KOC F&S

Kuwait Oil Company (K.S.C.)

Fire & Safety Regulations

Table of Contents

S.No

CHAPTER

Page No. 4

1

Classification of Petroleum Hazards

2

Pressure Testing of Equipment, Systems & Pipelines

8

3

Fire Prevention & Loss Control

15

4

Industrial Accident, Protective Equipment, Medical, Health & Hygiene

21

5

Operational Safety for Export & Marine Facilities

33

6

54

10

Operational Areas Handling, Storage of Materials, Hazardous Chemicals, Explosives & Radio Active Substances Documentary Control of Hazardous Work & Work Permits Compressed Air Equipment, Breathing Apparatus, Grit Blasting & High Pressure Water Jetting Boilers, Pumps and Electrical Safety

129

11

Crude Oil Storage Tank, Pipelines & Oil Spill

135

12

Laboratory Safety

159

13

Building & Construction-Scaffolding, Painting, Asbestos

164

14

General Emergency Procedure

173

15

Power and Hand Tools

188

16

Welding

194

17

Lifting Equipment

204

18

Excavations

209

19

Code of Inspection for Plant and Equipment

215

20

Security & Installation Access Control

220

21

Oil Well Drilling, Workover, Exploration & Well Surveillances

225

22

Vehicles & Traffic Safety

241

7 8 9

F&S Regulations

68 97 120

June 2004 Page 1

Kuwait Oil Company (K.S.C.)

Fire & Safety Regulations

Table of Contents

1

Chemical Hazards & Material Safety Datasheets(MSDS)

Page No. 253

2

Standard Exposure Limits

255

3

Drilling & Work Over

257

4

Standard Industrial Safety Signs-(Cylinders Colour Identification Code)

258

5

Fire Fighting Equipment

263

6

Vessel/Tank/Confined Space Entry Procedure

268

7

Characteristics of Crude Oil Tank Fire

274

8

Specimen Forms

276

9

Safety Factors for Product Transfer Pumps

295

10

Electrical Work Safety

298

11

Radiation Protection

303

12

Kuwait Oil Company (K.S.C) Mina Al-Ahmadi Terminal

307

13

Noise Control

321

14

Hydrogen Sulphide

324

15

Safe Guarding of Machine

328

16

Industrial Safety Terminology

331

17

Guidelines for the use of Tools with Explosive Materials

334

S.NO

APPENDIX

F&S Regulations

June 2004 Page 1

Kuwait Oil Company

Fire & Safety Regulations

(K.S.C.)

CLASSIFICATION OF PETROLEUM HAZARDS

Chapter No. 1 June 2004

CHAPTER - 1 CLASSIFICATION OF PETROLEUM HAZARDS (TABLE OF CONTENTS)

Subject

S.No. 1.1

1.2

Page No.

CLASSIFICATION OF CRUDE OIL & ITS DERIVATIVES

2

A.

General Classification

2

B.

Classification For High Ambient Temperatures..& Heated Products2

...........................................

AREA CLASSIFICATION .....................................................

3

A.

Restricted Area.....................................................

3

B.

Hazardous Area....................................................

3

C.

Unclassified Area ..............................................

3

D.

Work Permit Areas................................................

4

E.

Approved Safe Areas..............................................

4

F

Open Areas..........................................................

4

F&S Regulations Chapter 1

June 2004 Page 1

KOC F&S Regulations

CLASSIFICATION OF PETROLEUM HAZARDS CHAPTER - 1

CLASSIFICATIONS OF PETROLEUM HAZARDS 1.1

CLASSIFICATION OF CRUDE OIL & ITS DERIVATIVES: A.

GENERAL CLASSIFICATION: Crude oil and its derivatives, by their nature, are considered as potentially hazardous materials. The degree of hazard is essentially characterized by its volatility and flash point. The hazardous materials are classified according to their “Closed Cup Flash Point” indicated hereunder: Flammable Liquid (Low Flash Stock)

Class I

Any liquid which has Flash Point below 37.8 °C (100 °F)

Combustible Liquid

Class II

Liquid having Flash Point at or above 37.8 °C (100 °F) but below 60 °C (140 °F)

Class III (A)

Liquids having Flash Points at or above 60 °C (140 °F) but below 93 °C (200 °F)

Class III (B)

Liquids having Flash Points at or above 93 °C (200 °F)

(Intermediate Flash Stock)

Flammable Highly Volatile Liquid

B.

CLASSIFICATION FOR HEATED PRODUCTS:

-

HIGH

Highly volatile liquids include Butane, Propane, Ethane & Ethylene, LPG, NGL and mixture of such. AMBIENT

TEMPERATURE

&

In case of high ambient temperature as during summer in Kuwait, or when the handling temperature of petroleum products rises above 37.8 °C and in circumstances where products are artificially heated, then Combustible Liquids categorized under Class II, III (A) & III (B) should be treated as Class - I Flammable Liquids.

F&S Regulations Chapter 1

June 2004 Page 2

KOC F&S Regulations 1.2

CLASSIFICATION OF PETROLEUM HAZARDS

AREA CLASSIFICATION: In industrial terms areas are classified as "RESTRICTED”,"HAZARDOUS" and "UNCLASSIFIED". A.

RESTRICTED AREA: A “Restricted Area” is that area, in which KOC exercises a control over all movements, operations & maintenance activities i.e. the areas within the fenced boundaries or open space where KOC has direct or indirect control for operational reasons. Entry to a Restricted Area is allowed only by an Access Control Pass, which is to be shown at the Security Check Point. There are also Controlled Areas within restricted area where entrance is obtained by application at the point of entry, even though the applicant may hold an Access Pass.

B.

HAZARDOUS AREA: A “Hazardous Area” is the zone in which a flammable atmosphere may be present during normal operation or under abnormal conditions. HAZARDOUS AREAS in the petroleum industry are classified according to the likelihood of a flammable atmosphere being present. A flammable atmosphere has a concentration of flammable gas, vapour, or mist, which is capable of being ignited.

C.

ZONE - 0

-

A zone in which a flammable atmosphere is present continuously or for long periods (Typically more than 1000 hours/year.)

ZONE - 1

-

A zone in which a flammable atmosphere is likely to occur in normal operations. (Typically 10 to 1000 hours/year)

ZONE - 2

-

A zone in which a flammable atmosphere is likely to occur only under abnormal operating conditions. (Typically less than 10 hours/year)

UNCLASSIFIED AREA: An Unclassified Area is the area, which not classified as Zone - 0, Zone-1 or Zone-2.

F&S Regulations Chapter 1

June 2004 Page 3

KOC F&S Regulations

CLASSIFICATION OF PETROLEUM HAZARDS “Unclassified Area” may not necessarily be considered as ‘Safe’. A good engineering judgement should be exercised to assess the hazard prior to using any standard electrical apparatus, conventional machines and industrial equipment.

D.

WORK PERMIT AREAS: It is a normal practice to consider a RESTRICTED AREA as a HAZARDOUS AREA for the purpose of access as well as where - using any form of ignition source, carrying out any operational & maintenance activity that has potentiality to generate spark / heat / fire / explosion or doing any excavation work and vessel entry activity – is strictly prohibited without proper authorization through WORK PERMIT.

E.

APPROVED SAFE AREA: Certain area within a RESTRICTED AREA may be designated as an approved safe area, such as approved smoking room, areas designated for pre-fabrication work, parking lot and certain work shops, etc. However such areas are to be clearly marked and regulatory instructions governing their use to be strictly adhered to.

F.

OPEN AREAS: An Area within a RESTRICTED AREA may be declared as an “OPEN AREA” where maintenance or construction work is allowed without raising Work Permits except in case of Vessel Entry, Excavation Activity, Electrical Work and Hot Work. The limits of such Open Areas must be clearly defined on the ground by fencing, barriers etc. with suitable control over operational & maintenance activities.

NB: (a) For further details on Hazardous Area Classification refer to KOC Standard KOC-G-002. (b) For Toxic / H2S Hazard: refer to Appendix – 14 of F & S Regulations (c) For Radioactive Hazard: refer to Appendix - 11 of F & S Regulations. (d) For Electrical Hazards: refer to Appendix – 10 of F & S Regulations

F&S Regulations Chapter 1

June 2004 Page 4

Fire & Safety Regulations

Kuwait Oil Company

(K.S.C.)

Chapter No. 2 June 2004

PRESSURE TESTING OF EQUIPMENT, SYSTEMS & PIPELINES CHAPTER - 2

PRESSURE TESTING OF EQUIPMENT, SYSTEMS & PIPELINES (TABLE OF CONTENT) Page No.

S.No.

Subject

2.1

INTRODUCTION & GENERAL PHILOSOPHY .............

2

2.2

PNEUMATIC TESTING ............................................

3

2.3

GENERAL TEST PROCEDURE ………………………..

4

2.4

TEST FLUID ..........................................................

4

2.5

HIGH PRESSURE OR VACUUM ................................

5

2.6

CONDITION OF EQUIPMENT ...................................

5

2.7

PROPERTIES OF MATERIAL OF CONSTRUCTION...

5

2.8

EQUIPMENT VOLUME ............................................

5

2.9

TECHNICAL PROCEDURE .......................................

5

2.10

COMPETENT SUPERVISION .....................................

7

F&S Regulations Chapter 2

June 2004 Page 1

KOC F&S Regulations

PRESSURE TESTING OF EQUIPMENT, SYSTEMS & PIPELINES CHAPTER - 2

PRESSURE TESTING OF EQUIPMENT, SYSTEMS & PIPELINES 2.1

INTRODUCTION & GENERAL PHILOSOPHY: 2.1.1

Pressure testing of equipment, system and pipelines is carried out to prove the strength of equipment designed to contain pressure or a fluid head or both. It may also be employed to check equipment / piping for leaks or conditioning favorable stresses.

2.1.2

Pressure may be applied hydrostatically, pneumatically or in combination.

2.1.3 The adequacy of testing procedure is generally outlined with the following considerations: • Basing the test pressure on the weakest member. • Observing allowable stress in relation to: a) Minimum Metal Design Temperature; b) Joint Efficiency; c) Area Classification (Design Factor); d) Minimum specified yield strength value. • Selection & treatment of testing medium. • Temperature of the test medium & the ambient temperature. • Installation of adequate pressure / vacuum relieving devices. • Proper support of the equipment / system under test. • Accuracy of pressure gauges and its proper calibration. • Installing pressure gauges at the lowest location to account for fluid head and monitoring during the test period. • Installing pressure gauge at the highest location to meet the proof test pressure. • Proper sizing of blinds & spades in accordance with ASME Sect. VIII, Div. 1, UG-34. • Proper venting • Correct pressure increase during test schedule. • Mechanical Clearance of all works. • Competent supervision. • Pressure testing of relevant segment rather than entire system. 2.1.4 Inadequate testing procedures may result in damage to equipment, personal injury, loss of life or property in addition to time & cost impact. These losses may not necessarily be confined to the actual equipment under test and to the personnel directly involved in the test. The following considerations towards pressure test failure must be kept in view: (a)

The magnitude of loss during pressure test is generally a function of energy stored in the equipment under test alongwith secondary affects on failure of equipments in hazardous service.

(b)

The stored energy due to pressurized fluid may be considered as proportional to the pressure and / or head in addition to the fluid volume under test.

F&S Regulations Chapter 2

June 2004 Page 2

PRESSURE TESTING OF EQUIPMENT, SYSTEMS & PIPELINES

KOC F&S Regulations (c)

For the same pressure & volume, the energy stored in equipment under pneumatic pressure will be much higher (>200 times) than hydrostatic pressure. The pneumatic pressure test must have approval from Team Leader - Inspection & Corrosion.

2.1.5

The likelihood of a test failure is dependent on stress levels and on the presence of any local defect or weakness. Whilst stress levels can be readily determined however it will be difficult to rule out the presence of weakness or defects in the system

2.1.6

It is mandatory to ensure proper material handling and following considerations to be met: (a) (b) (c)

(d) (e)

The material shall be procured from Company’s approved manufacturer’s list. Full technical detail in conformation to material specification shall be made available. The company can send its representative to witness all or part of inspection & testing activity during manufacturing or assembly phase, as deemed essential to ensure the equipment integrity and functional reliability. The fabrication work shall commence only after quality assurance of material and workmanship. The following documents are to be submitted prior to commencing any pressure test: • Material Test Certificate including material identification • The inspection report witnessed by company representative during manufacturing & assembly. • All NDT (Non – destructive Test) reports

2.2 PNEUMATIC TESTING: 2.2.1

Pneumatic testing shall be considered only under following circumstances and with prior approval from Team Leader – Inspection & Corrosion: a) Where strength has been satisfactorily proven by a prior hydrostatic test and it is necessary to pressure test the same by pneumatic pressure. b) Where the equipment cannot be safely filled with liquid. c) Where trace liquids cannot be tolerated & their complete removal is considered impractical.

2.2.2

The test area shall be clear from any obstructions and cordoned off to prevent any unauthorized intrusion.

2.2.3

The cooling affect due to temperature reduction while depressurizing the system shall be taken into account addressing the risk of brittle fracture.

2.2.4 The pressurization procedure as listed hereunder shall be taken into consideration: • The equipment shall be gradually pressurized up to 50% of test pressure and allowed to stabilize. F&S Regulations Chapter 2

June 2004 Page 3

PRESSURE TESTING OF EQUIPMENT, SYSTEMS & PIPELINES

KOC F&S Regulations • •

Thereafter the pressure shall be increased in stages @ 1/10th of test pressure each time alongwith stabilizing period in between. The test pressure shall be constantly monitored and controlled safely.

2.3 GENERAL TEST PROCEDURE: The following precautions shall be kept in view during general test procedure: 2.3.1

The pressure testing shall not be carried out with valves closed for the system.

2.3.2

A Dead Weight Tester shall be utilized to cross check the pressure gauge reading.

2.3.3

The test pressure shall be monitored with a minimum of one gauge at the pressurizing source and one each at extreme end, the highest & lowest point of the equipment / system under test.

2.3.4

The pressure-relieving device (PRV) [installed on the equipment / system under test] shall be set at the maximum allowed test pressure.

2.3.5

All pumps / compressors to be utilized for pressure testing shall be of suitable pressure & capacity ratings.

2.3.6

The pressure gauges shall have rating & range more than 1.5 to 2.0 times the test pressure.

2.3.7

The Halides content of the testing medium shall not be more than 25ppm for the testing of Stainless Steel equipment / system.

2.3.8

The test procedure and the package shall be approved by the company prior to commencing any pressure test.

2.3.9 Once the test pressure is attained and stabilized, all pumping connection and accessories shall be disconnected after safe depressurizing. 2.4 TEST FLUID: 2.4.1 Consideration should be given to the possibility that supports may not have been designed for the weight of test liquid. 2.4.2 Flammable gas should never be used for pressure or leak testing purposes. 2.4.3

The use of flammable liquids should be avoided if possible. The flash points should exceed by an ample margin of the maximum surface temperature of the equipment under test and in any case must be not less than 50° C. The boiling point must be well in excess of test temperature.

2.4.4

Consideration should be given to corrosive and other potentially detrimental effects on materials of construction. Whilst not affecting safety during the test, the safety of future operations may be compromised by a leak or failure caused by using an unsuitable test medium.

2.4.5

When testing to high pressures pneumatically, an inert gas must be used if there is any possibility of a flammable material being present. This is to avoid the possibility of internal compression-ignition.

F&S Regulations Chapter 2

June 2004 Page 4

KOC F&S Regulations 2.5

PRESSURE TESTING OF EQUIPMENT, SYSTEMS & PIPELINES

HIGH PRESSURE OR VACUUM: Whenever the pressurizing source has the capability of applying a pressure higher than the code test pressure, consideration should be given to the provision of a pressure-relieving device. When this situation arises in hydrostatic testing, the need for a relief device should be assessed on the basis of the degree of pressure control attainable and the value of the equipment under test. A relief valve should always be used when this situation arises with pneumatic testing because of the greater potential hazard. A pressure-reducing valve may also be desirable for pneumatic testing but this would not obviate the need for a suitably sized relief device. It is absolutely imperative that tank vents are open and clear when emptying after test to avoid creation of a vacuum. It is also imperative that competent personnel are in attendance whilst tank vents are closed during a test since these would need to be opened in the event of a loss of liquid for any reason.

