist.
6.1.2 Work on Existing Pipelines §
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Before repair work is performed on pipelines or associated equipment, all affected employees shall be informed.
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Pipelines shall be assumed to be under pressure regardless of precautions taken. When possible, pipelines shall be physically traced to determine the sources of pressure that need to be blinded. A check valve shall never be depended upon to prevent backflow in a pipeline. Valves shall be locked/tagged out, both upstream and downstream of the work area. The pipeline pressure shall be bled down. Before initiating hot work or using spark producing equipment, the pipeline shall be purged with inert gas, flushed with water, or ice/mud plugs set. The atmosphere in the area shall be continuously monitored for hydrocarbon vapors. When practical, work shall not be performed on equipment under pressure. When the equipment must remain pressurized, approval shall be obtained from your team leader and other precautions shall be taken to avoid the hazards posed by the pressurized equipment. When a bolted connection is to be removed, bolts shall be loosened just enough to allow any trapped pressure within the pipe to be relieved. Pipelines under cathodic protection shall have the rectifier switched off or a shunting cable attached to both sides before the line is separated. If a section of pipe is to be removed temporarily, but not immediately replaced, the pipeline shall be blinded. All gas lines and gas system equipment, including existing systems from which pressure has been relieved, shall be thoroughly purged with gas to remove air before operations begin. Until air is completely removed, low-pressure levels and low-gas velocities shall be maintained. Removal of foreign material by blowing-down (purging) shall not be performed until air is purged from the system. This is to prevent
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ignition of an air-gas mixture. Ignition sources shall be eliminated during purging, blowing-down, and cleaning operations. In some hot work, it is not possible to evacuate the line and it is necessary to perform a “hot tap”. Hot taps shall be performed only by qualified persons. To prevent finger injuries, flange spreaders should be used when gaskets, blinds, and orifice plates are installed.
6.1.3 LOTO and Blinding Procedure
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Blinding is the preferred method of isolation for all equipment in hydrocarbon service. Blinds shall be installed on or in all piping connected to tanks/vessels or equipment scheduled for maintenance, entry, or hot work. Blinds shall be near the tank/vessel, preferably on the first flange from the tank/vessel shell. In instances where a blind cannot be installed near the tank/vessel, other methods, of isolation can be used as long as the method provides equal protection for employees as would be provided by blinds. In some instances a valve, spool piece, or other device shall be removed from the line and a blind flange installed on the line and the tank/vessel. A blind shall be installed with three major considerations in mind: • Will the blind effectively accomplish its purpose in the location selected? • Can the blind be safely removed? • Is there access to the selected location?
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6.1.4 Valves, Piping and Tubing §
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Grease and operate valves in accordance with manufacturer's specifications. Gate, plug, and ball valves are designed to be fully opened or fully closed; they are not designed for throttling. Only bolted bonnet steel valves should be installed in hydrocarbon service, unless Technical Services approves another type for the particular application or service involved. (For example, some screw bonnet valves may be installed in locations where pressure and other factors may allow their use.) Use stainless steel tubing and tubing fittings on all tubing installations in hydrocarbon service. Mark valves requiring manual operation in the event of a fire or other emergency. The sign or markings should indicate which valves are in water service, which ones are used for hydrocarbons, etc. Plug all valves in hydrocarbon service that open to the atmosphere. Use a solid steel plug, or blind off the valve. Cut clean, smooth pipe threads to ensure good, tight connections.
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Valves that control bleed operations should be opened and closed slowly.
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Do not hammer on lines or fittings that are under pressure.
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When repressuring lines and equipment, open valves slowly. Everyone along a line or in front of the equipment should stand clear until normal operating pressures are reached.
6.1.4.1 Block Valves
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The pressure of a flowing well shall not be controlled by a block valve in the flowline at the tank battery header or between the header and the separator.
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In switching from one pressure vessel to another, the valves to the pressure vessel being activated shall be opened first and flow established before the valves on the pressure vessel being deactivated are closed.
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Chains that operate overhead valves shall be properly secured from walkways when not in use. Block valves shall be operated slowly.
6.1.4.2 Check Valves
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A check valve shall never be relied on to hold line pressure to protect persons during maintenance operations.
6.1.4.3 Pressure Relief (Safety) Valves
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Pressure relief valves shall be tested according to company policy. Pressure relief valves shall be set based on the lowest pressure-rated vessel in the system.
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Block valves should not be located between the vessel and the pressure relief valve or between the relief valve and the discharge vent, unless they are locked and sealed in the open position.
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Piping from the pressure relief valve outlet shall be at least the same size as the outlet of the relief valve. If more than one relief valve discharges into a common vent line, the line shall be sized so that it can handle the volume from the vessels should two or more relief valves release at the same time. Discharge vents to atmosphere shall be designed in accordance with SOPs and regulatory requirements.
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Design and installation methods shall be used to prevent fluid accumulation at the discharge of the pressure relief valve. Leaking pressure relief valves shall be replaced as soon as possible.
6.1.4.4 Valve Actuation
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Employees shall not operate (open or close) a valve unless they know what purpose it serves. Valves that are part of emergency shutdown systems shall be inspected at least annually. Chevron Pipe Line Company
6.1.4.5 Pressure Gauges
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Never tighten or loosen pressure gauges while the gauge is under pressure.
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Equip pressure gauges in product service with safety plugs or safety backs.
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Gauge pressures should range between 33 percent and 67 percent of the maximum gauge reading for safety and accuracy. For example, the recommended operating range of a 5000 lbs. gauge should be 1660 to 3350 psig. A process gauge connection size should not be less than 1/2” NPT.
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Never install gauges directly into a tap in a vessel or line. Install them into a valve that has been installed into the tap. Special gauge valves with bleed ports are preferred.
6.1.5 Scraper Traps
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Make sure the trap is equipped with both a pressure gauge to indicate pressure, and a pressure relief valve capable of safely relieving pressure in the barrel. Refer to the Design and Construction Manual. Follow the procedures for opening the scraper trap. There are several types of scraper trap closures in use throughout the company. Be sure you understand the safe operation of the unit you have in place.
6.1.6 Engine and Motor Operation
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Do not begin repairs on any machinery until the power source has been turned off and provisions have been made to prevent revolving or reciprocating parts from turning over accidentally. This policy does not prevent minor adjustments being made by authorized personnel, such as tightening packing glands and adjusting fuel injectors and valve tappets. Follow the lockout/tagout procedure whenever any work is being done on a shut-down engine or motor.
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Before starting an engine or motor, the person in charge should inspect the engine, checking to see that all guards are in place, tools and equipment are “in the clear,” and the engine is ready to start.
6.2 Tank Gauging 6.2.1 Ascending and Descending Tanks
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Keep one hand free to grasp the handrail when climbing or descending tank stairs. Keep both hands free to grasp rails when climbing or descending ladders. If necessary, utilize a hand line for equipment. Take extra care with footing and hand holds when climbing a tank under windy or moist conditions.
6.2.2 Tank Top Safety §
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Under some operating conditions, it may be necessary to access a roof after dark. Use adequate lighting and a buddy or notification system. Follow confined space entry procedures when descending onto floating roofs. Do not walk on tanks with visible or known roof deterioration, or on tanks posted with “Keep Off - Unsafe” signs. When possible, stand on the upwind side when opening the hatches on tanks to avoid breathing vapors and gases given off by contents of the tank. Follow precautions for hydrogen sulfide if labeling on the tank indicates that it contains H2S. Wear a respirator/SCBA when required (i.e., for benzene exposure, if posted on heated crude oil tanks or gasoline tanks).
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Do not leave hatches open unless there is a specific reason for doing so (such as ventilating a tank). Tag the open hatch, identifying the reason the hatch is open. If hatch is required to be left open, contact your air specialist to ensure compliance with local air district rules. Do not slam hatches open or shut. Avoid any practice that could generate sparks or static electricity. Do not leave tapes, plumb bobs, rags, etc., on tank tops. Any loose equipment left on a tank top may fall onto someone below. Immediately wipe up all oil or other liquid spills to prevent slipping.
6.2.3 Gauging § § § §
Use gauge wells or “target gauges” where available to avoid descending onto tanks. Follow the above procedures for ascending/descending tanks and tank tops safely. Do not gauge from the roof of a tank during a thunderstorm or an electrical storm. For more information contact the measurement specialist.
6.2.4 Static Electricity See Section 5.12.5 for static electricity issues associated with tanks.
6.2.5 Sampling and Gauging See Section 5.12.6 for electrical issues associated with tanks sampling and gauging.
6.2.6 Tank Dike Maintenance §
Lock dike drains closed except when draining accumulated water from within the dike area. Before releasing accumulated water, follow local water testing regulations.
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Use only walkways and stiles for berm access. In the event of berm damage or collapse, immediately notify a team leader, your local Spill Prevention Containment and Contingency Plan/SPCC if applicable, or your water specialist.
6.3 Tank and Vessel Cleaning 6.3.1 General Precautions
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Exercise extreme care while working in or around tanks that contain, or previously contained, petroleum or its products. These tanks may contain vapors that can cause asphyxiation or that may be in the flammable range. Some crude oil and separation tanks also may contain Normally Occurring Radioactive Material (NORM). The team leader shall: • Utilize confined space procedures. • Ensure that the atmosphere in the tank is safe to enter and remains safe to work. • Continuously ventilate tanks prior to, and during, cleaning operations.
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• Make sure all tank cleaning personnel are aware of all dangers and the procedures necessary to minimize them. Schedule the job for a time that minimizes any hazards. For example, tanks near a highway should be ventilated when the wind is blowing in a direction that will carry the vapors away from the highway. Dispersion of gas and vapors is slower in cold weather and during dead calms, particularly if ground fog prevails. Follow hotwork permit procedures as applicable.
Chevron Pipe Line Company
6.3.2 Equipment 6.3.2.1 Light Inside Tanks
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Use only explosion-proof flashlights inside any tank that has contained petroleum products, except when the tank is tested and found to be 10 percent or less of lower explosive limit (LEL). Then approved, grounded, vapor-proof, 110-volt hand lights may be used.
6.3.2.2 Personal Protective Equipment
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The PIC must complete the Safe Work Permit including outlining the personal protective equipment requirements.
6.3.2.3 Atmospheric Monitoring Equipment
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Test the indicator to see that it is in proper working condition. Follow the instructions (i.e., those fixed to the lid of the carrying case) and use the test gas (in the indicator case) to verify that the gas detector works properly.
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When transporting the indicator, keep it in its carrying case. Periodically service the gas indicator and keep it clean at all times.
6.3.2.4 Ventilating Fan or Exhauster
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Ventilate so that the volume of air in the tanks is changed three to five times per hour when possible. For large tanks (approximately 150,000 bbls and greater), a minimum of one change per hour is permissible.
6.3.3 Cleaning Procedures For details on tank and vessel cleaning procedures, see your team leader regarding cleaning and repairing tanks procedure. Following are some safety reminders regarding tank and vessel cleaning.
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6.3.3.1 Prepare the Area
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Clear the area around the tank of ignition sources (for distance of 100 feet or more, if possible). Leave all matches, lighters, cigarettes, etc., at an area determined “safe” by the team leader. Signs should designate areas for smoking.