2.6

CONDITION OF EQUIPMENT: Condition of equipment should be assessed by referring to previous maintenance or status record as well as through physical inspection at site. However when applying high pressure pneumatic testing, a thorough inspection should be performed immediately prior to the test and supplementary non-destructive testing will often be advisable. The need for temporary restrain of bellows or other expansion joints and spring supports should be assessed. Whenever possible, manufacturers’ recommendations should be consulted.

2.7

PROPERTIES OF MATERIALS OF CONSTRUCTION: The primary considerations are that materials should not be subject to excessive stresses and they should not be highly stressed at temperatures approaching those at which brittle fracture may occur. Reference should be made to design and construction data. The possibility that the equipment may have been modified or that components may have been replaced by inferior materials should also be considered. The possibility of brittle fracture during testing should be considered. Although the potential for this type of failure is low in Kuwait’s climate, thick walled vessels may still be vulnerable and materials of construction of older equipment may have inherently poor toughness. Heated test water may be desirable in isolated cases in winter.

2.8

EQUIPMENT VOLUME: Test termination blinds should be located as close as practical to the equipment under test in order to minimize the test volume.

2.9

TECHNICAL PROCEDURES: Testing against closed valves should only be carried out when unavoidable, e.g. against butt-welded or socket welded valves and wafer type butterfly valves. In any case, this technique may only be utilized for piping and not for equipment items. The seat rating of the valve must not be exceeded. The un-pressurized side of the valve should be vented.

F&S Regulations Chapter 2

June 2004 Page 5

KOC F&S Regulations

PRESSURE TESTING OF EQUIPMENT, SYSTEMS & PIPELINES

It should be ascertained that test fittings such as spades, blinds, hoses etc. are adequate for the test pressure and that a full complement of bolts of the correct grade is provided for all pressure flanges. Fittings, which are not stamped with a pressure rating, should be treated with suspicion. Before pneumatic testing or pipeline testing, hoses and screwed fittings should as a minimum be visually examined and it may be prudent to seal weld screwed joints where practical. A suitably calibrated gauge should be used and there must be no intervening valves between the gauge and the equipment under test. A gauge should not be used if there is any doubt about its accuracy or functional condition. The gauge must be clearly visible to the operator controlling the pressure. Where permanently installed relief valves would lift under test conditions, they should normally be removed and blanked. Under no circumstances must the stem be gagged or the adjuster tampered with to prevent lifting. Spades should be avoided in relief lines, as failure to remove them after test would render relief valves inoperative in future service. Bursting disk should always be removed prior to testing. Before filling equipment with liquid, the arrangement should be checked to ensure that all air can be vented. In addition to aiding leak detection, this also serves to minimize the energy stored and the potential hazard. When testing piping systems, due note should be taken of any check or non-return valves. The test procedure must ensure that pressurization is applied where required and that depressurization of all section is achieved before opening after test. To avoid undue stresses from temperature gradients, test fluid and equipment should be allowed to reach the same temperature before pressurization. It is always desirable to pressurize slowly or incrementally. This is particularly important when pressure or volumes are high. It is also important to apply this technique to the filling of tanks and to monitor settlement when filling a new tank for the first time. Screwed pugs and connections should never be tightened during pressurization as these may blow out or otherwise fail. For hydrostatic testing only, flange bolts may be tightened to a reasonable degree but excessive force should not be applied. The specified test pressure should never be exceeded by a significant amount. It is dangerous and unnecessary to apply extra pressure in the belief that this will give a "better" test. It is also dangerous and unnecessary to apply any form of shock loading, such as hammer testing, during examination of equipment under test. Test pumps shall be disconnected when unattended for any appreciable length of time; however for brief unattended period, valve isolation will suffice. 2.10

COMPETENT SUPERVISION: It is important that competent personnel supervise all stages of testing. In addition, it

F&S Regulations Chapter 2

June 2004 Page 6

KOC F&S Regulations

PRESSURE TESTING OF EQUIPMENT, SYSTEMS & PIPELINES

will often be necessary for tests to be witnessed to satisfy contractual requirements or internal instructions or procedures. Apart from providing data on the condition of equipment as mentioned above, Inspection & Corrosion Team shall provide guidance on the mechanical properties of construction materials and also to establish a suitable test pressures. +++++++++++++++++

F&S Regulations Chapter 2

June 2004 Page 7

Kuwait Oil Company

Fire & Safety Regulations

(K.S.C.)

FIRE PREVENTION & LOSS CONTROL

Chapter No. 3 June 2004

CHAPTER - 3 FIRE PREVENTION & LOSS CONTROL Contents

Subject

3.1

INTRODUCTION........................................................

2

3.2

FIRE STATION.............................................

2

3.3

FIRE PREVENTION....................................................

3

3.4

PRECAUTIONARY MEASURES ...........................................

4

3.5

FIRE RESPONSE........................................................

5

3.6

INJURY TO PERSONNEL.............................................

6

3.7

FIRE ALARMS, DRILLS AND EQUIPMENT TESTING...

6

F&S Regulations Chapter 3

Page

June 2004 Page 1

KOC F&S Regulations

FIRE PREVENTION & LOSS CONTROL

CHAPTER - 3 FIRE PREVENTION & LOSS CONTROL 3.1

INTRODUCTION: All personnel whether KOC or contractors employee working in company premises are committed to contribute, promote and establish safety as an accident prevention and loss control strategy. It is intended to summarize the recommended practices & precautionary measures in regard to fire prevention, communication procedure in emergency, loss control equipment and familiarization schedule towards asset integrity scheme.

3.2.

FIRE STATIONS: A.

B.

The company has its own Fire Stations, one each for S&EK, NK and WK areas. These stations work round the clock to cater the emergency demand for damage control issues. The respective fire station can be contacted through radio on dedicated channel (identified as KOC Fire Channel) as well as through telephone on the following contact numbers: •

Burgan Fire Station: 22221, 22222, 66669, and 3986373.

•

West Kuwait Fire Station: 20348, 20320, 20278, 20276

•

North Kuwait Fire Station: 23100, 23111 and 3985197

The following minimum information need to be provided when reporting an accident or incident, to the respective Fire Station: •

Identification of Reporter such as Name, Designation and Department

•

Nature of accident / incident

•

Location of accident / incident

•

Date & Time of occurrence for accident / incident reported

•

Personnel & equipment involved in the incident / accident

• Name & telephone number of immediate Supervisor (NB: Assure the message is understood at the other end.). C.

What to be Reported: Occupational injury, Traffic Accident, Fire, Damage to Equipment, Oil, Gas or Chemical leaks, Suspected Objects (Explosive Ordinance Device), Bomb Threat, Near Miss Cases, Security Incidents.

3.3.

FIRE PREVENTION:

F&S Regulations Chapter 3

June 2004 Page 2

KOC F&S Regulations

FIRE PREVENTION & LOSS CONTROL

It is the prime duty of all personnel to take utmost care and necessary measure to prevent fire at the work locations and its surroundings. The following precautions must be kept in view as a preventive action:

3.4

A.

Reduce the possible risk of fire by maintaining a high standard of house keeping. Any unexpected smell of gas / burning / smoke should be investigated thoroughly and the source shall be identified alongwith loss control action to be taken immediately. Such occurrence must be reported to the respective area Fire Station.

C.

Smoking is not allowed inside company operational facilities. The individual must deposit cigarettes & lighter / matchbox to Control Room prior to stepping towards plant area.

C.

All cotton rags, oily waste materials, oil soaked gloves etc., must be disposed off in a safe manner to a covered metallic container, which shall be emptied out regularly.

D.

All flammable liquids such as paint, thinners, etc. should be properly segregated and stored in a safe location and the necessary safety sign posted over there. The quantity stored must be kept to the minimum required and the containers lids or cover must not be left in the open condition..

E.

Any leakage or spill of hydrocarbon liquid, vapour or chemical must be arrested, cleaned and disposed off immediately in a safe manner (Refer Chapter – 7 for further detail)

F.

The extreme care shall be taken while dealing with pyrophoric deposits (Iron Sulphide) particularly when opening equipment, vessels, piping, pig barrel etc. If pyrophoric scale deposition is suspected then the equipment /piping /vessel must be sufficiently wet with water, preventing air contact with pyrophoric scales (Refer to Chapter – 11 for further detail)

G.

No maintenance activity shall be taken up without authorization through required work permit. The equipment installation, commissioning, decommissioning including electrical isolation / de-isolation shall be carried out by the competent & authorised person in compliance to work permit system (Refer to Chapter - 10 for further detail)

H.

The necessary care should be taken to ensure inhibition of potential fire hazards prior to leaving a room unoccupied.

I.

Any fault, defect or malfunction noticed in the damage control or fire fighting equipment must be reported to Fire Team for necessary action to replace, refill or repair as per procedure.

PRECAUTIONARY MEASURES: A.

It is strictly forbidden to carry the following (As defined in Chapter 1.): -

F&S Regulations Chapter 3

items into HAZARDOUS AREAS

June 2004 Page 3

KOC F&S Regulations

FIRE PREVENTION & LOSS CONTROL

-

Matches, Lighters and any source of ignition

-

Mobile Phone, Pager, Torch Light, Camera, electronic gadgets or any spark potential equipment that are not intrinsically safe.

-

Any battery or power operated equipment, which are not certified for respective hazardous areas classification.

The use of any spark potential equipment shall be regulated by the controlling team / asset owner in compliance to Work Permit procedure. (Refer Chapter – 8 for further detail)

3.5

B.

Smoking is not permitted in HAZARDOUS AREAS, however a Smoking Room may be designated in unclassified area with due approval from Fire Team and respect area HSE Team.

C.

Warning notice prohibiting the entry of any” ignition source and spark potential appliances” shall be posted at the entrance point of all hazardous areas and operational facilities.

D.

Any electrical operated equipment to be carried inside a HAZARDOUS AREA must be certified for use in those areas by company approved certifying authorities of international recognitions.

E.

The source of ignition as listed hereunder (but not limited to) must be controlled by Hot Work Permit: (i)

All naked flames, spark generating device, fire potential appliance, exposed incandescent materials including pyrophoric deposits, electric arcs etc..

(ii)

Electric and gas welding equipment.

(iii)

Blow lamps, Stoves and Boilers.

(iv)

All internal combustion engines (petrol driven).

(v)

Any electrical generator, equipment and machine capable of producing source of ignition.

(vi)

Power operated grinding and cutting machines.

(vii) (viii)

Hand operated metallic tools in contact with dry concrete, stone or masonry. Power operated ferrous tools.

(ix) (x)

Grit or shot blasting machines. Needle guns.

FIRE RESPONSE: A.

Emergency Evacuation Procedure as developed by each group / team should be placed at prominent location in the respective premises. This procedure should

F&S Regulations Chapter 3

June 2004 Page 4

KOC F&S Regulations

FIRE PREVENTION & LOSS CONTROL

clearly state the safety response in the event of a fire and subsequent evacuation to the designated assembly point through nearest emergency exit. B.

The general response in case of fire is summarised hereunder with the intention to minimize the anticipated loss: (i)

Raise the local alarm. (Either by breaking the cover glass at Manual call Point or shout for assistance).

(ii)

Call the fire station by telephone, radio or other suitable means.

(iii)

Attempt to fight the fire using the nearest available equipment without exposing yourself to imminent danger.

(iv)

Isolate the fuel or energy source. (Persons familiar with the apparatus or plant concerned should do this.)

(v)

The person(s) with no assigned task for emergency situation must leave the premise by the nearest emergency exit and report at the designated assembly point / muster station.

(vi)

Fire Fighting Crew should be briefed about the prevalent danger due to presence of any hazardous material, pressurized equipment or other risks at the scene of fire. (Refer Appendix –5 for detail information on Fire Extinguishers & Damage Control Equipments)

C

Small fire can be fought by available persons on the spot under the supervision of the senior most person. However fire-fighting crew take over from them on arrival at the scene of incident.

D.

Based on the potential severity and contingency, the senior most person will decide the further action after due consideration: (i)

Any further assistance or rescue needed from internal or external support agencies to minimize the damage through control measure.

(ii)

Ensure evacuation has been or is to be carried out and all persons are accounted for.

(iii)

Instigate a search or investigation if necessary.

(iv)

Demarcation of immediate danger zone and raising necessary barricade to prevent intrusion.

(v)

Arrange for a additional control and communications facility. .

(vi)

Keep Senior Management informed of the current situation.

E.

The requirement of additional resources including manpower or material for damage control or operational reason must be placed at an earliest.

F.

If at any stage it is assessed that event has escalated to a major incident, then Emergency Procedures as laid down in Chapter 14 will be come into force.

F&S Regulations Chapter 3

June 2004 Page 5

KOC F&S Regulations G.

3.6

3.7

FIRE PREVENTION & LOSS CONTROL

Once the immediate danger is resolved, the concerned Supervisor will ensure that a detail report is submitted to management alongwith recommended preventive measures & rehabilitation scheme. (Refer Chapter – 4 for further detail)

INJURY TO PERSONNEL: A.

The relief assistance for personnel injured in the course of a fire or emergency situation shall be dealt under Medical First Aid Regulations. (Refer Medical First Aid & Industrial Accident in Chapter-4)

B.

Immediate assistance can be approached by calling Ahmadi Hospital on telephone numbers 66777, 3982222, or through Radio (Channel - KOC Medical), providing necessary detail for nature of injury & casualty.

D.

The instruction for reporting of injuries and accidents are detailed under Industrial Accidents in Chapter - 4.

FIRE ALARMS, DRILLS AND EQUIPMENT TESTING: A.

There are various types of fire detectors such as Smoke, Flame (UV & Infra red), heat detectors and Manual Call Point (Break Glass Cover) have been installed at different location in company facility with the intention of alert and control measure.

B.

These detectors should be function tested at least once in three months taking all Override action in consultation with respective maintenance and operation teams. A status report of such periodical testing shall be forwarded to Fire Team & respective area HSE Team for information and advice.

C

Evacuation drills for company facility should also be conducted at least once per year. The evacuation scenario should conform to a reasonably real event, considering circumstances prevalent including its operational & HSE impact. However the familiarization drill without total evacuation may be conducted once in three months in agreement with asset owner, Fire Team & respective area HSE Team to enhance the confidence level in case of real emergency situation. +++++++++++++++++++++++++++++

F&S Regulations Chapter 3

June 2004 Page 6

Kuwait Oil Company (K.S.C.)

Chapter No. 4 June 2004

Fire & Safety Regulations

INDUSTRIAL ACCIDENT, PROTECTIVE EQUIPMENT, MEDICAL, HEALTH & HYGIENE CHAPTER - 4

INDUSTRIAL ACCIDENT, PROTECTIVE EQUIPMENT, MEDICAL, HEALTH & HYGIENE Contents 4.1

Subject INDUSTRIAL ACCIDENTS.................................................... A. B. C. D. E. F.

4.2

4.3

4.5

2

Definitions................................................................... 2 Action in Case of Accident............................................... 3 Damage Control Strategy ................................................... 3 Reporting an Accident ……….................................... 5 Accident Investigation ........................................................ 6 Accidents Investigation Checklist......................................... 6

PROTECTIVE EQUIPMENT...................................................

7

A. B. C. D. E. F. G. H. I.

7 7 8 8 8 8 8 9 9

Protective Clothing.............................................................. Head Protection .................................................................. Ear Protection................................................................ Eye & Face Protection..................................................... Safety Footwear.................................................................. Hand Protection............................................................ Safety Belts, Harnesses & Lifeline.................................... Safety Nets & Basket ................................................... Life Jackets & Lifebuoys...............................................

RESPIRATORY EQUIPMENT................................................ A.

4.4

Page

9

Types of Respiratory Equipment......................................... 9

MEDICAL FIRST AID..........................................................

11

A. B. C. D.

11 11 11 11

First Aid Boxes............................................................. Eye Bath & Wash Solution ................................................. Emergency shower........................................................ Health & Hygiene..........................................................

ATTACHMENT …...........................................................

12

Incident Report Form ………………………………………

13

F&S Regulations Chapter 4

June 2004 Page 1

INDUSTRIAL ACCIDENTS, PROTECTIVE EQUIPMENT MEDICAL, HEALTH & HYGIENE

KOC F&S Regulations

CHAPTER - 4 INDUSTRIAL ACCIDENTS, PROTECTIVE EQUIPMENT MEDICAL, HEALTH & HYGIENE 4.1

INDUSTRIAL ACCIDENTS: A.