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Block roads leading to the tank and post signs indicating “Danger from Escaping Gas” or “Danger Flammable or Combustible Vapors,” etc.
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Lay out a fire hose, if available, with combination solid stream and fog nozzle from the water source to the tank. Charge the hose before starting to ventilate the tank.
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Empty the tank as completely as possible.
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Ventilate the tank.
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No worker shall enter any tank or other container, provided only with manholes in the top, until confined space entry procedures have been implemented. This procedure requires that a rescue plan be developed for each authorized entrant. This plan must outline the provision for the rescue of all authorized entrants.
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Avoid workers cleaning or hosing from inside the tank. While workers are in the tank, periodically test the air inside the tank.
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Follow guidelines for the required number of workers for standby and support.
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Install blinds. Lines in hydrocarbon use must be blinded or completely disconnected, misaligned and capped. Only after the exhausted vapor tests 10 percent or less LEL should you clean the tank out through the manhole.
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Test vapors progressively throughout the tank, using the exploring probe to obtain samples at least five feet ahead of the tester. Also test near the bottom of the tank and in places where packets of vapor might accumulate.
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Keep the escape route open, Move all obstructions away from the manhole, both inside and outside of the tank. This is the responsibility of the person in charge of the job.
6.3.3.2 Cold Repair Work
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No cold repair work shall be done outside or inside any tank that has contained petroleum products until the person in charge of the job has determined that the tank is “safe.”
6.3.3.3 Hot Repair Work
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Under ordinary circumstances, hot/work or open fires will be permitted 300 feet or more from a tank that is not vapor-free, except where unusually large quantities of vapor are likely to be discharged.
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In all cases, the team leader shall: • Perform the tests or designate someone to do so. • Determine when prevailing conditions are such that any vapor discharge from the tank is not likely to reach the work. • Give instructions for the work to proceed. • Designate the “safe” location for other sources of ignition (such as welding).
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7.0
Transportation Safety
7.1 Motor Vehicle 7.1.1 Vehicle Operation
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Company-owned, leased and/or rented vehicles are to be used for company business only. They are not to be used for regular commuting except under a team leader's instruction. Vehicles should be left on company property at night and on weekends, unless you've received prior management approval to do otherwise. (Note: The use of company vehicles for personal business or commuting is considered a form of taxable income and must be reported to the Internal Revenue Service.) For insurance reasons, non-employees (including contractors) are not allowed to drive company vehicles. The driver and all passengers must wear seat belts. All passengers must ride in the cab or passenger compartment.
7.1.2 Driver Responsibility
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As the driver of a company vehicle, you must: • operate the vehicle in a safe, proper, legal manner and observe traffic regulations • use the vehicle only for authorized purposes • instruct all passengers to wear their seat belts • provide for the safety of employees helping load/unload, or otherwise working on or around the vehicle • have in your possession a valid driver’s license appropriate for the vehicle and its use
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• ensure the safety of your passengers Drive in accordance with the law. Do not operate equipment that is defective or that is not in compliance with the law. Drivers are personally liable and responsible for the consequences of violating state and community laws. Employees are strictly forbidden to drive a company vehicle while under the influence of drugs or alcohol. Certain vehicles require placarding. Proper placarding is the sole responsibility of the operator. Picking up hitchhikers is prohibited.
7.1.3 Safe Driving Principles
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Operate company vehicles in a defensive, alert manner. Try to anticipate what might occur under the existing conditions and drive to avoid potential hazards. Be considerate of, and courteous to, the traveling public and pedestrians. Yield the right-of-way to avoid accidents. Drive at speeds consistent with existing conditions, such as weather, ranging cattle, etc. Use these principles to reduce driver fatigue and costly vehicle maintenance: • aim high when steering • get the “big picture” when driving • keep your eyes moving. Avoiding staring. • leave yourself an available out • make sure others see you
7.1.3.1 Inspecting Vehicles
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The driver of any company vehicle should regularly inspect the condition and operation of tires, horn, windshield wipers, rear-view mirrors, brakes, steering gear, windshields, headlights, tailights, turn signals and stop lights. Also ensure that you have sufficient levels of gasoline, oil and water.
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Immediately report any missing or defective motor vehicle equipment.
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Immediately contact your team leader if you have reason to believe that any motor vehicle is unsafe to operate.
7.1.3.2 Backing
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When backing is required: • check to be sure path is unobstructed • walk around your vehicle before you start • ask for assistance, if necessary, to avoid hazards • continually check clearances while backing • stay at the vehicle controls while backing • back slowly
7.1.3.3 Turning
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When driving trucks with trailers or other long equipment, make sure you allow enough space to make the turn. Use the street you're turning onto as “extra space”, swinging wide, if necessary, to complete the turn.
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When turning a truck or long equipment into a narrow street or alley, try to approach it so you'll be making a left turn, rather than a right turn.
7.1.3.4 Following
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Maintain a “space cushion” around your vehicle at all times to help prevent accidents. Leaving ample space around your vehicle gives you more time to react to conflicts or other changing conditions. This space cushion should take into account traffic, icy roads and other driving conditions. 7.1.3.5 Parking
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Park vehicles where permitted and they do not present a hazard to other traffic.
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Look for a parking space where backing is not required. When practical, vehicles shall be parked so they can be driven forward when next moved.
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Vehicles shall be parked so as not to roll out of control. Park vehicles with ignition turned off, hand brake set, and transmission placed in “park” or low gear. Use extra caution when parking on hills. Turn front wheels to the curb/bank or place chocks under rear wheels.
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The person in charge may authorize the vehicle to be parked with the motor running and the hand brake set when necessary to operate power take-off, electric or communications equipment for periods of time that would run down the vehicle battery. In these cases, select a level parking place if available. In all cases, chock blocks must be set.
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When operators are out of their vehicles, the engine shall be shut off and the parking brake set. In extremely cold areas, the requirement to shut off the engine can be modified by local management.
7.1.3.6 Loading and Unloading
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Post vehicle load limits in the cab or on the outside of the vehicle as appropriate.
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Do not overload vehicles with materials or passengers.
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Loads shall not extend directly over a truck cab unless the cab is protected for the potential hazard.
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Employees shall not be used as counterweights to correct improperly loaded trucks. The load shall be rebalanced or lightened.
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Chain binder (boomer) handles shall be secured to prevent accidental release.
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Load stakes shall be checked to see that they are securely in place prior to relieving tension on the chain binders.
Properly place and secure all vehicle loads. Mark all material that extends more than two feet beyond the cargo bed with a red flag.
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Employees shall not stand directly over the chain binder handle when tensioning or releasing a chain binder.
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Employees shall not attempt to stop a shifting, falling, or tumbling load.
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Employees loading or unloading pipe shall not stand between the truck bed and the pipe rack.
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A truck from which pipe is to be unloaded shall be in a direct line with the pipe rack to provide an even roll of pipe down the skids to the pipe rack.
7.1.3.7 Use of Cellular Phones While Driving
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Cellular phones (even hands-free), radios, PDAs, pagers, and similar electronic devices are a distraction while driving. • Electronic devices such as cellular phones shall not be used in company cars, rentals, personal cars on company business or on company property while the car is in motion. Pull over and stop when making or receiving calls. Remember to leave the freeway when stopping. Dial while the car is legally stopped. • Do not take notes while the car is in motion. • Leave them inside the vehicle while re-fueling.
7.1.3.8 Transporting Tools and Other Materials
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Do not leave tools and equipment loose in the cabs or passenger compartments of cars or trucks. Stow all equipment in proper tool chests or compartments whenever available.
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Do not leave loose articles on the seat or dash when the vehicle is in motion. These may fall to the floor or blow around, distracting or interfering with the driver. Use chart carriers or clipboards for papers. Similarly, don't store anything under the driver's seat that might roll out and interfere with braking or other actions.
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Portable safety containers shall be removed from vehicles while being filled with flammable liquids.
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Cargo or heavy tools shall not be transported in the passenger compartment of vehicles at the same time as passengers. Vans that carry tools and/or equipment in the cargo compartment shall be equipped with a protective barrier between the cargo and passenger sections.
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Hard hats or other loose objects shall not be stored in the rear window tray or the front dashboard of vehicles.
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Gasoline or other flammable material shall be transported only in approved (for example, UL, etc.) safety containers outside the vehicle passenger compartment, as required by Department of Transportation (DOT) regulations. Use only DOTapproved containers and fasten them securely to prevent tipping or rolling.
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In addition, explosives, pesticides, flammable and combustible liquids, and other hazardous materials shall not be carried in the passenger compartment of trunk of any company vehicle. Such materials shall not be stored in vehicle passenger compartments or automobile trunks. Carry properly completed shipping papers where required.
TO JUMP START, REMEMBER 4. Engine Block*
3.
Dead Battery
1.
Good Battery
2.
*(Connect last clamp away from battery) Batteries are the same voltage. Both negative posts grounded. Check fluid, check for freezing. Cars not touching. Ignitions off, accessories off, gears in “PARK” or “NEUTRAL,” brakes on. Attach clamps in order shown. Remove in exact OPPOSITE order.
7.1.4 Breakdowns
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If your vehicle breaks down, guide it completely off the main roadway if possible. If it is necessary to tow equipment, don't stand between a towed vehicle and the towing vehicle. Place warning devices between the vehicle and traffic.
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7.1.5 Trucks §
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Trucks shall be maintained in proper operating condition, with particular attention to the condition of the brakes, signals, lights, horns, windshield wipers, steering gear, and tires. A vehicle operator who detects a mechanical defect or potential safety hazard in a vehicle shall make arrangements for prompt repair or report the mechanical defect or potential safety hazard to his/her supervisor or the designated person responsible for vehicle maintenance. Wheels of trucks and mobile equipment shall be checked periodically to confirm that lug bolts and axle flange nuts are in place and tight. Truck beds and cabs shall be kept clean and orderly. Trucks shall be equipped with fire extinguishers, first aid kits, and disposable drinking cups when potable water is provided. Employees shall not ride on trucks, forklifts, and other mobile equipment not equipped for transporting passengers. The operator shall check clearances when operating a vehicle. When necessary, the operator shall obtain aid from a guide. Operators and other employees shall watch for electrical lines and equipment when working or driving vehicles equipped with gin poles/“A” frames, masts, or other protruding objects.
Winch Truck Operation §
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The operator of a winch truck is responsible for the examination of the winch lines and load guys to the gin pole/“A” frame. Winch and crane lines shall be visually examined daily or prior to use or anytime they are subjected to potential damage.
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Utility poles shall not be used as anchor points. Employees shall not stand between the truck and a load when there is a strain on the winch line. Winch lines shall not be used for assistance when climbing onto truck beds. Winch lines shall be terminated into a tail chain or other end attachment using an approved termination fitting (spelter socket, wedge lock, or crimp connection). An overhand knot in the end of the winch line is not an approved termination. The tail chain or other end attachments on the winch line of a gin pole/“A” frame shall not be pulled against the sheave (pulley) as it might become fouled or otherwise create a potential hazard. The winch line hook shall be securely fastened to the truck bed or other fastening point when not in use. Gin pole/“A” frame operators shall check truck positioning and anchoring prior to use. If the brakes are not sufficient, the wheels shall be chocked (blocked) to prevent the truck from moving. Outriggers shall be used when available. Employees shall not walk or stand under a suspended load. When heavy equipment is moved with a crane or gin pole/“A” frame, a tag line shall be attached to the load to enable the helper to stand in the clear and still control the load. Trucks should not transport suspended loads except within the immediate work area. When loads are handled by gin poles/“A” frames, the gin poles/“A” frames shall be securely anchored to the truck bed.
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7.1.6 Commercial Driver’s License
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Special training requirements must be met for commercial drivers' licenses (chauffeur licenses). Each employee who needs to carry a commercial driver's license is responsible for meeting these requirements and for notifying his/her team leader to schedule necessary medical tests. This includes a medical examination every two years, and inclusion in a random drug screening process (which is more stringent than the process required for general pipeline employees).
7.1.7 Accidents
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Report all accidents involving a company vehicle, rental vehicle or personal vehicle used for company business to your team leader. Team leaders shall report all vehicle accidents involving the company as soon as possible by telephone, and all information should be entered into the Loss Prevention System. In case of a vehicle accident, the employee driving should: • Pull off the road, if possible, to avoid obstructing traffic. • Render aid to any injured persons. • Place warning reflectors on the road as necessary. • Report the accident to his/her team leader and to law officers as soon as possible. • Use the LPS “Loss Investigation” form to gather essential information at the scene of the accident. This form should be carried in the glove compartment of all company vehicles.
7.2 Water 7.2.1 Marine Travel (Boat Transportation)
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The boat operator have complete authority to make all decisions concerning the suitability of weather, condition of the vessel, loading and unloading and Chevron Pipe Line Company
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any other factor relating to vessel operation. The boat operator may elect not to conduct or continue any voyage. Others shall not question an operator's decision. Follow the skipper's instructions regarding loading procedures, storage of luggage and cargo, seating arrangements and smoking restrictions. In the event of an emergency, follow the skipper's instructions and posted emergency procedure instructions. If a person falls into the water during a transfer, immediately notify the skipper by shouting, “Man overboard!” Assist in the rescue as directed by the skipper. Crew boats that operate in federally regulated waterways shall meet U.S. Coast Guard requirements. Overloading of crew boats is prohibited. The following shall be observed: • Employees shall wait on the dock until incoming crews have disembarked. The boat shall be boarded in an orderly and safe manner. • Passengers shall be seated in the cabin. Unless required, no one is to be outside on the deck when the boat is in motion. • Passengers shall observe good housekeeping. • Boats shall be equipped with fire extinguishers. The boat operator shall be responsible for examining fire extinguishers on a monthly basis. • Flammable or other potentially hazardous materials, compressed gas cylinders, pipe, or drilling tools shall not be transported on crew
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boats at the same time the boat is transporting passengers, unless the boat is certified for this service. • Passengers and crew shall wear appropriate hearing protection when necessary.
7.2.2 Personal Floatation Devices (PFDs)
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United States Coast Guard Type I PFDs (life jackets) are required on “for hire” vessels and offshore structures. USCG Type V PFDs (work vests) are considered an “open classification.” Approved Type I or Type V PFDs must be worn when: • Transferring to or from any watercraft. • Working at any over-water location that does not provide handrail protection. • Loading or unloading cargo from any boat, barge or other waterborne structure. (This includes the crane operator in the cab at an offshore location.) • Riding in any open or semi-open watercraft. • Operating any watercraft alone. • While being transferred with a personnel basket over water. • Entering the water to perform work. (Diving operations are excluded from this rule.) • Traveling in helicopters over open water or to offshore locations. If FAA-approved inflatable PFDs are provided in an aircraft, they may be worn in place of Type V PFDs. In fixed-wing aircraft, pilots will advise passengers when PFDs are needed. Wear the PFD that is used in any water survival training. • Conducting USCG fire emergency drills at overwater locations. (Type I PFDs are required.)
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• Deemed necessary by a pilot, boat skipper, team leader or safety engineer, due to fog, haze, rough seas, etc. PFDs must be worn fastened, snugly fitted and in good condition. When required, flotation devices may be worn over fire resistant clothing. Boat skippers and captains are responsible for ensuring that all passengers boarding or leaving their vessels follow all PFD rules. Boat skippers and captains will refuse boarding to any passenger not adhering to these rules, and will report all infractions to the appropriate team leader.
7.2.3 Swing Ropes §
The swing rope is the most common device for transferring personnel to and from boats and structures. Follow the guidelines below when working with swing ropes: • Install swing ropes so that they will return or swing back and hang over the outer edge of the catwalk. • At a minimum, the upper 10 feet of a swing rope connected to the structure shall be stainless steel wire rope measuring at least 1/4 inch in diameter. (Single-well and low-profile structures are exempt from this rule.) The lower part of the rope should be a comfortable diameter for an average person's grip, usually 3/4 inch to one inch in diameter. A three-strand, twisted polypropylene/polyester blend rope is recommended. • The rope shall not hit below the landing area of the catwalk. • The rope shall have three knots - spaced four, six and eight feet above the walking surface of the catwalk. • The lower section of the swing rope assembly must be properly maintained. Swing rope assemblies shall be visually inspected at least four
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times per year, and a record of these inspections noting the installation and/or inspection date shall be maintained at the facility. The lower section shall be replaced at least every two years. The rope shall be replaced sooner if it becomes excessively slick from oil, mud or chemicals; if a structure has been painted; or if the rope is otherwise damaged. • Always follow a skipper's instructions when using a swing rope to transfer between a boat and platform. Wear a snugly fitted and securely fastened PFD. • When using a swing rope from boat to platform, have both hands and arms free. Catch the knotted rope high enough to clear the catwalk on the structure when the boat is on top of a swell, and swing to the platform by pushing off from the boat with your feet. Once you've landed on the platform, release the rope and be ready to help the next person using it. Transfer your luggage or other materials via a material basket and crane, or by handing them from the boat to personnel on the platform. • When using a swing rope from platform to boat, swing from the catwalk as the boat is beginning to rise from the bottom of the wave or swell. Time it so both your feet are on the boat's deck as it is reaching the top of the swell. Never release the swing rope until you are safely on the deck. If you miss the boat, continue to hold the rope; you will automatically return to the safety of the catwalk, where you can try again. • Always keep your feet and legs clear of the platform landing face where the boat bumps against the platform.
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• A deckhand wearing an approved PFD must be on the deck at all times whenever a personnel transfer is being made. • If, for any reason, you don't think you can transfer safely using a swing rope, do not attempt to do so. Never let a boat skipper, deckhand or anyone else influence your decision or try to rush you. • Using a swing rope to transfer between two boats is prohibited.
7.2.4 Personnel Baskets
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Personnel baskets are permitted for use at facilities if management grants approval and governmental requirements are met. To use a personnel basket, stand on the outside rim of the basket and firmly grasp the upright basket ropes. Keep your knees slightly bent or flexed, and prepare for unexpected moves (particularly in rough seas). Only luggage and hand tools shall be placed inside the personnel basket. Never stand under a personnel basket.
7.3 Aircraft 7.3.1 General
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These instructions pertain to private charter flights. For commercial flights follow Airline Carrier Instructions. Passengers must report to the designated sign-up area 30 minutes before all flights to receive pre-flight instructions. If it is a passenger's first flight on the aircraft, she/he must inform the pilot or dispatcher so they can perform an appropriate briefing. • Wait for the pilot's signal before boarding or deplaning an aircraft.
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• Walk, never run, to and from the aircraft. • When boarding and deplaning, watch footing and use handholds. • Ear protection (plugs, muffs or headsets) is required on company or contract aircraft. • All passengers must keep their seat belts fastened for the duration of the flight. • Federal regulations (FAR 91.11) prohibit carrying anyone aboard an aircraft who is under the influence of intoxicating alcohol or drugs. • All baggage and loose objects must be stored in baggage compartments or other approved storage areas. Never block an exit with baggage. • If any explosives, flammables, compressed gases or radioactive substances will be transported, you must notify the pilot so special provisions can be arranged. • Never throw anything out of an aircraft.
7.3.2 Helicopter Travel Prior to initial flights on helicopters, passengers must view an introductory film. 7.3.2.1 Arrival at Departure Points
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Passengers shall report their name, ID number, weight (both personal and baggage), and destination to the Dispatcher as soon as they arrive at the departure point.
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All hazardous or flammable materials shall be properly containerized and the required paperwork completed before such material can be transported by helicopter.
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Passengers shall remain inside the designated waiting area until they are notified to board.
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Employees shall not loiter near helidecks during landings or takeoffs.
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Persons impaired by use of alcohol or drugs shall not be allowed to board any helicopter.
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Helidecks and landing/takeoff areas shall be kept free of debris, including, loose objects, baggage, and tools.
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Smoking shall not be permitted within 50 feet of a helicopter or a fuel installation.
7.3.2.2 Embarking and Disembarking Aircraft
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Upon embarking and disembarking the aircraft, passengers shall: • Wait until the pilot has made visual contact and signaled before approaching the aircraft. • Always approach or leave from the side of the helicopter. • Remain in the pilot's view at all times when approaching the aircraft. • Observe the path of the main rotor blades while they are turning and keep well under them. • Never walk around or under the tail rotor of any helicopter or around the front of the aircraft there often is a very low clearance between the ground and the rotor blade. • Never walk aft of the baggage compartment on any helicopter. After unloading baggage, leave the vicinity of the helicopter in a direction away from the tail rotor and in full view of the pilot. • Hard hats, safety glasses, light items, including, but not limited to, caps, hats, jackets, mail, paperwork, newspapers, and any other items that can be blown or sucked into the rotors or engine intakes must be secured or hand-carried in the vicinity of the helicopter. Long items shall be carried in a horizontal position below waist level to avoid contact with rotor blades. • Never chase after loose objects.
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• Follow the pilot's seating and cargo loading instructions. • Plastic garbage bags, plastic bags of any type, plastic wraps, and similar materials are strictly forbidden in and around heliports, helidecks, and landing and takeoff areas. • Always hold pipe, poles, etc. in a horizontal position when near a helicopter to avoid striking the rotor blade. • Passengers arriving offshore shall be clear of the helideck before departing passengers can be loaded. (Crew change is conducted below deck.)
Some rotor blades can dip below the 6 foot level 7.3.2.3 Pilot-In-Command
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The pilot in charge of the aircraft shall have complete authority to make all decisions concerning the suitability of weather and landing areas, condition of the aircraft for flight, loading the aircraft, the manner of flight, and any other factor relating to flight safety.
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A pilot may elect not to conduct or continue any flight. Others shall not question a pilot's decision not to fly. No one shall encourage pilots to violate or compromise any regulation. Passengers shall give the pilot their full attention and cooperation during the preflight safety briefing.
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7.3.2.4 Special Rules for the Sikorsky S-76
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Because the Sikorsky S-76 has a very low rotor blade clearance in the front of the aircraft, all passengers shall approach and depart from the sides only (either side is okay).
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Persons who must go around the front of the S-76 shall stay close to the nose and avoid touching the Pitot tubes as they can be hot enough to cause severe burns.