Definitions: Accident: An accident is an unplanned & undesirable event that results in injuries or harm to people, damage to equipment or material, loss of property or damage to the environment. Minor Accident: An accident causing minor damage to material or equipment and assessed as small financial loss or an injury where there is no lost time, can be categorized as a Minor Accident. A few examples of Minor Accidents: An on-job injury, which requires first aid treatment only without causing any disablement. Damage to equipment or vehicles, which needs minor repair. Fire in a waste paper basket, which caused no further damage. Spill or leak which can be easily cleaned up and the waste collected does not require any special disposal arrangements. Major Accident: Any incident, which results in temporary or permanent disabling injury, fatality or significant damage to material / equipment is categorized as a Major Accident. A few examples of major accident: A fatality associated with KOC operations. -

Multiple serious injury Significant adverse reactions from authorities, media, non – government organizations or the general public.

-

Accidental damage exceeding KD 250, 000,

-

Oil spills of more than 100 barrels, or less if the spill occurs in a designated environmentally sensitive area. . Gas release that prompts either automatic or manual shutdown of a facility. An uncontrolled release of more than 10 tonnes of a regulated chemical. A motor vehicle accident resulting in total loss or needing major repair. Loss of well control i.e. oil well blow out.

-

Near Miss: An unplanned event which under slightly different circumstances, could have resulted in harm to people, damage to environment or property or non – compliance with legal requirement.

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INDUSTRIAL ACCIDENTS, PROTECTIVE EQUIPMENT MEDICAL, HEALTH & HYGIENE

KOC F&S Regulations B.

Action in Case of Accident: (i)

Immediate Action: The safety & health of the employees, visitors, and the public must be the primary concern followed by safeguard and integrity of equipment & environment, immediately after an accident. The first response by concerned employees or contractor’s personnel must be to: - Take all steps necessary to provide emergency rescue and medical help for the injured. - Take those actions that will prevent or minimise the risk of further accidents, injury or property damage. - Inform Burgan Fire Station for rescue and damage control assistance. These immediate actions are a stop- gap measure to prevent further adverse consequences. Most accidents will require one or more of the following actions as soon as possible, by asset owners and respective area HSE Team in coordination with each other: - Secure, barricade or isolate the scene. - Collect transient or perishable evidences. - Determine the extent of damage to equipment, material or plant facilities. - Restore the operating facilities. It is mandatory to carry out investigation for all industrial - accidents, incidents, dangerous occurrences, nearmiss cases as well as motor vehicle accidents.

C.

(ii)

Recording the Scene: Following the elimination (minimisations) of residual hazards existing at the time of accident, steps must be taken by the respective area HSE Team, to record details / circumstances at the scene of accidents.

(ii)

Preserving Evidence: In addition to recording details at the scene of accident, it will be necessary for the respective area HSE Team, to identify and collect fragments, parts, hand tools etc. that could be vital evidence to the investigation.

Damage Control Strategy: It is extremely important to carry out damage control action so that loss resulting due to the accident can be minimized. The control strategy relevant to various scenarios are summarised hereunder: (i) Accident Resulting in Minor Injuries: After arranging the medical treatment for the injured person/s and informing Burgan Fire Station, the immediate supervisor shall complete relevant part of Incident Report Form and send it to respective area HSE Team within 24 hours for investigation. (ii)

Accident Resulting in Major Injuries: In the event of serious injury caused to employee, visitor or public, the respective worksite supervisor shall request an ambulance & medical assistance immediately by providing necessary details to Burgan Fire Station (or any future Central Control Headquarter) through available means of communications on the contact numbers as hereunder: • •

Burgan Fire Station: 22222, 22221, 66669 or 3986373 By radio contact on KOC Fire Channel

However if the time permits the worksite supervisor may also inform respective area Fire Station & Ahmadi Hospital on the contact number as indicated below: F&S Regulations Chapter 4

June 2004 Page 3

INDUSTRIAL ACCIDENTS, PROTECTIVE EQUIPMENT MEDICAL, HEALTH & HYGIENE

KOC F&S Regulations • • •

North Kuwait Fire Station: 23100, 23111 or 3985197 West Kuwait Fire Station: 20348, 20320, 20278, 20276 Ahmadi Hospital: 66777 or 3982222

Once injured person/s has been sent to Hospital & the accident site is made safe, then immediate supervisor shall carry out preliminary investigation & complete relevant part of the Incident Report Form and send it to respective area HSE Team within 24 hours from the time of accident for detailed investigation. (iii)

Accident Resulting in Death: Accident resulting in death of employees, contractor personnel or visitors must be reported immediately to Burgan Fire Station. The site of such an accident must be left undisturbed and steps must be taken by respective are HSE Team to record details at the scene of accident using suitable photography camera and sketches. However if leaving the accident site undisturbed may arise or cause further hazards, then the senior most member of the company / contractor staff present at the location must use his discretion & judgement to take remedial measure for preventing further accident, injury or property damage. Subsequently Incident Report Form shall be raised by immediate Supervisor and forwarded to respective area HSE Team within 24 hours from the time of accident for statistical record, advice and further investigation.

(iv)

Accident involving Contractors Personnel: Accidents involving contractors personnel while carrying out work in company premises will be initially dealt as for company employees with the purpose of rescue & damage control strategy. Subsequently Incident Report Form shall be raised by KOC job Supervisor and forwarded to respective area HSE Team within one week from the date of accident for statistical record, advice or further investigation as applicable. However in case of major accident or fatality the Incident Report must be raised by KOC Job Supervisor within 24 hours from the time of accident and forwarded to respective area HSE Team for record, advice and further investigation.

(v)

Non-Industrial Accidents: Accident resulting in injury to KOC employee during off-duty hours will be reported by immediate supervisor to area HSE Team, which may investigate it further if the circumstances requires to do so.

(vi)

Accidents causing Material Damage without any Injury: Accidents & incidents which has resulted in loss / damage to equipment, materials or environment but no injury to personnel are to be reported immediately to Burgan Fire Station who in turn will inform area HSE Team. Subsequently Incident Report shall be raised by immediate Supervisor and forwarded to respective area HSE Team within one week from the date of accident for statistical record, advice or further investigation.

(vii)

Motor Vehicle Accidents: Motor Vehicle Accidents resulting in damage to company Vehicle or hired vehicles allocated to & driven by company personnel (while on duty) shall be reported to Burgan Fire Station, who in turn will report Transport Operations (Contact No. 66107 or 3982763), respective area Fire

F&S Regulations Chapter 4

June 2004 Page 4

KOC F&S Regulations

INDUSTRIAL ACCIDENTS, PROTECTIVE EQUIPMENT MEDICAL, HEALTH & HYGIENE

Station & area HSE Team for rescue measure, statistical record and on-site investigation. Subsequently Incident Report Form shall be raised by immediate Supervisor and forwarded to respective area HSE Team within 3 working days from the date of accident for statistical record, advice or further investigation. In the event of serious damage, the vehicle(s) should remain undisturbed for on site investigation by Traffic Police and area HSE Team. In the event of company vehicle’s breakdown, transport operation shall be informed immediately. The contractors’ vehicle meeting an accident in the company premises will also be reported to the respective area Fire Station for rescue and investigation purpose. The incident report shall be raised by immediate supervisor and sent to the respective area HSE Team through the concerned controlling team, within one week from the date of accident.

D.

Reporting an Accident, Incident & Nearmiss Cases: Once the injured have been shifted for medical treatment and the accident site made safe, then formal reporting and investigation must be initiated. Immediate supervisor shall forward the incident report, filling relevant part of Incident Report Form, (within the time period for the category of accident as defined above), to the respective area HSE Team for statistical record, advice or detail investigation as needed. The incident reporting form (which can be downloaded from KOC - HSE website) is enclosed at the last page of this chapter All accidents involving injury to personnel or damage to the plant are to be reported without delay to Burgan Fire Station who in turn shall inform the immediate supervisor, respective Fire Station, Safety Team and area HSE Team for necessary rescue operation and damage control strategy. It is required to inform Manager – Medical also in case of major events and vital incidents. Team Leader – Safety will apprise Manager (HSE) about the accident. If the accident / incident happens to be of an acute nature, then the respective EAMD may constitute a Board of Enquiry on behalf of the Management. The Investigation Team will carry out a detail investigation and submit a formal report giving the findings, lesson learnt and recommendations to prevent reoccurrence in future. Incident involving contractor’s personnel working in company premises will conform to KOC Incident Reporting & Investigation procedure in addition to their own system. The reporting of Company’s HSE data (including that at of accidents / incidents) to KPC & other external agencies shall be done by Corporate HSE Group. Accordingly HSE System Team shall maintain a centralized record of such data forwarded by Fire Team & respective area HSE Team. To fulfil this commitment, the respective area HSE Team shall submit the weekly report (for the period from Wednesday to Tuesday) in the prescribed format, indicating HSE activities including training details, to HSE System Team for further compilation and reporting to KPC through Manager – HSE.

E.

Accident, Incident & Nearmiss Investigation: All accidents, incidents, dangerous occurrence and nearmiss cases must be reported and investigated so that the root cause of each accident/ incident / nearmiss is established and corrective action taken to prevent its recurrence. Every accident, incident, dangerous occurrence and nearmiss case shall be thoroughly investigated. It is the responsibility of immediate supervisor to

F&S Regulations Chapter 4

June 2004 Page 5

INDUSTRIAL ACCIDENTS, PROTECTIVE EQUIPMENT MEDICAL, HEALTH & HYGIENE

KOC F&S Regulations

initiate & carry out preliminary investigation (first line investigation); however area HSE Team will carry out detailed investigation. After immediate damage control action has been taken and site of accident is made safe, the Company’s site supervisor or immediate supervisor will raise “Incident Report Form ” (within the time period for the category of accident as defined above) and send it to respective area HSE Team for detailed investigation, which shall be completed within five working days on receipt of investigation report. The concerned team shall co-operate with respective area HSE Team to accomplish the task. The respective area HSE Team is accountable and custodian of original records concerning all accidents / incidents which have occurred in the asset. The asset HSE Team shall also assist on compensation claim and legal requests raised due to accident / incident occurred in their area of jurisdiction.

F.

Wherever possible photographic evidence should be obtained (by respective area HSE Team) capturing salient features of the occurrence. The observation & statement of witnesses to the accident must be recorded and authenticated to arrive at the root cause of accident. Wherever possible, the scene of such accidents should be left undisturbed until the initial investigation has been completed. Damaged parts, fragments items should be retained to assess damage & assist investigation. Accident Investigation Checklist: To obtain proper information and thereby establish the basic & contributory causes of an accident, a line of questionnaires as listed hereunder to be included as a guideline in the Accident Investigation Checklist: Accident Investigation Questionnaires: Check WHO

Detail • • • • •

• • • • • • • • • •

•

F&S Regulations Chapter 4

Observation

Was injured? Saw the accident? Was working with injured Had instructed & / or assigned the job? Else was involved? Knows what happened prior to accident? Instructions had been given? Specific precautions were identified? Specific precautions were taken? Protective equipment was identified for use? Protective equipment was used? Problems were encountered? Training had the employee received? Extenuating circumstances were involved? Did the employee or the witness see? Safety rules were violated?

June 2004 Page 6

INDUSTRIAL ACCIDENTS, PROTECTIVE EQUIPMENT MEDICAL, HEALTH & HYGIENE

KOC F&S Regulations WHEN

• • • • • • •

• WHY

• • • • •

• WHERE

• • •

• •

4.2

Did the accident occur? Did the damage become evident? Was the equipment last inspected? Did the job start? Was the equipment last maintained / repaired? Was it planned to start the job? Did the supervisor last visit the job site? Were all potential hazards identified / reported? Was the unsafe act committed? Were the instruction not understood? Was the employee in the position that he was? Was that tool or machine being used? Did not the employee check with the supervisor? Was the supervisor not there at that time? Is the damage? Did the accident occur? Was the supervisor at that time? Were other persons at the time? Were witnesses when accident occurred?

PROTECTIVE EQUIPMENT: A. Protective Clothing: Protective Clothing is designed to protect workers from injuries that can result due to contact with hot or cold surface, chemicals, electricity or sharp objects. The company as well as contractor employee working in hazardous area must wear KOC approved Coveralls (Boiler Suites). The personnel working near rotating equipment shall not wear necktie and should properly secure any loose items such as cufflink, strap & rings etc. to avoid being caught in the machinery. The personnel exposed to hot spark or heat radiation shall wear fire – retardant clothing. The protective clothing must be kept in good condition and be cleaned regularly. When handling chemicals in any form, rubber or neoprene clothing and gloves must be worn. It is also recommended to wear face and / or eye protection also in such cases. The person should wear a reflective or fluorescent type jacket while working on road. B. Head Protection: Helmet shall be worn anytime people are required to be outside offices, control rooms, accommodation area or where there is a possibility of head injury. The helmet shall be suitable and approved for the specific service or potential hazard. Metallic hat should not be worn, as they conduct electricity and retain damage when struck by or against a falling / heavy objects. The helmet should be regularly checked to ensure that there is no visible damage or cracking of the outer shell, and the harness is clean & in good condition. Long hair should be tied up so that it does not become entangled in moving equipment or machinery. Special helmet must be worn when working with chemicals, prays, shot / grit blasting, welding, etc.

F&S Regulations Chapter 4

June 2004 Page 7

KOC F&S Regulations

INDUSTRIAL ACCIDENTS, PROTECTIVE EQUIPMENT MEDICAL, HEALTH & HYGIENE

C. Ear Protection: Ear protector is of critical importance, since hearing loss can be permanent. Where the sound levels exceed 85 dB, hearing / ear protection such as Ear Muff or Ear Plugs. Plugs are not as affective as muffs for providing adequate hearing protection. Earplugs should be cleaned or disposed of if they become dirty. D. Eye & Face Protection: Eye protection is required whenever there is a chance that personnel could be exposed to airborne particles or splashing liquids. Safety glasses with side shields are effective in providing protection from flying particles. However Goggles are preferred to glasses as it provides more protection from flying particle and splashing liquids. Goggle can also be worn comfortably over prescription glasses for enhance eye protection. The Goggles / Safety Glasses must be suitable for adequate protection against light intensities, IR & UV rays, chemicals and abrasive particles etc. Face shields are necessary for some jobs to provide protection to the entire face and eyes while handling any hazardous liquids, chemicals or carrying out welding. The type of face shield needed will depend on the nature of the hazard that may be encountered. E. Safety Footwear: Safety Footwear must be worn to prevent injury resulting from contact with falling or heavy objects. Safety Footwear also provides additional support when walking on rough or slippery surface. High top boots with extra protection over the top of the foot, containing puncture proof soles shall be worn as a protective guard against specific job hazard. Safety Footwear conforming to ANSI Z41 specs fulfils the industrial requirements in general. Safety footwear should be inspected regularly for signs of damage or excessive wear. F. Hand Protection: Hand protection such as suitable Gloves shall be worn to provide adequate protection against potential hazard associated with material or equipment being handled. Gloves may be made of cotton, leather, rubber, neoprene or mesh reinforced (for working with sharp objects). Special gloves are required for electrical works. These must be regularly tested by an approved lab for its integrity and potential damage. Gloves used for handling chemicals should be inspected prior to each use and discarded if any contamination of the interior surface is suspected. Additional skin protection can be provided by barrier creams, which shall be used to prevent direct skin contact with crude or mineral oils. In such application hands and arms are to be thoroughly washed at the end of work. G. Safety Belts, Harnesses & Lifeline: Safety Belts and harnesses of approved type must be worn when there is a danger of falling from height. It must be worn also when entering a confined space in addition to appropriate breathing apparatus. In such situation the other end of lifeline must be held by a competent standby person stationed outside the confined space keeping constant surveillance of the entrant. If safety belts and harness are used as alternatives to safety nets or baskets, the lifeline must be attached to an appropriate anchorage or winch. The harness & lifelines must be so adjusted and worn that the wearer can be drawn head first through any manhole or other opening. The code of signals as summarised hereunder shall be used in such cases:

F&S Regulations Chapter 4

June 2004 Page 8

KOC F&S Regulations Signal on line

INDUSTRIAL ACCIDENTS, PROTECTIVE EQUIPMENT MEDICAL, HEALTH & HYGIENE Given by Wearer

Given by Attendant

1 Pull

I am all right

Are you all right?

2 Pulls

Pay out more line

I am paying out more line

2 Pulls-pause

Stop paying out

I am ceasing paying

2 Pulls

Out or lowering

Out or lowering

3 Pulls

Haul in slack or Haul up

haul up

Danger- Help me out

Danger - I am hauling you out as quickly as possible

Repeated sharp Pulls

I am hauling in slack or

H. Safety Nets & Baskets: Safety nets and / or baskets should be rigged where necessary to protect men at work. Safety nets and baskets shall be suitable for the required service and should be inspected for wear & tear each time before using it. It shall be maintained in good condition and secured firmly when rigged up. Safety nets can be used in conjunction with ship's gangway. I. Life Jackets & Lifebuoys: The workers must wear life jackets as a protection against accidental fall into water. Lifebuoys must be also available at work site for rescue and survival contingency requirement. Lifebuoys should have adequate length of lifeline and a self-operating marker light attached to it.