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There are three rows of passenger seats in an S-76. Only passengers in the center row can access the locking pin in the doors that must be lifted before the doors can be opened, so someone must be seated in the center of the middle row.
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The emergency exits are jettisoned differently in the S76 from other helicopters. Passengers shall pay particular attention to the pilot during the flight briefing.
7.3.2.5 In Flight
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Pilots and passengers are prohibited from smoking onboard all helicopters.
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Passengers shall never throw objects out of helicopters or in the vicinity of landing and takeoff areas, helidecks, and heliports.
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Passengers shall not distract the pilot in flight and shall be especially quiet during takeoffs and landings. However, the pilot shall be advised of any unusual occurrence within or outside the helicopter.
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Passengers shall never unfasten seat belts or change seats while in flight. Passengers must be able to fasten the seat belts as designed or they will not be permitted to depart. For safety reasons, do not use seat belt extenders.
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In the event of an emergency, passengers shall carefully follow the pilot's instructions and remain with the helicopter. Passengers shall be familiar with the location and operation of emergency exits and lifesaving equipment on board a helicopter.
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Exit-qualified passengers should advise the pilot so they can plan the seating arrangements. Exit-qualified passengers must be familiar with the emergency evacuation instructions and express a willingness to give their full attention to following these procedures should it become necessary.
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Hearing protection shall be worn around helicopters and during flights.
7.3.2.6 Miscellaneous Rules
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Crane operations during helicopter approaches or departures are prohibited. If possible, the crane operator shall position the boom 180 degrees away from the helicopter's approach path, and lock the swing brake or place the boom in the cradle when a helicopter is landing or departing the platform. The operator shall then step out of the cab so the pilot will know the crane has been shut down.
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The crane operator shall place the crane and load in a safe position in a prompt but safe manner and vacate the crane cab, while remaining clearly visible to the pilot. This indicates the crane is shut down.
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Helicopters shall be electrically grounded before refueling can begin.
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Employees responsible for refueling helicopters should undergo a special briefing and be issued an authorization card.
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Employees shall familiarize themselves with helicopter safety posters, practices, and briefings each time they fly.
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Injured persons who may need assistance should be accompanied by a person other than the pilot or pilots.
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Offshore landing areas shall be properly identified, painted (marked), lighted, cleared, and have nets or fencing as per regulations.
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Hard hats shall be secured with chin straps or handcarried in the vicinity of helicopters.
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If in doubt, ask - never take chances in and around helicopters.
7.3.3 Fixed Wing Aircraft
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Always wait for the pilot's signal before approaching or deplaning a fixed-wing aircraft with the engines running. Always stay behind the wing until the propeller is fully stopped.
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When boarding and deplaning, watch footing and use handholds. Do not rush.
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Smoking is prohibited during take-off and landing.
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The pilot will advise passengers when personal flotation devices (PFDs) are needed. PFDs are located under each aircraft seat.
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Passengers and/or boat captains waiting for other aircraft shall stand clear until an aircraft is safely airborne.
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Passengers awaiting aircraft arrival should be present at landing to assist in docking.
Passengers in the front seat should assist the pilot in watching for air traffic (and boat traffic in water operations). Never obstruct the pilot's view by reading a newspaper, etc.
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8.0
Ergonomics
8.1 Musculoskeletal Injuries & Cumulative Trauma Disorders
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The objective of ergonomics is to adapt the job and workplace by designing the tasks within the workers' capabilities and limitations.
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In many cases, evaluation of a workplace to determine risk to injury will require the experience and education of a professional, however there are general questions that can be asked to determine if ergonomic issues need to be addressed. These, for example, include questions on topics such as manual material handling, cumulative trauma disorders, environment, general workplace hazards, tools, and gloves.
8.2 Alternative Work Breaks
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Task breaks are one of the most effective actions you can take to prevent the discomforts of prolonged computer use. Remember to get up and move around periodically. If you type continuously, a good rule of thumb is to do other tasks for ten minutes every two hours.
8.3 Workstation Design
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Repetitive movements, such as keyboarding and using a mouse, combined with restrictive posture, can cause injuries commonly known as repetitive strain injuries.
8.4 Work Habits §
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8.4.1 Lifting Keep your back muscles in shape through proper exercise. You can avoid most back injuries simply by taking care of yourself. Consult your physician for advice.
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Before lifting determine the following: • Always complete a Safe Performance SelfAssessment prior to changing work tasks. • Can the object be moved by another means, such as a mechanical device? • Is the object so bulky that it would obscure your vision while lifting it? If so, get another person to help you carry it. • Is the object within your strength limits? A preliminary 'tug' will tell you. If the load is too heavy, get help.
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• Is the footing around the object solid? Slips can lead to injury. The proper lifting procedure is as following: • Bend at the knees, with your back nearly vertical and your feet shoulder-width apart. Your body should be as close to the object as possible. • Take a firm hold and straighten the knees, keeping the back straight and upright. • Pull the load close to your body and lean back slightly to keep the center of gravity over your feet. • Avoid twisting your body when lifting or carrying loads. • When handling material with other personnel, teamwork is very important. Agree on who will act as leader and give the signals. Loads should not be released until everyone is ready.
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8.4.2 Back Injury - Low Back Pain Most back injuries occur because the worker uses his or her back muscles for something the muscles cannot tolerate, he/she is not flexible enough to meet the required range of motion, he/she had to compensate for a large mid-section, or excessive use of the back muscles caused inflammation.
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To avoid back injury the employee should focus on: • Exercizing to strengthen the muscles of the back. • Obtaining training on lifting techniques and proper use of back muscles. • Using stretching exercises for hamstrings, gluts, and lower back prior to beginning work • Maintaining appropriate body weight. • Using back resting techniques and endurance training.
8.5 Exercises
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The following exercises can help you release muscle tension and reduce the risk of aches and pains:
§ Shoulder Rolls - Gently roll shoulder forward, up and drop back Do slowly and rhythmically 5 to 10 times. § Finger Stretch - Gently open and close hand, stretching fingers while hand is in the open position.
§ Trap Stretch - Sit on hand to help stabilize. Tip head down as if looking in your shirt pocket. Hold.
§ Pyramid Stretch - Start with hands in pyramid position. Keeping shoulders relaxed, raise palms together overhead. Slowly bring arms down, staying together, until you feel a good stretch on the underside of your forearms.
§ Side Bending - Lower ear toward shoulder. Repeat other side. § Shoulder Blade Pinch - Rotate arms to back, pinching shoulder blades together. Palms will naturally rotate back -- let them.
§ Hug Stretch - Grasp arm at elbow. Pull arm forward and across body as if you are hugging somebody.
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§ Chin Tuck - Keeping head level, slide chin back making a double chin. Hold two seconds and release.
§ Hand Stretch - Make gentle fist. Open hand at first joint keeping fingers bent. Open hand straightening fingers all the way. (Do stretches gently. Don't do any stretch that causes pain. Hold each stretch 15 to 20 seconds.)
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9.0
Office Safety
Many office workers may be lulled into believing that serious accidents simply do not happen in offices. Unfortunately, the office environment has potential hazards just like any other work site. That's why it's important to observe the following precautions at all times.
9.1 Computer Workstations
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To help prevent repetitive strain injuries, your workstation should be adjusted to reduce strain on your body:
§ Your chair should be easily adjusted, learn and use all available adjustments. § The monitor should be lined up with the user and the keyboard. § The keyboard should be located directly in front of the monitor and allow the wrists to maintain a neutral position. § Position the mouse directly to either side of the keyboard and at the same height.
§ Feet should be flat on the floor or on a footrest. There should be sufficient leg space, this should not be used as a storage area.
§ If there is a document holder, locate it close to the computer screen. § Your telephone should be within easy reach without twisting. If you use the telephone often, don't cradle it between your neck and shoulder. See if a headset can be adapted to your phone, or try a receiver shoulder rest. Avoid holding a handset and typing at the same time.
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§ Do not keep drinks by the keyboard area. Spills inside the keyboard can cause electrical shocks. Before applying any cleaning fluid to a computer screen, make sure the computer is off to prevent the screen from cracking and exploding.
§ If overhead lighting is uneven or insufficient, use task lighting to shed light on hard copy or highuse areas of your desk to minimize eye strain.
9.2 Floors Floor finishes should have anti-slip qualities. Eliminate tripping hazards by keeping work areas free of clutter. Repair or replace loose carpet, defective tiles or boards, plastic floor mats and warped and worn floor mats under chairs.
9.3 Aisles and Stairs Keep passages free of obstructions. Place wastebaskets, telephone and electrical cords and outlets, low tables and office equipment against walls, in corners, under desks or in some other suitable place to prevent tripping. Check stairways and exits regularly to be sure they are unobstructed and properly lighted.
9.4 Office Equipment
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Repair chairs with poor adjustment features. Equip desk and file drawers with safety stops. Make sure glass tops on desks and tables are free of cracks. Equip paper cutters with guards. Equip fans with guards of a mesh that does not exceed one-half inch. Equip rolling ladders and stands with brakes that are engaged when weight is applied.
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Use extra caution around filing cabinets. They are a major cause of office injuries. Close file drawers with the handle only. Open only one file drawer at a time. Where possible, bolt file cabinets together or otherwise secure them to prevent toppling over. Warn people in
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the area if you open a file drawer so they do not turn around or straighten up quickly and bump an open drawer.
9.5 Electrical Connections Arrange electrical devices to avoid the use of extension cords. Cover any extension cords with approved guards or tape to prevent hazards. Do not exceed outlet capacity.
9.6 Material Storage Stack boxes, paper and other heavy objects in a manner that will not create an avalanche-type spill. Store razor blades, thumb tacks and other sharp objects in boxes or with the edges otherwise covered when stored in drawers. Minimize the accumulation of trash and unused material.
9.7 Fire Protection
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Don't throw matches and cigarettes into wastebaskets. Provide ashtrays of adequate size in smoking areas. Construct waste containers of a noncombustible material.
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You are responsible for knowing the location of fire extinguishers, alarms and exits in your office building. Ask your team leader what the approved escape procedure is for your office.
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If you discover a fire:
§ turn on the alarm
§ alert fellow workers
§ if trained to do so, use proper firefighting equipment
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All offices should have written evacuation plans. Depending on the location, plans may provide for at least two gathering locations: one near the site, for evacuations of only the office building; and one about a mile from the office, in the event an evacuation of the area occurs. These plans should be posted for anyone to read, and all employees should be familiar with the details of the plan.
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10.0 Emergency Procedures Be familiar with the emergency procedures at your facility for occurrences such as fires, explosions, injuries and other major emergencies. Chevron Pipe Line Company Emergency Response and HES Procedures manuals can provide you with additional information. § Do what you can to protect your co-workers and company facilities, but do not endanger your personal safety. § Notify team leaders and local management of an emergency as soon as possible.
§ Any contact with the news media should be made by a company supervisor or public relations representative. If you must answer questions, state only known facts.
10.1 Work Site Fire Emergencies
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Before beginning a project that may increase the potential of a fire igniting, such as welding, cutting, grinding, or electrical equipment repair, check the condition and location of fire hose systems and extinguishers.
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Repair or replace defective equipment before you begin work. Fireproof the area as much as possible, by removing flammable or combustible materials from around hot-work areas.
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If a fire is started, evaluate the situation quickly before taking action. If swift action can extinguish a small fire in a safe manner, then take the appropriate steps. If the fire is already larger than you can handle safely, call for help, and then take what measures you can to protect lives and limit property damage.
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When emergency help arrives, identify yourself as an employee, and offer assistance. Even though the responsibility for attacking the fire is transferred to the fire department as they arrive on scene, you are most familiar with the facility and can aid the department in isolation and shutdown of pipeline operations.
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All fires that occur, regardless of size, must be reported to the company within 1 hour of the occurrence. Each fire must be investigated to determine the causes and corrective actions to prevent a reoccurrence. If a fire involves any portion of Chevron Pipe Line Company facilities regulated by the Department of Transportation, other reporting requirements also must be met.
10.2 Emergency Response Plans
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Each employee should respond to any emergency in accordance with the training and information provided by Chevron Pipe Line Company and the local team leader. In addition, each employee should be familiar with the following emergency response plans: § Emergency Response Plan This book has been developed to help employees and team leaders locate general response procedures and telephone numbers for most locations along the pipeline. This book includes information on notifying the home office, public affairs responsibilities, medical facilities and doctors, fire and police assistance, bomb threat plans, and so forth. The book is kept up to date by team leaders and the Emergency Response Specialists. § HAZWOPER HAZWOPER refers to the Hazardous Waste Operations and Emergency Response regulation. Under these requirements, only employees with proper training may perform work during an emergency. Emergency response specialists and Safe Practices Handbook – 2006
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your team leader can provide you with current information about these requirements, they can let you know if and where you should be trained.
§ Site-Specific Emergency Response Plans These emergency response plans provide detailed information for specific sites. They include maps showing such things as sewer outlets, good locations for placing booms in the water, maps outlining practical routes to the site, and so forth. These are used quite extensively during emergency response drills, and are revised as conditions and techniques change. Site-specific emergency response plans are kept current by the team leader and the HES group.
10.3 Emergency Drills Fire drills shall be conducted, where required, at prescribed intervals. Fire drills shall be documented. Employees shall be familiar with evacuation procedures. Employees shall be familiar with and respond to all alarms.
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11.0 First Aid and CPR First aid is the immediate, temporary care given to a victim of an accident or sudden illness until a physician arrives. First aid must be limited to treatment necessary to prevent further injury or death, to relieve pain, and to prevent or reduce shock. Most Chevron Pipe Line Company employees receive first aid and cardiopulmonary resuscitation (CPR) training. This section is not intended to replace that training, but rather to serve as a reminder for what to do in case of emergency. The company does not recommend that you apply first aid (including CPR) unless you have a current training certificate in the necessary techniques. Also, all providers of first aid should protect themselves from contact with bodily fluids of the injured person. Remember the three First Aid principles: CHECK, CALL, CARE
11.1First Aid Equipment 11.1.1 First Aid Kits
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Kits are provided at all work locations. You should know the location of the first aid kits at your work location. They should be used as needed. Report depleted supplies to your team leader. USCG-approved first aid kits are required for offshore (manned facilities).
11.1.2 Eye Wash and Safety Showers
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Where potentially injurious corrosive chemicals are used, emergency eyewash and body drench stations (stationary, mobile, portable) should be provided. Stations shall be clearly marked and readily accessible. When employees may be exposed to corrosive chemicals, employees shall locate and verify operation of eyewash and body drench stations prior to beginning work.
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11.2 Basic First Aid Steps
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The basic procedures to follow in a serious or life threatening first aid incident are:
§ Treat the most serious conditions first, such as stoppage of heart, severe bleeding, stoppage of breathing, and shock.
§ Call 911 (if the service is available in your area) or the local fire department emergency number. Try to keep the victim comfortable. While waiting for medical help, an employee shall perform only those procedures for which he/she has been trained to help prevent the victim’s condition from worsening. When there is any doubt about the victim's condition, or if a head or back injury is suspected, the victim should not be moved unless in immediate danger. Move the victim only if necessary to remove him/her from danger. § Do not give liquids to a semi-conscious or unconscious victim.
§ Remove any dentures from the mouth of an unconscious victim.
§ Unless you are wearing respiratory equipment, do not attempt to rescue a victim if poisonous or suffocating gases are suspected in the area. § Use ambulance/medivac, watercraft, or, if necessary, by available vehicle. When transporting by available vehicle, attempt to notify the emergency medical service of your route so they can meet you en route.
11.2.1 Artificial Respiration
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If a victim is not conscious and is not breathing but has a pulse, you may be able to save a life by the prompt administration of mouth-to-mouth resuscitation. Immediate action is essential, do not wait for a physician or try to transport the victim to a medical facility. Chevron Pipe Line Company
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If you administer artificial respiration, protect yourself from contact with the victim’s bodily fluids to prevent potential transmission of viruses (including Hepatitis B and HIV). Persons trained in first aid/CPR shall also be trained in avoiding exposure to bloodborne pathogens. Universal precautions shall be taken when there is the possibility of being exposed to certain types of body fluids from other people. Follow these steps to administer mouth-to-mouth resuscitation: • check the area for safety • tap the victim’s shoulder and shout to see if the victim responds • phone emergency medical service for help (dial 911 or follow local procedures) • position the victim. Look, listen and feel for breathing for about five seconds. • open the airway • look, listen and feel for breathing for about five seconds • give two full breaths • check the carotid pulse • check for severe bleeding • begin rescue breathing. Give one breath every five seconds (count ‘one one-thousand, two onethousand, three one-thousand,’ etc.). Administer approximately 12 breaths. • recheck carotid pulse • continue rescue breathing as needed • if pulse is absent, administer CPR
11.2.2 Cardiopulmonary Resuscitation (CPR)
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Kneel beside the victim and place the heel of your hand on the victim’s sternum (located about two inches above the bottom of the chest plate). Safe Practices Handbook – 2006
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§ §
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Place your other hand on top of the first, lining up the heels of your hands on top of each other. Push down firmly, but not too hard - don't depress the victim's chest more than two inches, or you may break ribs. Ease up and press down again, establishing a rhythm of 80 to 100 compressions per minute. Do 15 compressions. This pressure causes the heart to compress and force oxygenated blood to flow to the central nervous system. Alternate compressions with two breath ventilations. Repeat compression/breathing cycle three more times.
11.2.3 Bleeding 11.2.3.1 Arterial
Symptoms: Bright red blood spurting from a wound Treatment: Elevate the wound. Apply pressure directly over the wound with as clean a dressing as possible. Maintain pressure until professional assistance is available. Do not remove the dressing even if it becomes saturated; instead, cover it with additional clean dressings. In most cases, bleeding can be controlled by this method. If bleeding continues or is very severe, apply hand pressure to the pressure point located between the wound and the heart. There are four main pressure points to use: one on the inner side of each upper arm (the brachial artery) and one of the inner side of each thigh (the femoral artery). Also treat for shock (see below). A tourniquet should be used only as a last resort. Never use a tourniquet if bleeding can be controlled in any other manner, as it may lead to necessary amputation. If you must use a tourniquet, use a wide band of material, not a narrow cord. On the victim's forehead, mark a 'TK' and the time the tourniquet was applied.
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Never release the tourniquet on your own - only a qualified physician should do so. 11.2.3.2 Venous
Symptoms: Dark red blood flowing steadily from a wound. Treatment: Elevate the wound. Apply pressure directly over the wound with as clean a dressing as possible. Loosen tight clothing. Treat for shock.
11.2.4 Burns Symptoms: Reddening of the skin, and blistering or charring of tissue, bone exposure, pain. 11.2.4.1 Thermal
Treatment: For victims with first or second-degree burns, immerse the burned area in cold water as soon as possible after the injury. The temperature of the water should be comfortably cold for the victim, usually under 70 degrees Fahrenheit. (Heat from the burn will raise the water temperature. Add ice to the water as needed to keep it cool.) Do not insist on placing a burn under cold running water; the pain caused by water pressure may make matters worse and even induce shock. Next, cover any blisters with a sterile wrap. If burned surfaces are raw, cover with a loose, light, dry dressing. If an extremity is burned, elevate the limb to reduce swelling. For victims with severe second or third-degree burns, or burns over a large portion of their body, cover the victim with a clean dry sheet or blanket and transport to a medical facility immediately. If ice is available, place ice bags over the sheet or sterile dressing. Treat for shock.
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11.2.4.2 Chemical
Treatment: If burned by a chemical, flush the affected area immediately and continuously with large amounts of water for at least 15 minutes. Once the chemical is completely washed away, treat the affected area as you would a thermal burn. Chemical burns to the eye should be flushed for at least 15 minutes with a gentle stream of water from a faucet or drinking fountain. Next, cover both eyes with a sterile compress and seek medical attention immediately. 11.2.4.3 Electrical
Treatment: Before assisting any victim of an electrical emergency, first de-energize the electricity source. If the accident occurs inside, disconnect the power at a fuse box or circuit breaker. If the accident occurs outside, contact the power company to de-energize the circuit. Until the power is safely off, never touch the victim or any wire. When power is turned off and it is safe for you to touch the victim, check for responsiveness. If the victim is unconscious, check for breathing and pulse. Administer mouth-to-mouth resuscitation and/or CPR as needed. If the victim is breathing and has a heartbeat, check for burns. They often are found at the point of contact with electrical current and where that current exited the body (such as feet). Cover any burns with loose, dry, sterile dressing and bandage in place. Treat for shock.
11.2.5 Thermal Stress 11.2.5.1 Heat Stroke/Heat Prostration (Sunstroke)
Early symptoms usually include a headache, dizziness, a depressed feeling and dryness of the mouth and skin. Then the face becomes red, but with no perspiration.
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The skin is hot and dry. The pulse is strong and rapid. Breathing is heavy, even sounding like snoring. Victim may be unconscious and have a high body temperature. Move the victim to a cool place and lay the victim on his/her back. Remove the victim's clothing and place him/her in a cool bath or wrap in a wet sheet. Be careful not to induce shivering. Be prepared to reverse treatment, as heat prostration victims can lapse into shock. 11.2.5.2 Heat Exhaustion
Early symptoms usually include dizziness and nausea. Next, the face becomes pale. Skin is sweaty, moist and cool. The pulse is weak and shallow. The body temperature is low. Move the victim to a cool place and have him/her refrain from activity for 24 hours. Remove enough clothing to cool the victim, but not to induce chills. Give fluids and treat for shock. 11.2.5.3 Frostbite
It tends to occur to small, specific areas of the body exposed to prolonged cold, such as fingers, toes, nose, ears and cheeks. Symptoms include pale skin and decreased circulation. If the skin is frozen, it may feel hard and woody. Pain may or may not be present. Thaw tissue by placing it in tepid water of approximately 110 degrees Fahrenheit. Blot area dry and splint for protection (without constricting the blood flow). Refrain from using frostbitten area. Never attempt to thaw frostbitten skin by rubbing it. Little damage occurs to tissue that remains frozen. It is the action of freezing and thawing and re-freezing that causes the most problems.Therefore, do not attempt to thaw frostbitten areas if there is any possibility of them re-freezing.