4.3 RESPIRATORY EQUIPMENT: Appropriate respiratory protection is to be used where the nature of job involves exposure to chemicals, dusts, vapours, fumes and other toxic substances such as H2S, Sulfur Dioxide, Carbon Monoxide or Oxygen deficient atmosphere. The nature and duration of potential exposure will dictate the type of respiratory protection that can be used. The workers must have adequate training for use of respiratory equipment, its donning / removal procedure, pre-donning inspection, maintenance and cleaning practice. All respiratory equipment must be regularly inspected, maintained and stored in ready condition for use. A. Types of Respiratory Equipment: (i) Fresh Air Breathing Apparatus: It consists of a hose leading from a source of fresh air to the facemask or helmet worn by the user. Air is supplied by a bellows or a rotary pump The air supply source must be must be constantly attended to ensure its availability at the required pressure. (ii) Self-Contained Breathing Apparatus: The equipment consists essentially of a fullface mask, a flexible breathing tube, a pressure gauge, a regulator, an air supply cylinder, a harness assembly and a low-pressure alarm device. There are numerous types of BA sets available and wearers must be fully conversant with the type being used at the facility. SCBA is used where there may be: • • F&S Regulations Chapter 4

High concentrations of toxic substance. Oxygen deficient atmosphere. June 2004 Page 9

KOC F&S Regulations

INDUSTRIAL ACCIDENTS, PROTECTIVE EQUIPMENT MEDICAL, HEALTH & HYGIENE • •

Levels of toxic smoke. Environments considered hazardous to life.

After each use, this equipment must be cleaned, disinfected if necessary, recharged with air and returned, ready for use, to its storage location. Frequent inspection is required to ensure that the air pressure is adequate and that the regulator, facemask and harness are in good condition. The wearer should withdraw to fresh air conditions immediately when the low-pressure alarm sounds. The work, which requires wearing of breathing apparatus due to the presence of harmful gases or oxygen deficiency, must be covered by WORK PERMIT PROCEDURE (Refer Chapter –8 on Work Permit System) (iii) Air Line Breathing Apparatus: The air line breathing apparatus is similar to SCBA in that it also has a full face mask, a flexible breathing tube, a regulator and a small air cylinder to be used in emergency situation. The major difference is that the air for this apparatus is supplied from a large cylinder, a bank of cylinders or other suitable source connected by hose through a regulator and filter. The airline breathing apparatus is usually preferred for maintenance and repair work where an air supply for longer periods of time is required. The other advantage is its lightweight and ease of movement. The disadvantage is that air hose can get entangled up in other equipment and in the event of an emergency; the user must remember to disconnect the air supply line and turn on the small cylinder for escape. (IV)

Canister Type Respirators: The Canister or cartridge type respirators are designed for protection from some dust, fumes and vapours. The chemical cartridge will specify the type of contaminant it is to be used for. It is of critical importance that the contaminant is identified and in some cases, quantified by professional monitoring, so that proper job planning can adequate and specific protection for personnel. Care must also be taken to ensure that the concentration of contaminant and the duration of exposure do not exceed the capacity of the chemical cartridge. If there is any doubt about the contaminants or the capability of a canister respirator to provide adequate protection, SCBA or airline breathing apparatus must be used.

(V)

Filter Type Respirators: Filter type respirators must be worn when personnel are required to work in atmospheres that are or may be contaminated with harmful airborne dusts & fibres, mist and / or vapours. The type of respirator selected must be approved for the type of contaminants to which the employee may be exposed. The confirmation is essential, since filter type respirators are usually designed to provide a specific level of protection against a specific contaminant or hazard.

4.4

MEDICAL FIRST AID: A. First Aid Boxes: First aid boxes are supplied to all locations where people are employed, unless medical facilities are within easy reach. First Aid Boxes should be in the control of a person qualified to render Medical First Aid and who has been trained by Medical Department. He must ensure the contents of the box are

F&S Regulations Chapter 4

June 2004 Page 10

KOC F&S Regulations

INDUSTRIAL ACCIDENTS, PROTECTIVE EQUIPMENT MEDICAL, HEALTH & HYGIENE

maintained in proper condition for immediate use and must arrange for Medical Department to inspect and replenish as necessary. Under no circumstances are Medical First Aid supplies to be used for any purposes other than First Aid. B.

Eye Baths & Wash Solution: Eye wash solution and equipment for immediate washing of eye is provided with all Medical First Aid Boxes and additionally in all places where hazardous materials are being handed and eye contamination may occur. Workers in such areas should be familiar with the location of such eye washing facilities and its use in emergency. It is recommended to seek medical advice immediately after eye washing in case of contamination with hazardous material. Eye wash bottles once opened should be disposed and replenished with sealed bottles.

C. Emergency Showers: In all work places where acids, corrosives or other such hazardous materials are used or handled, emergency water shower facilities have been provided and which shall be used immediately in the case of body contamination. It is the responsibility of local Supervisors to ensure that these facilities are functional and kept ready for immediate use. D. Health & Hygiene: The employees are required to observe all safety, health and welfare regulations, which is laid down by the Company. Each employee while at work has to take reasonable care to ensure the safety, health and welfare of himself and other persons who may be affected by his acts or omissions. No persons shall intentionally or recklessly interfere with or misuse anything provided by the Company in the interests of health, safety and welfare. The following health & hygiene guidelines must be kept in view while working inside company premises. •

Where work procedures require the use of protective clothing, etc., respiratory protection or other protective gear, these are to be maintained in a clean and hygienic condition.

•

All persons working inside the company premises are required to maintain a clean and tidy status at their place of work, including for personal lockers, wash rooms, laboratories & rest rooms, etc.. Persons handling or carrying out any work with chemicals, paint, toxic or other harmful substances, or any work involving dust or fumes, must thoroughly wash their hands before taking meals and before leaving worksite.

•

•

Where persons are required to lift or move heavy objects by hand, they should be trained in the correct methods of lifting and/or moving such objects.

•

Barrier creams approved by Medical Department are available at the location where its use is envisaged however it is to be used as instructed.

F&S Regulations Chapter 4

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INDUSTRIAL ACCIDENTS, PROTECTIVE EQUIPMENT MEDICAL, HEALTH & HYGIENE

KOC F&S Regulations •

4.5

Hand cleaning solvents approved by Medical Department are provided in all washrooms and are to be used as directed. The use of non-approved solvents (gas oil, kerosene etc.) is forbidden.

ATTACHMENT:

Incident Report Form on next page

F&S Regulations Chapter 4

June 2004 Page 12

Kuwait Oil Company (K.S.C.) Chapter No. 5 June 2004

Fire & Safety Regulations

OPERATIONAL SAFETY REGULATIONS FOR EXPORT & MARINE FACILITIES CHAPTER - 5

OPERATIONAL SAFETY REGULATIONS FOR EXPORT & MARINE FACILITIES Contents

Subject

Page

5.1

SHIP MASTERS COMPLIANCE WITH PORT REGULATIONS & CONDUCT OF VESSEL..................

2

5.2

FIRES, LIGHTS, TORCHES AND SMOKING......................

5

5.3

LOADING / DISCHARGING OPERATIONS .......................

7

5.4

COMMUNICATIONS......................................................

9

5.5

EARTHING, BONDING, CATHODIC PROTECTION, STATIC ELECTRICITY..............................................

10

PROCEDURE IN CASE OF FIRE OR OTHER INCIDENT AT EXPORT FACILITIES.....................................................

11

PROCEDURE IN CASE OF FIRE ON BOARD A VESSEL ALONGSIDE.....................................................

12

5.8

PREPARATION FOR MAJOR EMERGENCY.....................

13

5.9

NOMINATION OF DUTY PERSONNEL ON SINGLE POINT MOORING OR ANY OTHER TERMINALS..............

13

WORK UNDER WATER...............................................….

15

5.6 5.7

5.10

F&S Regulations Chapter 5

June 2004 Page 1

KOC F&S Regulations 5.1

OPERATIONAL SAFETY REGULATIONS FOR EXPORT & MARINE FACILITIES

SHIP MASTERS COMPLIANCE WITH PORT REGULATIONS AND CONDUCT OF VESSEL: Any vessel (“Vessel”) intending to use the Kuwait Oil Company (“Company”) Export & Marine facilities and approaching the same must comply with the Port Regulations as per Kuwait Law numbers 21 of 1961, 12 of 1964, 105 of 1976, 26 of 1968 and all the Conditions laid in the Berthing Documents (which are attached to these Regulations as Appendix 12). All Vessels will also comply with the instructions received, either visually or orally or through the agent, from the Harbor Master and must, on no account, approach or lie at any part of the Company Export & Marine Facility without the assistance of a Company Pilot. Pilotage is compulsory within the Port limits. Master of the Vessel, its Officers and Crew when approaching and berthed at Company Export & Marine Facility must comply at all times with the Port regulations and any other requirements officially promulgated by the Harbour Master or the Company in order to ensure the safety of personnel, Vessels, jetties and installations etc.. Responsibility for the safe operations on board the Vessel within the Danger Zone rests with the Master of the Vessel. The Master or the officer of the watch shall take appropriate corrective action when infringement on board the Vessel or associated with it of any of these regulations are brought to their attention. Where corrective action is not taken within a reasonable time, the Company may take necessary measures to rectify the infringement. The Master on observing infringement of these conditions by the Company shall bring these to the notice of the loading master. The Master may have all operations stopped where there is immediate threat to the safety of the Vessel from any action or equipment under the control of the Company. A. Exchange Of Information Before Berthing: Essential information should be exchanged before berthing. Such information may include draft and trim of the Vessel, tug assistance, any leakage that might affect loading/unloading or cause pollution, flange dimensions, mooring line requirements, method of communication used during mooring, berthing etc.. ‘Pilot/Master Information Exchange & Operational Checklist’ is appended at Appendix 12

B. Exchange Of Information On Berthing: There must be an adequate exchange of information between the Master of the Vessel and the Company immediately after berthing in order to ensure that all Port, Company and any other regulations are known and will be observed while alongside. Joint signatures must be obtained on behalf of the Vessel and the Company to a safety checklist and any other documents affecting fire and safety.

F&S Regulations Chapter 5

June 2004 Page 2

KOC F&S Regulations

OPERATIONAL SAFETY REGULATIONS FOR EXPORT & MARINE FACILITIES

All berthing documents are appended at Appendix 12 including ‘Safety Conditions’, ‘Agreement on Smoking Places’ and ‘Ship/Shore Safety Checklist’. C. Inspection: The Company Loading Master and any authorized representative of the Company's Export & Marine Operations Group or HSE Group has the right to board the Vessel alongside the Company Marine Facility to ensure that the Fire and Safety regulations are being observed. D. Hazardous Areas (Also called ‘Danger Zone’): The following areas / vessels are classed as Hazardous Areas (Also called “ Danger Zones”): 1. The whole of the Single Point Mooring terminal, the Vessel made fast alongside and an area within a radius of 300 meters of any point from the above location, together with all the water enclosed within the area. 2. All Vessels and craft within the Danger Zone. 3. Any areas or facilities, which the Company may from time to time declare to be hazardous area. All industry safety rules, safety regulation and safety measures, including these Fire & Safety Regulations must be observed within the Danger Zone. (Also see under Chapter 1 (‘Classification’) Item 1C – ‘Classification by Area’) E. Mooring: All Vessels must be adequately secured alongside the berths (onshore and offshore) in the correct position at all times with efficient moorings. The moorings must be properly tended and kept taut to the satisfaction of the terminal staff. If self-tensioning winches are fitted, these must be put on manual brake whilst the Vessel is alongside the terminal. As per the latest port regulations coming in force from 01 July 2003, at least 8 moorings are required for all tankers. For tankers below 75,000 DWT, at least 5 should be wires. For other bigger tankers and LPG vessels of any size, at least 8 wires are required. High Modulus Synthetic Ropes may be used as a substitute or in a combination with wires, without mixing moorings. Additionally, 2 more moorings of any type to be kept standby for bad weather situations. F. Anchors: No Vessel must lie alongside any berth with an anchor on the bottom. Should anchors be used during berthing operations, they must be weighed (lifted) home on completion of securing alongside.

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G. Emergency Towing Lines (“ Fire Wires” ): Any vessel lying alongside a Company terminal, must provide Fire Wires of size and length in accordance with the latest Company Regulations, for towing purposes in case of any emergency, forward and aft, as near as possible to the extremities of the Vessel. The inboard end of the Fire Wires must be made fast to the Vessel’s bitts and the outboard eye to be maintained at, or near the water level at all times. H. Gangway: Every Vessel must provide, rig and tend a safe gangway for access to and from the Vessel. When the Vessel’s deck is higher than 3 meters above the landing a safety net must be rigged on the gangway / accommodation ladder. A lifebuoy with not less than 15 fathoms (28 meters) of lifeline attached must be positioned on the Vessel near the gangway/ladder. I. Warning Flag And Light: Whilst loading/discharging each Vessel will fly by day where it must be easily seen, the International Code Flag letter "B". By night from sunset to sunrise red light shall be exhibited where it can be seen best and visible all round the horizon. J. Passengers And Stores: Whilst the Vessel is loading or discharging petroleum cargoes, no other cargo or stores must be loaded or discharged or passengers embarked or disembarked, without the prior approval of the Harbor Master, Loading Master or Pilot. K. Tugs, Launches, etc.: No tugs or unauthorized launches are allowed alongside the Vessel while loading or discharging operations are in progress unless authorized by the Harbour Master, Loading Master or Pilot. L. Supervision: A responsible member of the Export & Marine Operations Group must be on duty at all times when a Vessel is loading or discharging at a Company Loading Facility. His location and telephone number must be provided to the responsible ship's officer and to any Company operative attending the loading / discharging. Valves, gauges, etc., Single Point Mooring, or any other terminal may be operated or their operation authorized, only by a responsible member of Export & Marine Operations Group. M. Emergency Shutdown: Any emergency shutdown must be authorized by a responsible member of the Export & Marine Operations Group in collaboration with a responsible officer of

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the Vessel. Such other Team as may be concerned with the loading / discharging operations at the time, must be informed immediately of the action taken. N. State Of Readiness Of Vessels Alongside: The main engines, other essential machinery and personnel of the Vessel alongside must be maintained in a state of readiness for vacating the berth at short notice. Immediately prior to arrival at Company Marine facilities, the Vessel’s fire hoses must be prepared and connected to the fire main, one forward and one aft of the Vessel’s manifold, unless the Vessel is adequately equipped with fire monitors, then hoses are not required to be laid out. The Vessel’s fire pump shall be on standby condition and ready for immediate operation. Portable fire extinguishers of a suitable type shall be conveniently placed for use near the Vessel’s manifold. O. Incidents: In the event of an incident which warrants cessation of loading / discharging operations, the Vessel’s manifold valves and at-least one tank filling valve must be left open to facilitate hose draining prior to activating quick release hose coupling, in preparation for unberthing. 5.2 FIRES, LIGHTS, TORCHES AND SMOKING: A. Fires-Galleys: The use of oil or open fires on Vessels in the HAZARDOUS AREAS is permitted only with the approval of the Export & Marine Operations Group and jointly agreed with the Master of the Vessel on the ‘Agreement on Smoking Places and Galley Fires’ (See Appendix 12). B. Lights, Wandering Leads (Loose Electrical Cords), Torches, Walkie-Talkies, etc.:

Lamps, torches, portable UHF/VHF transceivers (Walkie-talkies) and any other portable battery operated equipment must be of a type approved and marked or covered by a certificate issued by a recognized classification authority and approved by KOC Export & Marine Operations Group. Portable domestic radios, photographic flash equipment, portable electric calculators, mobile phones, pagers and other battery powered equipment of an non-approved type must not be used within the Company Export & Marine facilities or on the tank deck of the Vessel within the Marine Facilities, except with the special written authorization of the responsible terminal staff.

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(Small personal battery powered items such as watches & miniaturized hearing aids are not significant ignition sources when correctly used and are permitted to be worn under normal working conditions). Any equipment not complying with these regulations is to be deposited with the Gatekeeper at the North or South Pier control posts or at the Craft Operations Office at Small Boat Harbour. Wandering leads (Loose electrical cords for portable equipment) must not be used on the Company facility or on board the Vessel alongside during cargo operations. Should it become necessary to use equipment with wandering leads on Company facility or on board the Vessel alongside during cargo operations, such equipment must not be used without an appropriately authorized Company Work Permit. While such equipment is being used, appropriate precautions as laid down in ISGOTT must be observed. C. Smoking: The carrying of matches and lighters is prohibited within Company facilities or on board the vessel. Shore personnel must leave any means of ignition or non-safety equipment with the entrance security personnel. Ship's Personnel must leave such items on board the Vessel. Smoking within the Export and Marine facilities is permitted only in approved smoking places. Smoking is permitted on Vessels within the HAZARDOUS AREA only in approved inside accommodation areas specifically agreed jointly by the Export & Marine Operations Group and the Master of the Vessel on the ‘Agreement on Smoking Places and Galley Fires’. In agreeing the location of smoking places on the Vessel while alongside, special note should be taken of conditions that may suggest danger such as of wind, or any indication of usually high gas concentration. Multi-lingual No Smoking notices must be prominently displayed at all entrances to HAZARDOUS AREAS and also within view of the Vessel lying at the Company Facility. D. Electrical Storms: During electrical storms in the vicinity of the Vessel, the handling of volatile petroleum, loading non-volatile petroleum into non-gas free tanks, ballasting of non-gas-free tanks, inert gas purging, tank cleaning or gas freeing after the discharge of such cargoes should be stopped and all tank openings and vent-line valves closed.

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E. Hot work: Hot work must not be carried out on the Company facility or anywhere on board the Vessel during handling of volatile petroleum, loading non-volatile petroleum into non-gas-free tanks, ballasting of non-gas-free tanks, inert gas purging, tank cleaning or gas freeing after the discharge of such cargoes. 5.3 LOADING / DISCHARGING OPERATIONS A. Hoses: Flexible hoses must be examined visually before each hosing-up operation commences. Any hose showing signs of damages must not be used and is to be removed as soon as possible from the ready-use hose stowage. The complete life history of each length of hose must be recorded in the appropriate register showing the dates of all full examinations, tests and repairs carried out on them in addition to any incidents which may have caused undue strain or suspected damage. Test pressure should be carried out in strict compliance with the OCIMF (Oil Company International Marine Forum) recommendations. B. Handling, Lifting And Suspending Cargo Hoses: Hoses must be handled with care and protection is to be provided at any point where chafing or rubbing might occur. Hoses must not be dragged or rolled in a manner, which twists the body of the hose. Hoses should not be allowed to come in contact with hot surfaces. Lifting bridles and saddles must be used and steel wires must not be used in direct contact with the hose cover. Hoses must be supported at a number of places so that they are not bent to a radius less than that recommended by the manufacturer. Excessive weight on the ships manifold should be avoided and adequate support given to the hoses when connected to the manifold. C. Flexible Hose Connection: Flexible hoses must be examined visually before each hosing-up operation commences. Any hose showing signs of damages must not be used and it to be removed as soon as possible from the ready-use hose stowage. The complete life history of each length of hose must be recorded in the appropriate register showing the dates of all full examinations, tests and repairs carried out on them in addition to any incidents which may have caused undue strain or suspected damage. Test pressure should be carried out in strict compliance with the OCIMF (Oil Company International Marine Forum) recommendations.

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D. Loading Arms: The operation of loading arm installations should be fully understood by Operators to ensure they are used within the design limitations. Operators must ensure that the Vessel’s manifolds are maintained within the operating envelope during all stages of loading and discharge. A close watch must be kept on wind speeds and directions, and operations should be suspended and arms drained and disconnected if weather conditions reached a limit which in the opinion of the Harbour Master or the Pilot are not safe to continue the operations. During periods that the arms are connected, the ship's moorings must be frequently monitored by ship and shore personnel and tended as necessary to restrict any movement of the ship to that acceptable by the metal arm operating envelope. If drift off or range alarms are actuated, all transfer operations must be ceased immediately and remedial measures taken. Arms must not be allowed to foul each other. Excessive vibration must not be allowed to continue, but its cause ascertained and corrected. E. Accidental Oil Spillage And Leakage: Both ship and shore personnel must maintain a close check against the escape of oil when starting and during loading and discharging. Care must be taken to ensure that all pipeline valves are firmly closed if not in use. Every possible precaution must be taken to prevent oil escaping into the sea from either ship or shore operations. Before cargo handling commences, all deck scuppers should be effectively plugged to prevent spilled oil escaping overboard. Unless there are permanent means for the retention of any slight leakage at ship or shore connections, drip pans must be used to catch any such leakage. If a leakage occurs from a pipeline, valve, hose or loading arm, operations through that connection are to be stopped until the cause has been ascertained and the defect remedied. If a pipeline, hose or metal ram bursts, or if there is an overflow, all cargo and bunker operations are to be stopped immediately and must not be restarted until the fault has been rectified and all hazard from the released oil eliminated. Steps must be taken to ensure that no flammable gases from a spillage enter the engine room intake of a Vessel along side. All shore pipelines; product loading arms and cargo hoses not in use at berth shall be securely blanked.

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In the event of serious oil spillage at Single Point Mooring, or any other marine facility the alarm must be sounded and the laid down emergency procedures implemented and Harbour Master must be informed so as to initialize oil spill contingency plan. F. Repairs To Structures Or Plant: No repair work of any kind may be carried out on Single Point Mooring, or a Company loading facility if the Vessel is along side, without the written authority of the Export & Marine Operations Group. Agreement of the Vessel’s Master must be obtained in so far as the work might affect the safety of the Vessel. An appropriate Work Permit shall be prepared and authorized as indicated in Chapter - 8 for any work other than normal routine operations on the marine facilities. Where necessary the agreement of the Vessel’s Master must be obtained and his signature placed on the Work Permit. No Work Permit should be authorized for a period exceeding one working day. G. Vehicles And Plant: Mobile or semi-mobile plant required for use on Single Point Mooring, or any other Company loading facility must be inspected and approved by Export & Marine Operations Group before a Work Permit for their use can be issued. They will be placed and used in accordance with the conditions specified in the Work Permit. 5.4

COMMUNICATIONS: All communications equipment used in a Hazardous Area must conform to regulation 5.2 sec B of this chapter. All personnel working in the Export facilities should understand the emergency communications systems and have frequent instruction in its use. Should language difficulties be likely to arise, arrangement should be made to standardize terms and expressions to be used, particularly for emergency use and/or between ship and shore. Where necessary a member of the Company staff with knowledge of tanker practices should remain on board a Vessel during loading operations. The main transmitting aerial and radar scanner must not be energized while a Vessel is alongside unless specific arrangements have been made between the Master of the Vessel and responsible terminal staff. The main transmitting aerial must be earthed. There must be adequate communication facility between ship and shore. Telephone equipment and interconnecting cables are to comply with recognized standards and be inspected and approved by the Company’s IT Group. The repair and servicing of communications equipment on a Vessel may necessitate compliance with the Company's Work Permit regulations and must not be permitted without the approval of the Company Harbour Master.

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5.5 EARTHING, BONDING, CATHODIC PROTECTION, STATIC ELECTRICITY: A. Earthing, Bonding and Cathodic Protection: Cargo hose strings and cargo metal arms must be fitted with an insulating flange or a single length of non-conducting hose to ensure electrical discontinuity between ship and shore. When handling static accumulator oils, all metal on the shore side of the insulating flange or the non-conducting hose must be electrically continuous to the jetty earthing system and all metal on the seaward side must be electrically continuous to the ship. When an insulating flange or single length of non-conducting hose is installed, it must not be short-circuited by contact with external metal. Insulating flanges must be visually inspected periodically to ensure the insulation is clean and in good condition. The switching off of a cathodic protection system (or impressed current system) on the shore or on the ship is not a substitute for the installation of an insulation flange or length of non-conducting hose. As the polarization of the charge takes many hours to dissipate after the impressed current system is switched off, it is really not necessary to switch it off. B. Static Electricity: Overshot or splash fitting and the pumping of water/oil mixtures are to be avoided. Loading and discharge pumping rates and flow velocities are to conform strictly to manufacturer’s specification for the hose or as per KNPC specification for the loading arm. No conductive probes or floating conductive objects are to be lowered into tanks or compartments. No metallic objects such as sample cans, gauging tapes, thermometer, etc., shall be lowered into a tank or compartment during or for a period of 30 minutes after all pumping into or circulating within the tank has stopped. Where filters on shore are used between shore and ship a relaxation time of 30 seconds shall be allowed. 5.6 PROCEDURE IN CASE OF FIRE OR OTHER INCIDENT IN EXPORT FACILITIES:

A. Immediate Action By Shore And Sea Island Personnel: In case of fire, dangerous occurrence or accident within the Export facilities, the Company Harbour Master and Fire Team must be informed immediately. Fire alarm signals should be sounded as follows:

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KOC F&S Regulations •

Sea Island and Single Point Mooring terminals - the continuous sounding of the Company general alarm system.

•

On a Vessel alongside - blasts of the ship's siren or whistle, each blast of not less than 10 seconds duration and continued for at least one minute, and to be supplemented by the sounding of the Company general alarm system.

Fire - fighting or other appropriate action must be undertaken, using available local equipment, by all available hands under the control of the senior most shore official present. Fire - fighting personnel will deploy equipment to control the fire. During the disconnection of loading hoses or arms and when a Vessel is being removed from the berth, fire extinguishing equipment will be concentrated at strategic points from where it will be possible to minimize the risk of fire spreading during these operations. B. Information To Be Given: Information should be passed to Products Pump Station, Tank Farm Control and LPG Storage Control (See Action to be taken by products pump station). All duty deck officers of Vessels alongside at the location of the incident should be informed of the situation and the action, if any, they should take. If the Sea Island & or a Single Point Mooring terminal is involved, as soon as practicable, the Ahmadi Control Room and Burgan Fire Station on 22222; 22221; 66669 or 3986373 should be informed and given a brief report of the situation, the action being taken and what help, if any, is needed. C. Use of Telephones: During a fire, all personnel not actively concerned with the operation, shall not use the telephone or other communication systems. D. Fire Officer In Charge: Immediately an alarm has been sounded Burgan Fire Station to be informed and Fire Officer from Fire Team will proceed to the Single Point Mooring, or any other terminal from which the alarm originated and take charge of fire fighting operations. He will maintain close liaison with the Senior Marine Official present or any other Senior Officials, i.e. Ship's Master or Company’s Marine Operations Team Leader. E. Suspension of Loading: Operational staff should be prepared to initiate a controlled suspension of loading and be ready to close loading valves, disconnect hoses or loading arms, etc., on receipt of instructions.

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OPERATIONAL SAFETY REGULATIONS FOR EXPORT & MARINE FACILITIES

5.7 PROCEDURE IN CASE OF FIRE ON BOARD A VESSEL ALONGSIDE: In the event of any fire on board a Vessel alongside, loading operations, to the Vessel involved and to all other vessels on berths at the location involved should be suspended immediately until the hazard is over. Designated personnel should stand by to unberth or give any other assistance necessary. The Harbour Master should contact the Master or Deck Officer of the Vessel involved to ascertain what assistance can be given by way of equipment and personnel. Product Pump Stations, port, Crude Oil Control Center and LPG Storage Control room should be informed. A. Action To Be Taken By Ship's Personnel: Should a fire occur on a Vessel alongside, the ship's personnel should carry out their own pre-arranged fire -fighting procedures as if the Vessel was at sea. An alarm should be sounded by blasts on the Vessel’s siren or whistle of not less than 10 seconds duration and continued for at least one minute. •

The Harbour Master is to be informed of the circumstances immediately.

•

Ship engines shall be put on standby.

B. Tugs: In the case of a fire on a Vessel alongside or at risk from the fire, tugs shall take up their positions, awaiting orders to make fast to the Vessel’s fore and aft emergency fire wires, for taking up the tow and proceeding out to sea, to an agreed safe location. In the event of fire being extinguished, or the hazard to the Single Point Mooring, or any other terminal eliminated during the time taken to de-hose and release mooring lines, Senior Officers of the Export & Marine Operations Group and Fire Team present will decide if the removal operation is to be discontinued. In the event of a Vessel on fire being towed off, available Export & Marine Operations Group and Fire Team personnel will board the tugs and assist the Master should continuation of fire-fighting operations be necessary. 5.8 PREPARATION FOR MAJOR EMERGENCY: When notified to do so, personnel will carry out the Company Major Emergency Procedures regulations and Masters or Duty Officers of all Vessels alongside must be informed immediately (See Major Emergency Procedure - Chapter 14).

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KOC F&S Regulations

Action To Be Taken By Products Loading Control Room & Crude Oil Control Center: Upon receiving information of a fire from Single Point Mooring, or any other terminal the shift staff at Products Pump Station, port, Crude Oil Control Center will take immediate action to ensure that all valves supplying crude or other products to the location from which the alarm originated are closed. Staff should stand by to carry out further instructions and if a change of shift staff taken place, to fully inform the new shift of the situation and action so far taken. 5.9 NOMINATION OF DUTIES AT SPM OR ANY OTHER TERMINALS: The agreed nomination of duties for Export & Marine Operations Group personnel, which shall be undertaken in the event of fire on the Single Point Mooring or on the board a Vessel alongside, is as follows: A. Single Point Mooring Terminal (SPM): The Single point mooring terminal being an unmanned structure, special rules apply with regard to the nomination of duties in the event of fire. •

Harbour Master/ Pilot:

Take charge of overall operations until the arrival of a Fire Officer. However, if a tanker is moored at the SPM, the Pilot on board the Vessel will be in a better position to decide on what immediate action to take. Pilot therefore, will liaise closely with the Harbour Master advising him of his actions and measures taken to deal with the situation. •

Sea Island Controllers:

Deputy to the Pilot if the latter is mooring/unmooring a Vessel. Ensure that appropriate action has been taken to suspend loading operations at the Single Point Mooring terminal and inform Ahmadi Port Control & Products Pump Station / Crude Oil Control Center. To remain in control room unless required elsewhere. • Assistant Operator: Proceed to Sea Island Control Room and remain there until otherwise directed. •

Fitter: Report to "A" dolphin for dispatch to Single Point Mooring terminal when so directed.

•

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KOC F&S Regulations

a) Forman + Labourers: To report immediately to "A" dolphin and proceed in mooring boat to aid and assist in releasing and mooring at SPM and to fight pollution/fire if called on. b) Mooring Boat: Standby to proceed, as and where directed by Harbour Master. B. Sea Rescue Procedure: If it becomes necessary to give assistance to ships/craft/or aircraft in difficulties at sea, or to initiate search and rescue operations, the following procedure will be adopted:Manager Export & Marine Operations Group: or his deputy in his absence will immediately assume sole charge of all searches and rescue operations and will remain responsible until the successful completion of the operation. When "stand-down" is declared, he will advise the Heads of all participating Groups and organizations. He will make arrangement to dispatch a rescue party in a suitable craft complete with necessary stores, equipment, food and water. He will inform the following Heads of Departments: (i) (ii) (iii) (iv) (v) (vi)

Manager (Medical) Public Security Kuwait Coast Guard Kuwait Air Force State Fire Brigade (Marine Dept.) Manager (HSE)

He will maintain close liaison throughout the operation. Manager (Medical): Based on the information provided by the Manager Export & Marine Operations Group, the Manager (Medical) will decide to what extent medical personnel and equipment will be required and will then take action to implement the necessary arrangement for adequate medical services to be provided for the emergency operation. Manager (HSE): Should the Manager Export & Marine Operations request the use of helicopters for search and rescue operations, the Manager (HSE) will maintain contact and liaison with the Kuwait Air Force. 5.10

WORK UNDER WATER: A.

Employment of Qualified Divers No person should be hired as a diver unless he fulfils the following minimum criteria: 1.

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B.

OPERATIONAL SAFETY REGULATIONS FOR EXPORT & MARINE FACILITIES

2.

He has been judged as reliable, competent bearing strong sense of responsibility.

3.

Within the past 12 months, he has been certified medically fit for diving operations. A medical practitioner, who has specialization in underwater medicine and is approved by Company Medical Group, shall issue the medical certificate. His chest and bones should have been radiologically examined during past 12 months & the appropriate inoculations are in date.

4.

He, prior to taking up his assignment in the Company, has been satisfactorily tested under pressure to a minimum depth of 40m (approx.120 ft) in a compression chamber.