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11.2.5.4 Hypothermia
It results when the body's temperature drops below 95 degrees Fahrenheit. Symptoms include emotional changes such as withdrawal, depression, confusion and unconsciousness. Physical changes include staggering, stumbling, falling, sleepiness and loss of fine motor control (e.g., being unable to zip a zipper). Prevent further heat loss by moving victim to a warm area and covering him/her with a light blanket or jacket. Re-warm the victim slowly. Give warm liquids by mouth (but never alcohol). Do not immerse the victim in hot water. Be sure to check for other injuries.
11.2.6 Shock Shock is the body's normal reaction to loss of blood or any serious injury. Shock can be fatal. It should be suspected and treated even if all the symptoms are not obvious. Symptoms: Face is pale, dull and anxious; expression is vacant. Pupils are dilated; eyes are drooped. Cold perspiration is present on forehead and palms of hands. Skin is cold and clammy. Pulse is weak and shallow. The victim may sigh, yawn or gasp, and may experience chills, nausea and/or vomiting. Treatment: Try to make the victim comfortable. Place the victim on his/her back with feet elevated. If victim is short of breath, elevate head and shoulders instead of feet. Try to maintain a normal body temperature. In cold weather, cover with a blanket or coat; in warm weather, provide shade. If victim is conscious and assistance is more than one to two hours away, give fluids in small amounts by mouth. Watch for vomiting.
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11.2.7 Fractures Symptoms: Swelling, protruding bones, pain, tenderness, and/or a loss of motion in joints adjacent to the injury. If a fracture is suspected, treat it as one. Treatment: First treat any arterial bleeding. Immobilize the limb and apply splints. A straight stick, rolled magazine or newspaper, etc., can serve as a splint if it's long enough. Use a strip of clothing, a tie, a belt, etc., to tie the splint in place. Do not affix the tie within six inches of the suspected break. To reduce swelling, elevate an injured limb after splinting, unless it causes pain to the victim. Place ice packs or cool cloths over the injury. (Do not put ice directly on the skin surface.) If you suspect a neck or back injury, do not move the victim except to remove him/her from danger. If movement is necessary, exercise extreme care! Slip a straight board under the victim and keep him/her in the same position as when the injury occurred.
11.2.8 Foreign Body in an Eye A foreign body in the eye should be removed immediately, preferably by a physician. Place a light compress over the eye to protect it until the victim receives medical attention. Do not rub the eye, which may drive the particle deeper into tissues.
11.2.9 Choking Symptoms: Respiratory distress or loss of consciousness while eating. If the victim is coughing, leave him/her alone temporarily. If the victim cannot cough or speak, has a difficult time breathing, uses distress signals or loses consciousness, render treatment. Safe Practices Handbook – 2006
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Treatment: Position yourself behind the standing or sitting victim. Place the thumb side of your fist just below the victim's rib cage, slightly above the navel. Clutch the fist with your other hand and press into the victim's abdomen with a quick, upward thrust. Repeat as many times as necessary until the object is ejected.
11.2.10 Snake and Insect Bites §
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Poisonous snakes, black widow spiders, wasps, hornets and other poisonous creatures are common in many field locations. They frequently are found in valve boxes, old buildings, piles of stored materials and similar areas. To avoid bites, wear gloves where poisonous insects are prevalent, and always check for insects before reaching toward valves. Most snake bites occur below the knee, on the hand or on the forearm. Use gauntlet gloves, high-top leather boots, and extra care when walking in brush and when moving material on the ground. If your work location has snake bite kits, be familiar with how to use them.
If you are bitten by a snake, stay calm. Notify coworkers to help you seek immediate medical attention. § If you are working alone, contact a team leader or dispatcher. Notifying them of the bite, your location, and your vehicle description. Seek medical attention from the nearest medical facility. §
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Immobilize the affected limb, keeping the bitten part below the level of the heart. Apply a constricting band between the bite and your heart, but keep it loose enough to slip a finger under. Do not cut the bite open and/or suck out the venom.
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Do not apply ice, cold packs or freon spray. As with all puncture wounds, snake bites carry a high risk of infection, whether or not venom is injected. Clean the wound carefully with soap and water.
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12.0 Fire Protection 12.1 Fire Triangle The source of fuel can be oil or other petroleum products; solid combustibles such as paper, room furnishings, or plastic; or natural gas.
The source of ignition may be
FUEL
Good housekeeping and proper storage and elimination of potential fuel sources are key points to preventing fires.
IGNITION an electrical circuit arc, hot
FIRE TRIANGLE OXYGEN
surface, welding spark, hand tool, discharge of static electricity, flashlight, or camera. Proper attention to hot work permitting and observation of electrically classified areas is key to keeping sources of ignition away from sources of fuel.
Oxygen is present all around us in the atmosphere, and may be present in some chemical substances(peroxides, for instance). Oxygen may be controlled by inerting tanks, pipelines, and vessels (or by filling them with water) before hot work is preformed, and by using carbon dioxide fire extinguishers to displace oxygen away from a fire. Fire water forms steam, which also displaces oxygen.
12.2 Fire Classes Class A: Fires occur with ordinary not limited to, wood, tires, coal, cloth, and paper. The most commonly used extinguishing agent is water, which cools and quenches. Special dry chemicals that provide a rapid knockdown of the flame and form a fireretardant coating that prevents reflash are also used. Class B: Fires occur in the vapor-air mixture over the surface of flammable and combustible liquids such as, but not limited to, greases, gasoline, hydraulic oil, diesel fuel, and lubricating oils. Materials providing a smothering or combustion-inhibiting affect, such as dry chemicals, foam, carbon dioxide, and water fog are typically used.
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ORDINARY
A COMBUSTIBLES
FLAMMABLE
B LIQUIDS
Class C: Fires occur in electrical equipment where nonconducting extinguishing agents must be used. Dry chemicals, carbon dioxide, and halons are suitable. However, carbon dioxide extinguishers are not recommended for use outdoors because of dilution by the wind. Foam and water conduct electricity and shall not be used to combat an electrical fire. Class D: Fires occur in metals only, involving combustible metals: magnesium, sodium (spills and in depth), potassium, sodium-potassium alloys, uranium and powdered aluminum.
ELECTRICAL
C EQUIPMENT
COMBUSTIBLE
D METALS
Class K: Fires involving cooking oil and grease. These fire extinguishers are usually located at the kitchen.
12.3 Fire Suppression Equipment 12.3.1 Fire Protection Equipment Fire extinguishing equipment shall be conspicuously located and readily accessible. Employees shall be aware of the location of fire extinguishing equipment. Employees who are expected to extinguish fires shall be trained in the use of available, applicable fire extinguishing equipment. Unless otherwise trained and authorized, employees shall not attempt to extinguish any fire other than incipient stage fires.
12.3.2 Inspection and Maintenance of Fixed Fire Extinguishing Systems Water spray, sprinkler, halon, CO2, dry chemical, and foam systems shall be inspected and tested as required by the manufacturer's or Chevron's instructions, Safe Practices Handbook – 2006
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whichever specifies the shortest time period between inspections. For further information, refer to CPL's HES Procedures Manual, Fire Fighting Equipment Inspection, HES-302.
12.3.3 Portable Fire Extinguishers Portable fire extinguishers are to be used for extinguishing incipient stage fires only. Incipient stage fires are fires in early stages of development that, in the judgment of the employee, can be extinguished with portable equipment.
Hand-Held Portable Fire Extinguisher Dry Chemical Cartridge Type Puncturing lever
Cap
CO2 cartridge
Carrying handle
Siphon tube
Dry chemical agent (cutaway view)
Hand-held extinguishers shall be mounted on hangers or placed in an enclosure (cabinet) at a height required by applicable regulations to protect the bottom of the extinguishers from corrosion. Extinguishers shall have the manufacturer's name plate and UL label permanently attached. Fire extinguishers shall be marked with one of the following labels, or combinations such as ABC. Because of potential environmental damage, Chevron is no longer providing new halon fire extinguishers. Existing halon extinguishers should not be recharged after use or should be taken out of service and the halon removed by a qualified vendor when they are due to have a 12-year hydrostatic test. A discharged fire extinguisher shall be replaced immediately with a fully charged unit. Inspection and maintenance of portable fire extinguishing equipment: • A monthly visual inspection and annual maintenance shall be performed. • A record of monthly inspections and annual maintenance shall be attached to each unit.
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• Extinguishers showing evidence of corrosion or physical damage shall be removed from service and replaced. • An extinguisher removed from the premises to be serviced shall be replaced immediately by a spare extinguisher. • Extinguishers shall be recharged by qualified persons after use or as indicated by an inspection.
12.3.4 Wheeled Fire Extinguishers Wheeled Extinguisher Cylinder valve
Discharge tube
Nitrogen cylinder
Operating valve Dry chemical Nozzle
Hose Gas tube
(
cutaway view)
12.3.5 Fire Water Systems
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Fire equipment shall be used for fire protection and training only. Fire hoses shall not be used as washdown equipment.
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Hose wrenches and nozzles shall be maintained and stored near the hose reels.
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Fire water pumps shall be operated at least once a week, and the operation shall be documented.
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Fire hoses, nozzles, and reels shall be examined at least once a month for proper operation and condition.
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Hoses shall be dried and returned to the proper location after being used or tested.
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Hose connections shall be kept greased and protective caps tightened only enough to protect the threads.
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Fire hydrants and monitors shall be periodically operated and inspected.
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13.0 Occupational Health 13.1Work Environment Hazards
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Some potentially dangerous operations can be detected by visual observations, however, many operations require monitoring to determine if a potential hazard is present. Air monitoring for solvent or benzene vapors, or area monitoring for noise or naturally occurring radioactive materials (NORM) levels requires instrumentation to detect and verify whether or not conditions or activities are potentially hazardous. Principle means of employee contact are: • inhalation (breathing) • ingestion (swallowing) • absorption through the skin • contact with the skin
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• a combination of the above routes The safe use of potentially dangerous substances or chemicals is the responsibility of everyone associated with the workplace. Engineering controls, work practices, protective equipment, and procedures are designed to provide for the safe use of otherwise potentially hazardous substances or chemicals. Employees shall always follow safe work procedures and use appropriate personal protective equipment (PPE). Sometimes it is feasible to reduce potential IH hazards through the application of control techniques such as modifying work practices, substituting a different material, increasing ventilation, and requiring the use of personal protective equipment (PPE) discussed in Section 3, Personal Protective Equipment.