5.

He has a thorough knowledge of diving practice (including decompression, emergency procedures & first aid) for all water depths at which he may be required to work. If he is a trainee, a trained diver must supervise him during all diving operations & training.

Hiring of Qualified Deep Divers: The diving beyond 50 meters (approx. 156 ft) of water depth is considered deep. No person should be hired to work underwater as a Deep Diver unless he fulfils the criteria as hereunder, in addition to the requirements of 5.10 (A) above. 1.

He is below the age of 45 years.

2.

He has professionally carried a number of intermediate depth diving and he is well trained, competent and capable of deep diving to the required maximum depth. To continue his employment for deep diving operation, the diver should be kept up to date with at least one dive of maximum required depth during every 30 days. This may be with a stimulated wet or dry pressure chamber dive, or a normal dive in water.

3.

He is fully conversant with the diving system, diving apparatus & appliance in use and he has also successfully completed full time training in deep diving. Note: Past experience shows that an intensive training course of at least 4 weeks duration in required for converting an air diver to an Oxy-Helium diver.

C.

Competency for a Diving Supervisor: A competent person who has been appointed by the Company should supervise the diving operations. The Supervisor shall have thorough knowledge of diving operations and he is capable of taking charge on all aspects pertaining to any particular diving operation. He shall be an 'in-date' diver and must have enough experience for supervising the work in hand. He shall have full understanding of diving technique & decompression procedure in this regard. He should be

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capable of controlling compression chambers, recognizes the symptoms of decompression sickness including routine therapeutic treatment and first aid certification. D.

Competency Requirements For All Divers: All divers shall be fully conversant with diving system including practical diving experience as a professional. They should also have basic knowledge of therapeutic procedures and first aid treatment. The divers must be thoroughly conversant with all salient aspects of diving operations some of which are summarised hereunder:

E.

1.

Determining the working pressure including the relevant survey requirements for high-pressure cylinders as per manufacturer’s detail and material specification.

2.

The calculation of endurance of compressed air cylinders.

3.

The stripping, inspection, maintenance and re-assembly of SCUBA equipment.

4.

The operation & simple maintenance of low pressure & high-pressure compressors including its application to supply low pressure air for surface demand equipment and high pressure air for cylinder charging.

5.

The utility and meaning of single lifeline signals.

6.

The procedures for carrying out decompression in the water.

7.

The competent use of SCUBA in depths down to 40M (approx.120 ft) in open water. The term "competent" implies the ability to jump into the water wearing full equipment from a height not less than 1 M (3ft), conduct a search on the bottom in conditions of nil visibility, use a compass as an aid for navigation, share on SCUBA.

8.

Unit with a companion for 2 minutes (this entailing removal, clearance and replacement of the mouthpiece), remove the SCUBA, leave it on the bottom and perform a free ascent from shallow depths to the surface taking all necessary precautions to avoid the risk of burst lung & air embolism.

Additional Requirements For Helmet Divers - Standard Diving: Helmet divers should: 1.

Understand the theoretical applications of air supply volume requirements to the helmet and the dangers of inadequate ventilation.

2.

Be competent in the use of helmet diving equipment. The term "competent" implies the ability to walk to a ladder when properly dressed, remains on the ladder for 5 minutes without interruption of air

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supply, descends into the water, conducts a circular search in bottom conditions of nil visibility and in at least 0.6 M (approx. 2 ft.) of mud or soft silt, works on a platform or other suitable object that is at least 3 M (approx. 10 ft.) clear of the bottom. 3.

Be familiar with the care and maintenance of the equipment, particularly the functioning of the inlet and outlet valves.

4. Have used standard equipment to the maximum required depths, at least once every 30 days. F.

Additional Requirements For Divers Using SCUBA: (Semi-Closed Or Closed Circuit)

Divers using semi-closed circuit breathing equipment or closed circuit breathing equipment should:

G.

1.

Understand the principles and dangers involved in the operation of this equipment.

2.

Be able to recognize the signs & symptoms of oxygen deficiency and carbon dioxide poisoning, including its cause & remedial actions.

3.

Be familiar with causes and effects of oxygen deficiency in the counter lung.

4.

Understand the reasons for varying gas mixtures, its flow rates, different proportions and types of gasses.

5.

Be competent in the use of SCUBA including ability to strip, inspect, maintain, assemble and function test. To continue as a professional diver, he must use SCUBA at least once every 30 days to a depth of not less than 20 M (approx.65 ft).

6.

When using high-pressure oxygen, he should be aware of the potential fire hazards and the precautions measures for it’s handling and storage.

Additional Requirements for Surface Diving – Demand Breathing Apparatus: Special care is required due to possibility of prolonged dives.

H.

Out-Of Practice Qualified Diver: A qualified diver, who has not carried out any form of diving during the period of 12 months, must be carefully supervised until he conforms to the standard of proficiency as required for a Class III Diver. If the diver was previously holding a high status (i.e. Diver - Class I or II License) and demonstrates a high standard of ability and fitness during supervision period, he may regain his former status if the Supervisor feels that the diver has again reached the required standard.

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KOC F&S Regulations

I.

Diving Responsibilities: 1.

Rigging Supervisor: a. The Rigging Supervisor who undertakes a diving operation must ensure compliance with National Regulations and other recognized Diving Safety Regulations. b.

The Rigging Supervisor is responsible for nominating a competent Supervisor for every diving operations including arrangement of qualified divers to undertake the work.

c.

The Rigging Supervisor will give detail instructions to the nominated Supervisor ensuring that diving operations are conducted in a proper and safe manner. These instructions should be made available to the Client as well as to the National Authorities if it is requested. The Rigging Supervisor should prescribe the regulations, Diving Tables & Therapeutic Tables (to be used) and explain the principle involved. He should elaborate the diving technique to be followed alongwith adequate information about all the equipment to be used. The Rigging Supervisor should specify the arrangements for obtaining medical advice or assistance.

F&S Regulations Chapter 5

d.

The Rigging Supervisor will provide proper plant & equipment for the diving operation. He will ensure that such plant & equipment is tested in accordance with regulations & manufacturer's instructions applicable to it. He should develop a procedure for equipment preparation & maintenance relevant to the task in hand.

e.

The competent diving authority shall arrange the medical examination for divers as required by National Regulations.

f.

An up to date register detailing fitness tests & certification record s of individual diver shall be kept by Medical Group, while the diver continues in KOC employment. The diver or the concerned Medical Practitioner will have access to the individual record and the same should be handed to the diver when he leaves the Company employment.

g.

KOC must be in possession of the diver's current medical register before offering him employment in the company. If the diver fails

June 2004 Page 18

OPERATIONAL SAFETY REGULATIONS FOR EXPORT & MARINE FACILITIES

KOC F&S Regulations

to produce the current register, KOC may open a new medical register for the diver after confirming the required fitness certification prior to employment offer. The diver should apply for a fresh medical register when the existing one is full and further entry is required. h.

2.

In the event of an urgent diving operations before a medical practitioner trained in underwater medicine has examined the diver, the medical examination may be made and other medical practitioner duly approved by Company Medical Group can issue fitness certificate.

Supervisor: a. The Supervisor will be responsible for practical control over diving operations and should authorized to assume such responsibility. b.

The supervisor shall be responsible for the safety of those involved in the operation during entire period of diving and decompression.

c.

When operating from an offshore installation the Supervisor and his team will come under the overall authority of installation management. The similar criteria apply when diving operation is taken up from a ship.

d.

The supervisor shall ensure the availability of a competent team comprising divers & supporting personnel.

e.

The supervisor shall allocate the duties of the diving crew and, in particular, the procedure for operating 'stand-by' divers. While allocating the divers, the supervisor must be satisfied, that they posses not only a valid medical fitness certificate but also in his opinion they are "fit to dive" at the time operation starts.

f.

The supervisor shall consult other departments as appropriate to establish the requirements for diving operations, request-supporting facilities and ensure that no such activities are undertaken which might endanger the divers.

g.

The supervisor should ascertain that all concerned persons have been duly instructed about the diving plan and everybody understand his duty accordingly.

h.

The supervisor is responsible for the maintenance & preparation of diving plant, equipment and apparatus suitable for the operation including the availability of adequate gas mixtures for the diving and unforeseen emergency conditions.

i.

The supervisor is responsible for deciding on the commencement, suspension or cessation of diving operations.

j.

In the event of divers showing symptoms of decompression sickness, the supervisor is responsible for instituting therapeutic decompression in

F&S Regulations Chapter 5

June 2004 Page 19

KOC F&S Regulations

OPERATIONAL SAFETY REGULATIONS FOR EXPORT & MARINE FACILITIES accordance with the appropriate tables. If the symptoms are serious and injury is involved or circumstances are unusual, the supervisor should obtain immediate medical advice & assistance. A doctor from Medical Group will remain “on –call” when diving operations involve regular decompression or other activity with increased risk of divers illness or potential injury.

k.

Medical support does not relieve the supervisor of his responsibility from the pressure chamber & breathing mixture. If a doctor, (qualified & experienced in diving medicine) is present, he will determine the treatment and the supervisor must operate the chamber accordingly. If a doctor, (although not qualified in diving treatment) or a medical auxiliary is present, he will undertake all treatment of a medical nature, but the supervisor should retain responsibility for treatment by pressure or gas change. In such circumstances it is expected that the supervisor would be guided by medical advice as communicated by Medical Group.

I.

Should a doctor wish to enter a chamber under pressure for further treatment to the patient, the supervisor has to decide on the doctor's fitness for pressurized chamber. Whenever practicable, a doctor should be accompanied by a diver during compression & decompression. The supervisor is also responsible for the accurate recording of all dives (including therapeutic recompression & decompressions).

m.

The supervisor is responsible for the proper recording of the maintenance & testing of diving equipment in accordance with Company instructions in this regard.

n.

If the supervisor is incapacitated, his duties will be undertaken by a similar competent person available.

a.

The diver shall comply with the Company regulations other than those of recognized Diving Safety Rules in this regard. Any defect in the plant or equipment must be immediately reported to the Supervisor.

b.

It is the diver’s responsibility to keep himself fit for the work he undertakes. He should inform the supervisor if he has any doubt on his fitness or suitability, whether temporary or permanent for the work in hand. The diving operations are teamwork and a failure on any part may endanger others.

c.

The diver shall be responsible for his personnel equipment and must carry out the pre-dive preparation & test of his breathing apparatus. If he finds any fault in the equipment or considers it inadequate for the task, he must report it to the supervisor who should investigate & take corrective action.

F&S Regulations Chapter 5

June 2004 Page 20

3.

Divers:

KOC F&S Regulations

OPERATIONAL SAFETY REGULATIONS FOR EXPORT & MARINE FACILITIES

d.

Every diver shall report for medical examination as required by the Company regulations. The divers who wear dentures shall remove them prior to commence diving to avoid possible complications in the event of difficulty.

e.

All diving equipment or equipment for use under water by divers, or to support divers working under water, shall conform to the standards, laid down by any National Diving Regulations and those laid down by recognized codes of Safe Diving Practice.

f.

The principal Codes of Safe Diving Practice are CIRIA Underwater Engineering Group Principles of Safe Diving Practice. British Naval Diving Manual US Navy Diving Manual Siebe Gorman & Co. Ltd., Diving Manual and Instructions to Divers.

F&S Regulations Chapter 5

June 2004 Page 21

Fire & Safety Regulations

Kuwait Oil Company (K.S.C.) Chapter No. 6 June 2004

OPERATIONAL AREAS CHAPTER - 6 OPERATIONAL AREAS

Contents

Subject

6.1

TANK FARMS, MANIFOLDS, MINA CRUDE PUMP HOUSE ........

2

A. B. C. D.

3 3 3 4

6.2

6.3

6.5

Procedure in Case of Emergency…………………………………. Emergency at Tank Farms............................................ Emergency at Manifolds............................................................ Emergency at Mina Crude Pump House...................................

GATHERING CENTRES..........................................................

4

A. B. C. D. E. F.

5 6 6 6 7 7

Procedure in case of Emergency……………………………….. Fire Fighting Note For Guidance.......................................... Emergency at Pump Stations ..................................................... Emergency in Separator Area.................................................... Emergency in Tankage Area ......................................... Emergency in Condensate Recovery Unit .................................

DESALTER PLANTS................................................................ A. B. C. D.

6.4

Page

8

Duty of Desalter Plants...................................................... Fire Protection System....................................................... Safety Precautions............................................................. Procedure in Case of Emergency...........................................

8 9 9 10

BOOSTER STATIONS..............................................................

10

A. B. C. D. E. F.

Duty of Plants.................................................................. Gas Dehydration System..................................................... Liquid Dehydration System................................................. Fire Protection System....................................................... Safety Precautions............................................................ Procedure in case of Emergency...........................................

11 11 11 11 12 12

WATER INJECTIN……………………………………………………….

12

F&S Regulations Chapter 6

June 2004 Page 1

KOC F&S Regulations

OPERATIONAL AREAS

CHAPTER - 6 OPERATIONAL AREAS 6.1

TANK FARMS, MANIFOLDS, MINA CRUDE PUMP HOUSE: The area within the fenced perimeter of a Tank Farm, Manifolds or Pump Station is designated as a HAZARDOUS AREA and Company regulations concerning to such areas shall be strictly adhered to (Refer to Chapter – 1 for Hazardous Area Classification) No work (whether Maintenance, Modification or Upgradation etc.) is permitted in this area unless it is authorized under appropriate WORK PERMIT as stipulated in Chapter – 8 of this regulation. The entry to a Tank Farm, Manifold or Pump Station area is restricted to authorized personnel only. The person/s possessing a Company issued Gate PASS or Identity Card must deposit matches, lighters, any other source of ignition, non-intrinsically safe, and non-certified equipment (such as torch light, lamps, Camera, Mobile Phone etc.) to the Gate Controller prior to entering the premises. Entry to Manifold Areas is restricted to personnel authorized by Operating Team, whereas for others a separate permission from the Operating Team is required for obtaining the Gate keys, which shall be documented under signature of receiver. Entry of vehicles and mobile plant into these areas is prohibited unless authorized under appropriate WORK PERMIT (Hot Work Permit) after the vehicle / mobile has been duly inspected and approved by Transport Operation. In such cases the approved routes and working areas are to be specified on the WORK PERMIT. The Supervisors are required to have thorough knowledge of Plant Operating Procedures applicable to their work nature and have to ensure that all employees working under them are fully conversant with these procedures. The Supervisor has to ensure that any employee / worker carrying our the job under duly authorized WORK PERMIT are conversant with Fire & Safety Regulations applicable to their place of work.. It is the duty of each employee to report any mishap / accident / incident to his immediate Supervisor and the area Fire Station any of the following conditions:-

A Damaged or Defective Equipment.

-

Oil and / or Gas leaks.

-

Unauthorized use of non-intrinsically safe equipment.

-

Trespass by unauthorized persons, vehicles or equipment.

-

Any Damage or opening to security fences.

-

Suspected objects (Explosive Ordnance)

F&S Regulations Chapter 6

June 2004 Page 2

KOC F&S Regulations A.

OPERATIONAL AREAS

PROCEDURE IN CASE OF EMERGENCY: In all cases of fire inside Tank Farms, Crude Manifold, Gas Manifolds and Pump Station the following action shall be taken: (i)

Call Burgan Fire Station on Telephone Number 22222, 22221, 66669 or 3986373.

(ii)

Inform COCC Shift Supervisor on Telephone No. 66121, 67280 or 3989216.

(iii)

If possible try to fight the fire with extinguishers / fire fighting appliance available at site.

(iv)

Follow Emergency Procedures HAZARDOUS AREAS.

(v)

Liase with Marine & Export Operations Department.

&

Instructions,

posted

in

all

Fire Fighting Activity, Plant Shut - down System actuation and other immediate actions will be carried out under the direction of the senior most employees present at the site of incident, however the Fire Crew will take over fire fighting activity on arrival at the location. B.

C.

Emergency at Tank Farms: -

Inform COCC Shift Supervisor on Telephone No. 66121, 67280 or 3989216.

-

Standby to operate valves on other unaffected tanks as instructed by senior most personnel fro Export Operations available at site.

-

Take immediate action to operate Foam System.

-

Close all loading / filling tank valves on the affected and adjacent tanks and suspend all oil movement operations from those sources.

-

All entrances at the tank farms and routes to be cleared immediately (by Access Control personnel in liaison with Marine & Export Operations Group) and the gates to be opened on the arrival of the fire trucks.

-

Each Tank Farm is protected by means of Firewater pump and firewater ring main system. Also each tank farm is equipped with Foam System, comprising of Foam Pump, Foam supply ring main, foam proportioning unit, foam maker and foam pourers. Block valves are installed to facilitate the line isolation.

Emergency at Manifolds: 1.

Central Mixing Manifolds:

-

F&S Regulations Chapter 6

Carry out the emergency operating procedures as laid down in diagrammatic form, which is posted at the relevant control areas. June 2004 Page 3

KOC F&S Regulations

2.

OPERATIONAL AREAS

-

Inform COCC Shift Supervisor.

-

Liase with Production Operations Team (South) accordingly.

Filling Manifolds or Lines.

Re-route or suspend flow to isolate relevant manifold or line. Inform and liase with Production Operations Teams. 3.

4.

5.

Loading Manifolds or Gravity Lines:

-

Isolate the relevant gravity line or manifold at AHMADI and MINA and where appropriate operate intermediate valves.

-

Inform and liase with concerned teams.

Gas Manifolds:

-

Isolate all relevant lines.

-

Inform and liase with concerned teams..

Fire Protection Equipment at Manifolds:

Portable and mobile fire-fighting equipment will be used in the event of a manifold fire. D.

Emergency at Mina Crude Pump House: -

Suspend loading to the Single Point Mooring by closing all upstream valves of crude pump house.

-

Isolate all loading lines.

-

Isolate the gas & Kerosene supply to the CRUDE PUMP HOUSE AREA.

-

Inform and liase with KNPC Operations / PLCR.

The pump house is protected with the appropriate type of fire extinguishers and fire protection system. 6.2

GATHERING CENTRES: The area within the fenced perimeter of a Gathering Centre, Wellheads and all associated flowlines is designated as a HAZARDOUS AREA and Company regulations concerning to such areas shall be strictly adhered to (Refer to Chapter – 1 for Hazardous Area Classification). The entry to such areas is restricted to authorized personnel only. The person/s possessing a Company issued Gate PASS or Identity Card must deposit matches, lighters, any other source of ignition, non-intrinsically safe, and non-certified equipment at Shift

F&S Regulations Chapter 6

June 2004 Page 4

KOC F&S Regulations

OPERATIONAL AREAS

Operations Office prior to entering the plant. (Refer Section 3.4 of Chapter – 3 for Prohibited Items inside Hazardous Area) No work (whether Maintenance, Modification or Upgradation etc.) is permitted in this area unless it is authorized under appropriate WORK PERMIT as stipulated in Chapter – 8 of this regulation. Entry of vehicles and mobile plant into these areas is prohibited unless authorized under appropriate WORK PERMIT (Hot Work Permit) once the vehicle / mobile has been duly inspected and approved by Transport Operation. In such cases the approved routes and working areas are to be specified on the WORK PERMIT. Parking is prohibited in front of entrance gate, in the vicinity of firewater tank, firewater pump - suction line and other location of Gathering Centre, where it may cause obstruction to normal movement as well as access in emergency. The Shift Duty Operator is empowered to refuse access to vehicles or mobile plant even if covered by the Work Permits, if the entry would create a hazard. No temporary structures, including tents, could be erected even at a safe distance from the fencing of Gathering Centre, provided it has been approved in compliance to company procedure in this regard. The Supervisors are required to have thorough knowledge of Plant Operating Procedures applicable to their work nature and have to ensure that all employees working under them are fully conversant with these procedures. The Supervisor has to ensure that any employee / worker carrying our the job under duly authorized WORK PERMIT are conversant with Fire & Safety Regulations applicable to their place of work.. A.

PROCEDURE IN CASE OF EMERGENCY: In all cases of fire, notify as below: •

Call Burgan Fire Station and the respective area Fire Station through available means of communication.(Refer to Chapter – 3 on Fire Prevention & Control)

•

Call Shift Duty Controller of the respective zone. available, call another Shift Controller.

•

Try to fight the fire with the available extinguishers and fire fighting equipment.

•

Shut down the units as deemed under the circumstances.

•

Operate the fire pumps.

•

Open the gates of the gathering centre for safe evacuation and access of the Fire Tender.

If not immediately

Fire Fighting Activity, Plant Shut - down System actuation and other immediate actions will be carried out under the direction of the senior most employees F&S Regulations Chapter 6

June 2004 Page 5

KOC F&S Regulations

OPERATIONAL AREAS

present at the site of incident, however the Fire Crew will take over fire fighting activity on arrival at the location. B.

Fire-Fighting Note For Guidance:

C.

-

The initial attack on a fire will most likely be with available fire extinguisher and fire fighting equipment.

-

Electrical supplies should be isolated.

-

The fire pumps should be started and hose lines run out from the nearest hydrants.

-

Water spray or foam may be used but not applied at the same point, as the water spray will break down foam.

-

Water fog or spray can be used to protect personnel from radiated heat to enable an access to operate valves.

-

Detailed instructions on the use of fire-fighting equipment are given during routine fire training.

•

NEVER USE WATER IN CASE OF ELECTRICAL FIRE.

•

DO NOT USE DRY CHEMICAL POWDER ON THE FOAM OR WITH FOAM AT THE SAME TIME, ESPECIALLY ON A GROUND FIRE AS CHEMICAL POWDER WILL MAKE THE FOAM VANISH AND THE FIRE WILL RE-IGNITE.

Emergency at Pump Stations (Gathering Centres): In case of fire inside the Pump Stations, the pump must be shut down immediately and remain so until the fire is extinguished. Most of such fires can be extinguished by hand appliances.

D.

Emergency in Separator Area (Gathering Centres): Any fire in this area is likely to be of serious nature. In case of a small fire, the separators may be kept operating as the contents will tend to cool the vessels near the fire. If the separator relief valve opens with flames discharged from it just leave it and carry out a boundary cooling for the separator and the surroundings till the separator release the over pressure. If a carry over occurred on the separator with a fracture and a running fuel, cover the running fuel with foam after making a bund to contain fuel and carry out the boundary cooling by water spray on the separator to prevent any sudden vapour ignition.

F&S Regulations Chapter 6

June 2004 Page 6

KOC F&S Regulations

OPERATIONAL AREAS

In case of major fire, the incoming oil must be completely shut off, the transit pumps station shut down and the tank inlet valves closed. All other established / recommended operating procedures to be implemented to ensure plant safety. E.

Emergency in Tankage Area (Gathering Centres): In the case of a tank fire involving damage to the tank roof and leading to oil fire, all incoming lines as near as possible to the tank should be shut down. Follow the established procedure for the change over operation as per detail drawing indicating valve positions and the sequences of valve operation, displayed at each Gathering Centre Control Room. All staff should be familiar with this procedure. The change over operation will be carried out only on the instruction of a senior member from Production Operation Team available at site, in close co-ordination with Fire Officer from our Fire Team. All openings into tanks in the neighbourhood of tanks on fire should be closed down or protected by wet sacking or similar material. Should a fire on the top of a tank be of gas from a relief valve, the incoming line to the tank should be left open sufficiently to ensure a positive vapour pressure in the tanks. Such a fire may be extinguished by chemical dry powder or by smothering with wet sacks or similar material.

F.

Emergency in Condensate Recovery Unit (Gathering Centres): In the case of any type of fire, whether it be on the prime mover, vessel or compressor, the following action should be taken:a)

Shut down the unit, using the remote control.

b)

Shut make-up gas to obviate over-pressurizing the tanks and venting gas from the Varec Units.

c)

Shut main suction valve. Drop the second stage separator pressure if production rate is above 80,000 bbl/D.

d)

Carry out the procedures as mentioned in 6.2.

If the fire is on the Heat Exchangers (E101, etc.) isolate the crude oil coolant by routing direct to the transit line or to the tanks and close the isolating valves. This should be done immediately after action(a) above. For recommendations for Prevention and Control of Fire involving condensate, refer to Appendix 5 & 7. 6.3

DESALTER PLANTS: A.

Duty of Desalter Plants:

F&S Regulations Chapter 6

June 2004 Page 7

KOC F&S Regulations

OPERATIONAL AREAS

The function of the Desalter Plant is to remove salt water crude oil. The desalting process consists of two consecutive stages of dehydration and desalting. The wet crude stream, after removal of the free water in the separators/surge tanks is fed to the electrostatic coalescer type desalters (two stages in series) to remove the remaining water and salt content. The normal operating electrical voltage is between 16.5 KV to 40 KV. An established amount of demulsifying chemical agent is injected to the crude to aid in the separation of the emulsified water from the crude. Crude is also preheated to 140/160°F to reduce its viscosity and increase settling rate of water droplets in the desalters. Some amount of wash water, treated with oxygen scavenger, biocide, scale and corrosion inhibitor chemicals is also added and mixed with the crude by passing the stream through mixing valve prior entry to the desalter. The mixing valves serve to bring the lower salt brackish water into contact with the finely dispersed and highly brine water in the crude oil. The desalted crude from 2nd stage after cooling, flows to the dry crude tank. Effluent water from 1st stage desalter is sent to disposal pit outside Gathering Centre, after being treated in the Waste Water Conditioning Units. Waste water conditioning unit removes oil from the effluent streams down to a level of 10 ppm. B.

Fire Protection System: 1.

Existing Gathering Centre firewater ring main has been extended to encompass Desalter Plant. A separate fire pump suction connection (riser) is provided near Desalter Wash Water Tank. Portable extinguishers are posted at selected points throughout the plant.

2.

Remote and Local Emergency shutdown buttons are provided at Control Room & near each Desalter stage to facilitate individual train or total Desalter Plant shutdown.

3.

Existing Plant Emergency shutdown air switch/button located in Control Room, when operated will also initiate a complete Desalter Plant Shutdown.

4.

Appropriate fixed installation fire protection and fighting systems are provided for the wet tank. However, it must be noted that this system is not fully automatic as the water supply pressure in the ring main is manually controlled by the

F&S Regulations Chapter 6

June 2004 Page 8

KOC F&S Regulations

OPERATIONAL AREAS

Operator who is required to start the fire water pump when a genuine alarm is given.

C.

Safety Precautions: 1.

Whenever servicing Desalter vessels all primary circuit breakers should be locked out. It is the utmost importance that the electrical safety lockout procedure be followed.

2.

NEVER try to energize the Desalter unless it is 100% full of liquid. A vapour phase in the Desalter could explode if contacted by the high voltage electrodes. An internal safety float is provided to ground the electrodes, when the vessel is not entirely full, but this should not be fully relied upon.

3.

Effluent Water Conditioning Units: a)

Prevent accumulation of light residual crude in water tanks specially those with submergible pumps. The generation of static electricity normally takes place at the interface of dissimilar materials such as oil/water. The charged at the interfaces can initiate a static electricity hazard when they are mechanically separated by flow splashing or pump agitation. Potential hazards exist if the pump agitation. Potential hazard exist if the vapour/air mixture above the fluid is very high. Heavy crude oils are known to be non-static accumulators due to high conductivity effect, which counteract the accumulation of separated charges. However, note that charges can still accumulate:-

on insulated conductors.

-

in static accumulators (materials) flowing into the tank at high flowrates.

-

in mists and sprays when the air insulates the charged droplets.

If the installation is properly earthed and or bonded the possibility of electrostatic hazard is minimized. b).

F&S Regulations Chapter 6

Extra care should be taken when opening inspection covers of API/CPI/SPI separators/ floatation units due to toxic fumes concentration in these vessels... particularly in West Kuwait Gathering Centres where appreciable amount of H2S presence is known to exist.

June 2004 Page 9

KOC F&S Regulations 4.

D.

OPERATIONAL AREAS

Protective wear and safety rules governing handling of chemicals should be strictly followed as given in chapter 7.

Procedure In Case of Emergency: In all cases of fire, notify as below: 1.

Call Burgan Fire Station at telephone 22222 / 22221 / 66669 or 3986373.

2.

Call Duty Shift Controller for each respective area. If not immediately available, call another Shift Controller (of other area). Then extinguish fire with the appropriate and full fire fighting equipment available. When fire is discovered in any of the below units of the Desalter Plant, follow the procedure given in 6.2. a.

Wet Separators

b.

Wet Tanks

c.

Feed Pumps

d.

Indirect Fired Heaters

e.

Desalter Vessels

f.

Effluent Water Conditioning Unit.

Water jets should not be used to fight electric fires around Desalter transformers. Fire fighting actions in above areas necessitate complete shutting down of the Desalter Plant and isolation of electric circuit breakers at remote Station. This decision will have to be made in the light of the situation existing at the time and action must be taken without hazard to the plant, personnel and the equipment concerned if possible. Fire fighting, shutdown and other immediate actions will be under the direction of the Senior Employee present until the arrival of a Fire Officer from the Fire and Safety Department. Fire around Desalter Plant also necessitates complete isolation of dry crude outlet to Main Dry Tanks. 6.4

BOOSTER STATIONS: The Operating Procedures Manual for Booster Station provides detailed description of the operating principles, safety facilities, fire detection and fire protection systems.

F&S Regulations Chapter 6

June 2004 Page 10

KOC F&S Regulations

A.

OPERATIONAL AREAS

Duty of Plants: The Booster Stations receives gas from the Gathering Centres through the piping network. Natural gasoline (condensate) is extracted from the gas by a process of compression, cooling and condensation. The condensate recovered is transmitted to the LPG Plant by a separate pipeline. The gas dehydration plant at the Booster Stations removes water vapour and any residual traces of hydrocarbons from the "wet" gas.

B.

Gas Dehydration System: Process natural gas is usually saturated with water vapour. In order to prevent gas transmission problems, such as gas hydrate plugging or pipeline corrosion, most of the water vapour has to be removed from the gas. Removal of water vapour from gas is known as gas dehydration, and is accomplished by absorption with tri-ethylene glycol (T.T.G.). Process Description: Wet gas enters a vertical bubble- trays contactors tower (absorber). The wet gas passes upward through the bubble caps, intimately contacting the dry glycol during it's counter-current flow downward through the absorber. The dehydrated gas flows from top of the absorber tower and the water-rich glycol is discharged from the bottom to a flash drum and then by a process of "flashing" and filtering the absorbed water and small amounts of hydrocarbon are removed from the glycol before it is recirculated to the absorber column again to complete the cycle.

C.

Liquid Dehydration System: Liquid dehydration unit remove water from the condensate to a point of 50 ppm wt, where it will not cause corrosion to the liquid pipeline going to LPG plant. Process Description: In order to dry the condensate, it has to pass through the basket strainer (remove line trash, sand particles) and coalescer filter (remove free water) and charcoal filter (remove heavy oils) and finally the adsorber (remove the remaining dissolved water).

D.

Fire Protection System: The plant areas are provided with a fire main grid system with associated fire hydrants, fire pump suction connection, water storage tanks and water pumps driven by diesel engines. Boxes containing hoses and nozzles are located at selected points.

F&S Regulations Chapter 6

June 2004 Page 11

KOC F&S Regulations

OPERATIONAL AREAS

Special fire protection system is provided for the gas turbine and compressor housings. These consist of gas detectors to detect leaks of flammable gas which can create an explosion or fire hazard, and bimetallic type heat detectors capable of responding to the temperature of the surrounding air. In the event of fire condition being sensed, the system causes the turbine to be immediately shut down and CO2 discharged into each compartment. Wheeled and hand carried fire extinguishers are located at selected points throughout the plant. Fusible type heat sensors are strategically located around the process pumps, pumps for the liquid dehydration units and the compressors. In the event of a fire condition being sensed, the system causes an audible alarm to be activated and an automatic shutdown sequence is initiated in the associated fire zone. Fire "panic" buttons are placed in strategic locations to facilitate the “manual" activation of the fire alarm and automatic shutdown systems. E.

Safety Precautions: When any maintenance work is carried out outside a turbine housing, the switch on the lockout unit must be turned to lockout position. In the event of a discharge of carbon dioxide (CO2), due to fire, fire equipment test, or a malfunction, the compartment must not be entered by any person who is not wearing breathing apparatus until it has been adequately ventilated. Any person rendered unconscious by CO2 must be rescued as quickly as possible and revived immediately with artificial respiration.

F.

Procedure In Case of Emergency: In all cases of fire, notify as below: 1.

Call Burgan Fire Station by telephone - 22222 / 22221 / 66669 or 3986373.

2.

Call Duty Shift Controller for each respective zone. If not immediately available, call another Shift Controller.

3.

Extinguish the fire if possible with the full fire fighting equipment available. Shut down units as deemed necessary under the circumstances.

4.