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13.1.1 Chemical
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Gases - General Some gases encountered in company work sites may be harmful when inhaled. The following pages list general characteristics and effects of some of the more common ones. Before handling any of these substances, however, make sure you consult the appropriate MSDS for more information. Hydrogen Sulfide (H2S) Hydrogen sulfide (H2S) is a colorless, flammable and highly toxic gas. In low concentrations, it smells like rotten eggs. Do not rely on this odor, however, because your sense of smell is deadened after breathing the gas. H2S may be encountered in vessels, tanks, lines, compressors, pumps, flares and sewers. It is produced in toxic concentrations along with crude oil, water, and gas in certain producing fields. Activities in suspected areas that may lead to exposure include, but are not limited to, gauging tanks, repairing leaks, working in confined spaces, or cleaning and repairing tanks and vessels. H2S is flammable and produces toxic sulfur dioxide when burned. Exposure may cause unconsciousness and death. Remove workers exposed to H2S from the contaminated area immediately, but first protect yourself with an appropriate supplied-air breathing device. Have a third person stand by. If the exposed victim is not breathing, begin artificial respiration and call for help immediately. Where H2S is encountered or suspected initially in a field, measurements shall be made to determine concentrations and potential exposure levels. Various types of monitoring equipment are available to determine the presence of H2S. These include hand pumps with detector tubes, direct reading portable monitors, fixed monitor/alarm systems, and personal monitor/alarm systems. In addition, your local Safety
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specialist shall be notified so appropriate protective measures can be implemented. Hydrogen Sulfide Concentration (ppm)
Potential Effect
10 to 20
Eye irritation, especially in hypersensitive workers
20 to 100
Inflammation, corneal blistering and opacity of the eye, loss of the sense of smell, headache, cough, nausea
100 to 300
Respiratory difficulty, pulmonary edema, respiratory depression and irritation (within 30 minutes to 8 hours)
300 to 600
Central and peripheral nervous system effects; e.g., tremors, weakness, numbness of extremities, unconsciousness, and convulsions (within several minutes to 8 hours)
600 to 1000
Rapid unconsciousness (from one breath to several minutes) resulting in death if emergency aid is not promptly administered
1000 and greater
Instantaneous cessation of breathing and death
Note! Effects described at a specific concentration usually occur with increasing severity at higher concentrations.
Some facilities (for example, certain tank batteries), and work areas require the use of respiratory protection equipment. Employees who may be exposed to H2S shall wear respiratory protection equipment as required, including, but not limited to, gauging tanks and repairing line leaks. Suitable respiratory protection includes SCBAs and full-face airline respirators with 5minute egress bottles.
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Employees shall not work in an H2S area without first receiving training on potential hazards associated with H2S, in the use of respiratory protection, emergency response, and first aid. This training shall be done at least annually or as each individual job requires. Carbon Monoxide (CO) This gas is odorless and without warning properties. Prolonged exposure can cause death. A by-product of combustion, CO is always present in the exhaust of internal combustion engines. Be careful to prevent exposure to carbon monoxide when working in confined spaces around furnaces, kilns, or wherever flue gases or engine exhausts are not fully ventilated.
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Carbon Dioxide (CO2) Carbon dioxide is a colorless, odorless, non-flammable gas. Carbon dioxide is present in the breath we exhale and, in small concentrations, the normal air we breathe. A small increase in the air's CO2 percentage will increase the rate of breathing. In high concentrations, CO2 can paralyze the respiratory system and cause asphyxiation. Carbon dioxide is widely used in its liquid or solid (dry ice) form as a chilling agent. It also is used throughout the company to displace air in vessels or lines filled with substances that create a fire or explosion hazard when mixed with oxygen Carbon dioxide is heavier than air and will remain in vessels that are opened only at the top. If CO2 escapes into the atmosphere, it tends to gather in low spots. Inert Gas Carbon dioxide (CO2) and nitrogen (N2) are used as “inert gas,” either separately or as a mixture. If you must enter an area of inert gas, you must wear a supplied-air-breathing apparatus (SCBA). Ammonia(NH3) Ammonia is a colorless gas with a sharp, irritating odor. It is readily soluble in water. Ammonia is very irritating to the respiratory system and to the skin. Although the irritating odor usually drives people to fresh air before serious injury occurs, exposure to the vapor can cause death, often by constricting the throat or lung muscles. Use a supplied-air-breathing device when working around normal concentrations of ammonia; high concentrations also require the use of a special suit to protect the rest of your body from burns. Benzene Benzene is a colorless liquid with a sweet odor. It evaporates into the air very quickly and dissolves slightly in water. It is highly flammable and as a petroleum product, inherent in the numerous products that we transport.
Chevron Pipe Line Company
Prolonged contact with benzene and benzenecontaining compounds causes defatting of the skin. Acute exposures by inhalation cause narcotic effects, including headache, giddiness, vertigo, and confusion. Chronic exposure has been shown to cause leukemia in animals and is a suspected human carcinogen. Employees should follow safe work practices and limit skin contact with hydrocarbon materials by using appropriate personal protective equipment (PPE).
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Respiratory protection may be required for tasks having exposures to benzene-containing materials. Consult your local Safety Specialist for additional information. Chlorine (Cl2) Chlorine is a clear amber liquid that rapidly evaporates to a greenish yellow gas when exposed to the atmosphere. Its action is primarily one of irritation to the skin, mucous membranes, and respiratory system. It has an irritating, choking odor. Avoid all contact with the liquid or the vapor. Wear impervious protective clothing, gloves and a supplied-air-breathing device if there's a chance of being exposed to this chemical. Wear eye protection, too. Excessive concentrations of chlorine may cause injury to the eyes. If chlorine is inhaled, limit physical activity until you've received medical attention. Petroleum Gases All hydrocarbon vapors are flammable and may form explosive mixtures with air. Light paraffinic hydrocarbons - such as propane, butane, etc. - are intoxicating in light concentrations, and may cause suffocation in heavy concentrations. Aromatic hydrocarbons - such as benzene, cumene, toluene, xylene, etc. - are toxic. Avoid breathing any hydrocarbon vapors.
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Other Potential Exposures NORM (Naturally Occurring Radioactive Materials) Naturally Occurring Radioactive Materials (NORM) are natural materials which spontaneously emit ionizing radiation. NORM may be found in the scale that forms on equipment such as separators, pumps, heater treaters, filter housings, pipes, tubing and tanks. In oil and gas production operations, NORM may be generally considered to be confined to radium 226 and radium 228 and selected members of these isotopes' progeny. Potential exposures to NORM occur when dismantling and repairing oil production equipment that has been in service for extended periods of time. For more information, please contact your local Safety Specialist. Lead Lead is a metallic element that may exist in an organic or inorganic form. It is widely used in its inorganic form in paints, babbit metal, and soldering materials. Employee exposure to lead comes from working with lead coated painted surfaces and during burning, welding or surface grinding to remove coatings. Sand blasting and manual demolition of structures also present exposure concerns. Employees involved in maintenance, construction, repair, renovation, demolition, and disposal of leadcoated materials should be aware and trained in the hazards associated with lead.
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A competent person shall be assigned to oversee activities involving lead. Mercury Mercury is a heavy, silver-white, highly toxic metallic element. It is normally a liquid at room temperature.
Chevron Pipe Line Company
Mercury can be found in all types of equipment and instrumentation including: • flow controllers • gravitometers having mercury compensators • instrument maintenance • laboratories • measurement shops • mercury-filled manometers • mercury-type orifice meters • thermometers • warehouses where mercury and mercury instruments were stored Metallic mercury is toxic to the human body even in very small amounts. It may be absorbed by ingestion, through the skin, and most commonly by the inhalation of mercury vapor. Skin contact with mercury shall be avoided. Inhalation of mercury vapors shall be avoided. Food or drink shall not be kept or consumed in an area where mercury is handled. After handling mercury, employees shall wash their hands thoroughly before eating or smoking, and at the end of each job or tour. Smoking is prohibited while handling mercury. Impervious gloves shall be used when handling mercury. Contaminated clothing shall be immediately removed and properly disposed of. Mercury shall be stored in air-tight containers. Contaminated rags, paper, gloves, etc. shall be disposed of properly. They shall not be discarded in, or be collected and stored inside of, a work room or the passenger area of boats and vehicles. Mercury, mercury-containing instruments, tools, and other items that may have come in contact with
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mercury shall not be transported in the same compartment as passengers or the operator of a vehicle or boat. The workplace where mercury is used shall be well ventilated. Work involving mercury shall always be positioned between the worker and an exhaust ventilation system. Floors, counters, and other surfaces shall be kept free of dust and grease. Mercury spills shall be reported immediately to your team leader. Mercury shall not be allowed to come into contact with ammonia or its vapors. The mixture forms a compound that is shock sensitive and can cause fires if it contacts combustible materials.
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Mercury shall not be allowed to come into contact with aluminum equipment because mercury dissolves aluminum. Acids and Caustics Acids and caustics are usually handled in a liquid form. Both cause corrosive burns upon contact with the skin. Inhalation of acid mist or vapor may cause pneumonia-like symptoms, including coughing, congestion, etc. Avoid skin contact with all acids and caustics. At a minimum, splash goggles and gloves should be worn when handling these products. PCBs (Polychlorinated Biphenyls) PCBs are toxic to humans by all routes of exposure (that is, inhalation, skin absorption, and ingestion). PCBs can cause skin disorders and irritation to the eyes, ears, nose, and throat. In addition, adverse reproductive and carcinogenic effects may occur.
Chevron Pipe Line Company
Some transformers and capacitors may contain electrical fluids or oil contaminated with PCBs. Contact your local Safety Specialist for the guidelines to be followed for proper handling and disposal. A warning label shall be applied in a readily visible location on PCB containing equipment. In the event of a PCB spill, personal protective equipment (PPE) shall be worn to control skin contact. Records of the equipment containing PCBs shall be maintained. Contact your local HES representative for further information.
13.1.2 Physical Some physical agents, such as noise and heat, may be detected by the senses; others, such as radiation, cannot be detected. Excessive heat can be dangerous. If you must work in such an environment, dress appropriately and drink plenty of fluids.
13.1.3 Dusts
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Dusts are small particles of solid matter that have been dispersed into the air. They can enter the body via the respiratory system. Some dusts have a rapid effect on the body, others, such as asbestos and silica, may not result in damaging effects until years later. Protect yourself against these agents by using proper protective equipment. Asbestos Asbestos is a fibrous mineral that has excellent thermal insulating properties. In the past, it was widely used as an insulation and building material. However, it has been found that asbestos can cause several serious health effects. Asbestos substitutes are now required for new construction.
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Employees should be aware that asbestos may still exist in Chevron facilities. The practice is to remove deteriorated (friable) asbestos insulation that presents a potential exposure hazard to personnel. Additionally, asbestos insulation that is removed to perform maintenance functions shall be replaced with substitute insulation materials. Employees involved in maintenance, construction, repair, renovation, demolition, salvage, or disposal activities, or otherwise handling asbestos-containing materials, shall be trained in proper removal techniques and instructions consistent with their activities. Where asbestos is used in such items as gaskets, packing glands, and pipe coatings, strict care and precautions shall be taken to prevent the generation of airborne fibers that occur through cutting, tearing, grinding, or otherwise handling the materials in a way that changes the integrity of the material.
13.2 Monitoring Exposures Employees may be asked to participate in industrial hygiene monitoring to verify their work activity is free from recognized health related hazards. Either employees or their work area may be monitored. Employees who are monitored are generally asked to wear a small instrument while they either perform a task or work an entire shift. In either case, Chevron Pipe Line notifies the employee of the personal exposure results, including an interpretation of the results and what further action, if any, may be required. Employees who are selected to participate in monitoring shall assist by: • reporting unusual events, i.e., spills • reporting malfunction of the monitoring device
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• not tampering with the monitoring device by shutting off or directly exposing the instrument to contaminants. Hazards which are routinely monitored include: noise, benzene, total hydrocarbons, and hydrogen sulfide.
13.3 Bloodborne Pathogens Persons trained in first aid/CPR shall also be trained in avoiding exposure to bloodborne pathogens. Universal precautions shall be taken when there is the possibility of being exposed to certain types of body fluids from other people. First aid kits/body fluid barrier packs are available for those providing first aid. These packs include, but are not limited to, CPR mouth barriers, disposable latex gloves, and face and eye protection. Chevron shall provide proper means of disposal for materials that are considered regulated medical wastes (biohazards). Bags or containers marked with the biohazard symbol shall be handled by designated employees only.
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BIOHAZARD Employees who have occupational exposure to bloodborne pathogens shall be offered Hepatitis B vaccinations. Please contact your Safety Specialist if you think you may have had an occupational exposure to bloodborne pathogens.
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14.0 Environment Personnel shall: • Exercise all necessary care to protect and preserve the environment, including flora, fauna and other natural resources or assets at any location where work is performed.
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Minimize and mitigate unavoidable impacts to the local environment.
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Protect fossils and antiquities found at job sites from damage or disturbance.
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Report the location to your team leader and cease work at that location pending further instructions.
14.1Waste Management 14.1.1 Hazardous In general terms, hazardous wastes are materials that exhibit qualities that are potentially harmful to humans and/or the environment, and that are the remainder or by-products of production operations. They include materials and mixtures of materials that are toxic, corrosive, flammable, explosive, and carcinogenic. Some materials require special training to handle, package and ship. Oily rags and other contaminated materials, which may not specifically be classified as hazardous waste may require special handling. Specific regulations and procedures also must be followed when handling and disposing of wastes. Failure to do so can result in criminal penalties. For more information on the handling, recycling or disposals of hazardous materials or wastes contact your team leader or your waste specialist.
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14.2 Regulations 14.2.1 Clean Air Act This act regulates: • emissions of pollutants into the atmosphere, including hydrocarbon vapors • emissions by treatment technology, unless air quality requires stricter limits
14.2.2 Clean Water Act This act regulates: • discharge of wastewater to receiving waters and publicly owned treatment works • discharges by treatment technology, unless water quality requires stricter limits
14.2.3 Resource Conservation and Recovery Act (RCRA) This act regulates: • generation, manifesting, transportation, storage, treatment and disposal of hazardous solid wastes • storage of fuels in underground tanks
14.2.4 Comprehensive Environmental Response, Compensation and Liability Act (CERCLA) This act regulates: • cleanup of leaking landfills • reporting spills of certain chemicals • responsibility and liability for contaminated disposal cleanup
14.2.5 Superfund Amendment and Reauthorization Act (SARA Title III) This act regulates: • emergency response plans
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• right-to-know issues • chemical release reporting
14.2.6 Occupational Safety and Health Act (OSHA) This act regulates: • employee right-to-know • responsibility for keeping work area free of recognized hazards • specific procedures for job and industry safety
14.2.7 Toxic Substances Control Act (TSCA) This act regulates: • commercial use of most chemicals • use and disposal of asbestos, PCBs, and CFCs • reporting of all adverse health effects • use, labeling, and documentation for chemicals that pose a risk to health or the environment The Toxic Substances Control Act (TSCA) requires prompt reporting of any information reasonably supporting the conclusion that a chemical substance presents a substantial risk to human health or the environment. The law requires you to report any incident that you believe fits the description of possibly causing significant damage to human health or the environment. Information that should be reported to the company includes the following: • an illness or death associated with the use of company products or related to chemicals used at a work location • a pattern of illness occurring among employees or customers
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• results of laboratory experiments and tests which indicate potential adverse health or environmental effects may occur • spills or widespread contamination of chemicals not covered by other reporting regulations
14.2.8 Hazardous Materials Transportation Act This act regulates: • hazardous materials transported in commerce • activities associated with identifying and classifying hazardous material; marking, labeling, placarding and packaging the material, and documentation of the material • loading, unloading and incidental storage of hazardous material • reporting of unintentional releases; injury or death to a person; and property damage exceeding $50,000.
14.2.9 Safe Drinking Water Act This act regulates: • enforceable quality procedures for drinking water
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Appendix A. Glossary Loss Prevention System Loss Prevention is a system to prevent or reduce losses using behavior-based tools and proven management techniques.
Self-Performance Self-Assessments (SPSA) All employees will perform Safe Performance SelfAssessments at the beginning of the shift, before changing tasks or doing new activities for the first time, for nonroutine activities, and immediately following a near loss or loss. Assess the risk! Analyze how to reduce the risk! Act to ensure safe operations! Look over each new assignment to determine any possible hazards and determine what protective equipment/safety precautions may be needed
Loss Investigations (LI) All losses, including first aid cases, injuries, releases, equipment and property damage, motor vehicle accidents, regulatory violations, product quality losses, fires, business interruptions, and near losses, will be reported and investigated to determine the root cause. In addition, solutions will be developed to prevent recurrence.
Job Safety Analysis (JSA) A Job Safety Analysis (JSA) should be conducted for every major work process. Collectively, JSAs help ensure that procedures exist to design, construct, maintain, and operate facilities and equipment safely. The objective of a job safety analysis is to identify potential job hazards that could lead to a loss and develop procedures to eliminate or minimize those hazards.
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Loss Prevention Observations (LPOs) Loss Prevention Observations will be conducted on a recurring basis. In a planned fashion, all employees will do observations randomly throughout the shift, across all shifts, and in all operational areas. For more information review “Loss Prevention System Handbook.”
Pre-Startup Review Equipment shall be constructed, installed, and operated in accordance with company procedures and applicable local, state and federal codes and regulations. Ensure new and existing facilities are safe and ready for operations prior to startup after design changes, facility construction, or recommissioning of a facility are completed. Disciplinary action, including discharge, will be taken for disregard or violation of safety instructions/safe practices.
Job Site Safety Plan (JSSP) Job Site Safety Plan addresses safety and health hazards, including requirements for employee protection. A JSSP is required whenever there is a need for Emergency Response clean-up operations. This plan applies to all personnel, company and contractor, working in or on Chevron Pipe Line Company owned or operated facilities. The plan must remain on site and is maintained by the company inspector or project manager.
ASAP As soon as possible
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B. References Chevron’s Policy 530 – HES http://governance.chevrontexaco.com/policies/hes/530_hes.htm Operational Excellence (OE) Management System http://cpln-www1.ct/corphes/oehome.nsf Contractor Safety Management (CSM) http://cpl.chevron.com/cms/index.htm CPL Tenets Principles http://cpl.chevron.com/operationalexcellence/index.htm CPL HES Procedures http://www-CPL.chevrontexaco.net/manuals/cplhesgp/index.htm Occupational Safety and Health Administration http://www.osha.gov/ National Institute for Occupational Safety and Health http://www.cdc.gov/niosh/ American Conference of Governmental Industrial Hygienists http://www.acgih.org/
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C. Safe Work Checklist SAFE WORK PERMIT - HES 204 PROFIT CENTER: FIELD TEAM: REVIEWER:
DATE: FACILITY:
QUESTION
YES NO
COMMENTS
1 Is the permit posted? 2 Are all affected persons aware of the work? 3 Does the permit adequately describe what work is permitted? 4 Does the permit adequately show the hazards of work permitted? 5 Is the identified PPE adequate to protect against the hazards? 6 Are gas testing results recorded,if required? The work area may have any one of the following: Oxygen deficient or enriched atmosphere Flammable gas or vapor Toxic vapors, Carbon monoxide, Benzene, and Carbon dioxide 7 Have permit extensions been granted? Initialed and dated? 8 Are all the required signatures on the permit? Dates and times? 9 Is the work you observed adequately covered by the permit? 10 Are the permitted restrictions and conditions being followed?
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D. Excavations Checklist
EXCAVATIONS - HES 202 PROFIT CENTER: FIELD TEAM: REVIEWER:
QUESTION 11 Has the Permit been posted? 12 Has the competent person daily excavation inspection form been completed? 13 Approved signatures on the Permit and inspection form? 14 Competent person on site? 15 Attendant (standby) person on site? 16 Are Permit restrictions being followed? 17 Are authorized entrants listed on Permit? 18 Are protective systems adequate? 19 Excavation in excess of 20 feet in depth (If so, shall be designed by a registered professional designer)? 20 Has the regional one call been properly notified prior to excavation activity? Ticket number? 21 Are there additional hazards identified, that are not posted on the Permit?
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DATE: FACILITY:
YES NO
COMMENTS
E. Confined Space Checklist
CONFINED SPACE ENTRY - HES 201 PROFIT CENTER: FIELD TEAM: REVIEWER:
DATE: FACILITY:
QUESTION
YES NO
COMMENTS
22 Has the Permit been posted? 23 Are Permit Restrictions being followed? 24 Has periodic testing been performed? 25 Are signs posted (”DangerPermit Required Confined Space, Do Not Enter”)if Permit required confined space? 26 Are approved signatures on the Permit? 27 Has the evaluation been completed? 28 Attendance posted near the entry, if Permit required confined space? 29 Emergency action plan complete, if Permit required confined space? 30 Are authorized entrants listed on Permit? 31 Are there additional hazards identified, that are not posted on the Permit?
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F. LOTO Checklist
LOCKOUT/TAGOUT - HES 203 PROFIT CENTER: FIELD TEAM: REVIEWER:
QUESTION 32 Approved equipment specific procedure available? 33 Has a deviation been requested if applicable? 34 All affected employees notified? 35 Authorized employee conducting lockout/tagout process? 36 Equipment prepared for shutdown? 37 Equipment properly shutdown? 38 Was equipment isolated (operate, can not start)? 39 Lockout/tagout devices applied? 40 Sketch of equipment or system being isolated available? 41 Are there additional energy sources hazards identified that are not noted on the procedure?
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DATE: FACILITY:
YES NO
COMMENTS
G. Hot Work Permit
HOT WORK PERMIT - HES 205 PROFIT CENTER: FIELD TEAM: REVIEWER:
DATE: FACILITY:
QUESTION
YES NO
COMMENTS
42 Is the Hot Work Permit posted? 43 Is a Safe Work Permit completed and posted? (Pre-requisite) 44 Is the Permit marked for Open Flame or Non-Open Flame? 45 Are the Authorized activities specified? 46 Have the Initial Atmospheric monitoring results been documented and signed by a qualified Gas tester on the Hot Work Permit? 47 Has the frequency of testing been specified? (Results for subsequent testing should be on Safe Work Permit). 48 Are authorized entrants listed on Permit? 49 Are the Permit restrictions being followed? 50 Is required fire suppression and safety equipment on site and readily available? 51 If a Fire Watch is required, have the persons been identified on the Permit? 52 If required, has the Fire Watch’s training been verified? 53 Are all the required signatures on the Permit? Dates and times? 54 Have Permit extensions been granted? Initialed and dated? 55 Does the Hot Work Permit specify the type of hot work to be performed and limit the location of this hot work?
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Pipe Line Company P. O. Box 430 Bellaire, TX 77402-0430
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