Fire fighting, shut down and other immediate actions will be under the direction of the senior employee present until the arrival of a Fire Officer of the Fire and Safety Department. 6.5

WATER INJECTION: During the primary phase the reservoir produces out of its own energy. In view of increasing the ultimate recovery, the natural reservoir energy needs to be augmented

F&S Regulations Chapter 6

June 2004 Page 12

KOC F&S Regulations

OPERATIONAL AREAS

before it reaches the economic limit. At the end of the primary phase the reservoir will require energy input in order to produce, which is done by injecting water or gas. Water Injection is a pressure maintenance process where water is injected in the reservoir through injector wells to supplement reservoir energy and to improve oil-producing characteristics before it reaches economic productive limit. It is essential that the water (effluent water or aquifer water) be treated thoroughly before it is injected, so that it is free from bacteria, oxygen, suspended particles and other detrimental elements, which can cause wellbore and formation damage and cause corrosion of piping & equipments. The major factors that will affect the injected water are: • Suspended solids content & size distribution. • Dissolved oxygen • Bacteria • Scale Formation The general treatments given to the injection water are: • Sterilization • Filtering • De-oxygenation • Chemical conditioning A number of chemicals are required to be added to the injection water in order to prevent loss of injectivity caused by corrosion or, biological growth and to prevent scaling & corrosion to piping / equipment involved in the processing / injection system. Throughout the life of a water injection system, water quality monitoring is of extreme importance Water quality monitoring is carried out for the reasons as hereunder: a) b) c) d) 6.5.1

To ensure no off – specification water is injected. To optimise chemical consumption rates and maintain controlled dosing To allow evaluation of equipment guarantees. To aid troubleshooting

Chemical Hazard in Water Injection Plant: Several chemical are handled in Water Injection Plant and highest care shall be taken in storage and handling of hazardous chemicals with precautionary measure as hereunder: a)

Any chemical shall be handled as if toxic. Chemical handling shall occur away from flames or heat.

b)

Protective clothing, gloves and goggles shall be worn when handling chemical. A safety shower and eyewash station shall be available in ready to use condition in chemical handling area.

F&S Regulations Chapter 6

June 2004 Page 13

KOC F&S Regulations c)

OPERATIONAL AREAS

The required warning sign in both Arabic & English shall be strategically located in the chemical handling, injection and storage areas (Refer Chapter-7 for further information on Chemical hazard)

F&S Regulations Chapter 6

June 2004 Page 14

Kuwait Oil Company (K.S.C.)

Chapter No. 7 June 2004

Contents 7.1

Fire & Safety Regulations

HANDLING & STORAGE OF MATERIALS, HAZRDOUS CHEMICALS, EXPLOSIVES & RADIO ACTIVE SUBSTANCES

Subject

Page

HANDLING & STORAGE OF MATERIALS & CHEMICALS .................. A. Classification of Materials............................................................ 1. Explosive Materials........................................................... 2. Dangerous Substances......................................................... 3. Safe Materials..................................................................

4 4 4 4 5

B. C.

5 5 6 7 7

D.

E. F.

Cold Stores.............................................................................. Materials Handling ................................................................... 1. Mechanical Handling........................................................ 2. Manual Handling............................................................. 3. Chemicals Handling .......................................................... Storage of Hazardous Chemicals & Compressed Gases........................

7 7 8 8 8 8

1. Labelling...................................................................... 2. Overhead Storage........................................................... 3. Inter - reacting Chemical.................................................... 4. Compressed Gas Cylinders................................................ Flammable & Toxic Chemicals.................................................... Hazardous Chemicals Utilization in Operation / Process Plant.............

8 G. H.

Disposal Pit or Open Roof Tanks....................................................... First Aid Provision ....................................................................

8 8

7.2

HAZRDOUS & TOXIC GASES, VAPOURS, FUMES & DUSTS............... A. Handling of Corrosive or Hazardous Liquids........................................ B. Handling of Acids or Alkaline Solutions ................................. C. Handling of Corrosion Inhibitors or Acidization Additives.........................

9 9 9 10

7.3

SAFETY PRECAUTIONS WITH OTHER HAZRDOUS CHEMICALS...........................

10

A. B. C. D.

10 11 11 11

MSDS for Hazardous Chemicals ....................................................... Handling Drums Of Sulphuric Acid............................................ Handling Wet, Dry or Reactive Chemicals........................................... Storage Facility for Oils & Lubricants ......................................................

F&S Regulations Chapter 7

June 2004 Page 1

KOC F&S Regulations

E. F.

HANDLING & STORAGE OF MATERIALS, HAZRDOUS CHEMICALS, EXPLOSIVES & RADIO ACTIVE SUBSTANCES

Storage of Paints........................................................................ Handling of Mercury..............................................................................

11 11

7.4

EXPLOSIVE MATERIALS ......................................................................... General............................................................................................

11 11

7.5

EXPLOSIVE STORAGE FACILTY ............................................................ 12 A. Fire Prevention ............................................................................ 12 B. Responsibilities of Authorized Person for Explosive Storage Facility..........13 C. Planning for Explosive Storage Facility................................................ 13 D. Safety Precaution in Explosive Storage ................................................ 14 E. Detonator Storage...................................................................... 15 F. Inspection of Explosive Stores...................................................... 16 G. Safe Disposal Of Explosives & Detonators...........……………………. 16

7.6

TRANSPORTATION OF EXPLOSIVES.................................................... A. Portable Containers for Transportation of Explosives.............................. B. Transportation of Explosives through Vehicles......................................... C. Action in case of Vehicle Breakdown / Accident.....................................

16 16 16 18

7.7

SAFE USE OF EXPLOSIVE MATREIALS ............................................... A. Authorization.......................................................................... B. Precautions in Handling & Preparing Explosives...................................

18 18

C. D.

18 20

Misfires................................................................................. Precautions Against Extraneous Electricity During Electric Shot Firing..........................................................

21

7.8

EXPLOSIVE ORDNANCE DISPOSAL (EOD)....................................... A. The Danger............................................................................ B. Precautionary Measures ............................................. C. EOD Certification..................................................................... D. Action On Finding Suspected Unexploded Ordnance.......................... . E. Oil Lakes............................................................................... F. Minefields & Previously Mined Areas......................................... G. Off-Shore EOD Clearances...........................................................

21 21 22 22 23 23 23 23

7.9

RADIOACTIVE MATERIALS & IONIZING RADIATIONS......…...... A. General..................................................................................

24 24

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B. C. D. E.

HANDLING & STORAGE OF MATERIALS, HAZRDOUS CHEMICALS, EXPLOSIVES & RADIO ACTIVE SUBSTANCES

Sealed Sources.......................................................................... Unsealed Radiation Source...................... .................................... Emergency Action..................................................................... Medical..................................................................................

25 25 26 26

7.10

HOUSE KEEPING............................................................................ A. Scrap..................................................................................... B. Laboratories Waste Disposal......................................................... C. Pyrophoric Scale...................................................................... D. Nails In Scrap Wood.................................................................. E. Cleaning Tools & Machinery ...................................................

27 27 27 28 29 29

7.11

STACKING..................................................................................... A. De-Stacking of Materials................................................... B. Segregation of Materials....................................................

29 29 30

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CHAPTER - 7 HANDLING & STORAGE OF MATERIALS, HAZRDOUS CHEMICALS, EXPLOSIVES & RADIO ACTIVE SUBSTANCES, HOUSEKEEPING 7.1

HANDLING & STORAGE OF MATERIALS & HAZRDOUS CHEMICALS: A.

Classification of Materials: Material can be divided into different categories and each category requires to be handled according to its inherent characteristics. The different: categories of materials are: 1. Explosive Materials 2. Dangerous substances 3. Safe Materials 1.

Explosive Materials: These materials are classified as dangerous substances and require specialized knowledge related to loading, transporting, unloading, handling, storage and its usage.

2.

Dangerous Substances: These materials include hazardous substances, which may be flammable, corrosive or toxic in nature. These materials are supplied with complete details available in Material Safety Data Sheet (MSDS). Each consignment, package or containers carrying such materials must enclose MSDS, which shall have following information about the hazardous substance: i. Product Identification ii. Hazardous Ingredients and its TLV iii. Physical & Chemical Properties iv. Fire & Explosion Hazard v. Health Hazard & Emergency Treatment vi. Reactivity Data & Neutralizing Procedure vii. Spillage Hazard & Containment Procedure. viii. Safety Precaution & Emergency Procedure ix. First Aid & Medical Treatment. x. Any Special Instruction The container, package or drum containing such materials shall be clearly marked and labelled depicting following essential information conforming to UN Classification of Hazardous Material: a. Name of the Substance (Trade & Chemical Name)

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b. c. d. e. f. g. h.

Dangerous Concentration Safety Precautions Relevant Hazard Symbol Health Hazard & Emergency Treatment Fire & Explosion Hazard Date of Expiry The name & address of Manufacturer or Supplier.

The Standard Safety Symbol or Alert Sign must cover at least one-tenth surface area of the label and have a minimum area of 1cm2.(Refer Appendix- 4 for INDUSTRIAL SAFETY SIGNS). Examples of materials, which come within these categories, are: a. Flammable: These include low flash materials such as aviation spirit, gasoline, methylated spirit, volatile solvents, paints, varnishes and compressed gases such as acetylene, propane and butane.

3.

B.

b.

Corrosive: These include Acids, alkalis and corrosion inhibitors used in the plant and laboratories.

c.

Toxic: These include chlorine, ammonia, H2S, various inhibitors, demulsifiers and other toxic substances used in plant & laboratories. Plastic & Foam materials exposed to fire may emit toxic vapours. In case of leakage from a container having toxic material, the work in the affected area shall be immediately stopped and the concerned Supervisor as well as the area Fire Station will be immediately notified. The Supervisor shall take remedial action in consultation with the area HSE Team. l. The work will not be resumed until the area is declared safe after proper atmospheric monitoring. The required personal protective equipment will be used while monitoring, investigating or fixing the source of toxic release.

Safe Materials: These include materials such as foodstuffs, nonflammable items and equipment, which do not pose a fire or toxic hazard. However it may still cause injury to personnel if handled incorrectly.

Cold Stores: Cold Stores used for the preservation of food, ice, and other perishable materials should be thoroughly searched for the presence of any human being inside prior to locking it from outside. A caution notice in this regard must be prominently posted on each side of cold storage doors.

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If the cold storage doors cannot be opened from the inside, a suitable warning device, operable from inside as well as a safety bell must be installed to alert in case of accidental entrapment. C.

Materials Handling: Many accidents are caused in the course of material handling. The safety aspects during the material handling operations such as loading, unloading, transportation, stacking and stores arrangement, must be duly considered. It is the responsibility of Supervisors to ensure that personnel engaged in material handling & lifting operations have been adequately trained for the job. The material must be inspected for abnormality such as jagged edges, burrs, rough or slippery surfaces prior to initiate handling. The materials, which are greasy, wet, slippery or dirty, shall be wiped dry before handling. The workers must have adequate training in safety aspects of slinging, lifting and carrying of load including bulk handling of materials. The material must be stacked and handled taking all safety precautions. The required personal protective equipment such as hand gloves, safety boots, helmet and coverall must be worn while handling the materials. The mechanical devices such as handcarts, dollies, wheelbarrows and forklift should be used for bulk handling of materials. The workers must take necessary precaution while removing steel straps or wires from a packaged material. The site supervisor or the foreman should have sound judgement about the size and weight of the material for safe handling with appropriate appliance. While using lifting appliance, the workers must not stand directly under a suspended load and must keep away from wires or ropes under strain. The workers must be conversant with the safety in lifting & rigging operation as well as have familiarity with the banksman signals for such operations. The necessary care shall be taken while handling containers, which carry fragile items such as glassware or crockery etc. 1. Mechanical Handling: The appropriate lifting devices shall be utilized for heavy items and bulk handling of materials. The drums shall be stacked on a pallet and similarly loose items should be secured inside a container before lifting or shifting with mechanical device. The materials inside a fragile container shall be protected with a substantially strong outer covering. Extreme precaution shall be applied while handling hazardous, explosive, toxic or flammable materials. The materials should always be stacked considering accessibility, critical requirement and other stock management criteria. The aisles in the storage area should be wide enough to permit safe access and manoeuvring of mechanical handling devices. The Ramps shall be utilized to transport materials over obstacles that cannot be removed.

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HANDLING & STORAGE OF MATERIALS, HAZRDOUS CHEMICALS, EXPLOSIVES & RADIO ACTIVE SUBSTANCES The weight shall be verified prior to lifting the materials. The ground realities such as any spillage, prevalent danger or obstruction in the material handling area should be properly assessed. The load must be properly secured prior to raising or lowering it to prevent any accidental fall. The practical measures must also be taken to prevent a load coming into direct contact with other objects. The items must not be stacked loosed on a platform, grating or pallet being hoisted. The load shall not be left suspended or remain unattended in the absence of lifting appliance supervisor.

D.

2.

Manual Handling: The materials shall be stored on elevated shelves through appropriate use of ladders, stools or a lifting device as safe & convenient in the situation. The objects having sharp edges, pointed needles or barbed wires shall be stacked safely keeping sharp edges or needles facing towards inner side of the rack. A proper support and side restraint shall be provided between the rows for stacking drums, pipes, cartons and boxes etc. The objects susceptible to roll down or slip must be secured preferably through chock hitch. Some of the materials are packed inside a bag and such bags should be cross-tied with opening interlocked towards the inner pile. The containers such as bins shall be securely anchored to prevent overturning.

3.

Chemicals Handling: The risk associated with the handling of chemicals must be thoroughly assessed by the Chemist and Occupational Hygienist and accordingly protective measures are applied against the potential hazard. The Material Safety Data Sheet (MSDS) for each chemical must be available at worksite. The information on properties of chemicals, its harmful effects, associated hazards; recommended personal protective equipments and first aid instruction are included in MSDS. (Refer to Chapter – 4 for First Aid Information) The workers involved in handling of such harmful chemicals must use the required protective equipment and shall be trained in first aid procedures against the accidental exposure.

Storage of Hazardous Chemicals & Compressed Gases: The chemicals should always be stored separately away from other materials and access to chemical storage must be limited to authorized persons only. The manufacturer's instructions and MSDS must be followed for storage of chemicals. The following safety requirement must be observed. 1. Labelling: All containers, carboys, jerrycans, bottles containing chemicals must be clearly and distinctively labelled detailing product identity,

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2.

3.

4.

HANDLING & STORAGE OF MATERIALS, HAZRDOUS CHEMICALS, EXPLOSIVES & RADIO ACTIVE SUBSTANCES associated hazard, statutory warning, manufacturer’s name and date of expiry etc. Overhead Storage Facility: The glass containers carrying hazardous chemicals shall not be stored on elevated shelves or platform, rather such containers should be stored on a non-reactive skid at floor level for easier access and retrieval Inter-reacting Chemicals: Such chemicals must not be stored near each other inside the storage area and /or laboratory shelves. It is not safe to store acids near alkalis. Compressed Gas Cylinders: The compressed gas cylinders shall be kept securely stacked inside the purpose built rack in up-right position to prevent accidental fall. These cylinders must be kept away from heat or open flame. The protective cap should always be kept in place while transporting the cylinders. The cylinder should be transported through suitable trolley and under no circumstances a cylinder shall be dragged.

E.

Flammable & Toxic Chemicals: Such chemicals shall be stored inside a wellventilated room or fume hood, far way from any source of ignition. Moreover such chemicals should be stored at floor level in comparatively cold place without exposure to direct sunlight. An extraction duct closer to floor level must be provided in the store, where flammable vapours heavier than air might be released from such chemicals. A minimum quantity of such chemicals should be kept inside the laboratory. The containers for such chemicals must be examined for any physical damage prior to storage. It is not at all advisable to keep the containers 100% filled with such chemicals rather at least 5% by volume should be empty considering thermal expansion.

F.

Hazardous Chemicals Utilization in Operation / Process Plant: The workers handling hazardous chemicals in operational area or process plant must be aware with risks involved and its protection measure. The pipelines carrying hazardous or corrosive chemicals should be suitably protected from any probable damage due to traffic accident. The drip tray should be placed to contain small leakage. The chemicals collected in drip tray shall be neutralized or otherwise made safe, before discharging into plant drainage system. A warning notice shall be posted at prominent location in the chemical handling to alert the personnel there of.

G.

Disposal Pits or Open Roof Tank: The disposal pit or open roof tank containing harmful chemicals must be protected with fence of at least 3 ft height to prevent unauthorized entry, or accidental splash. The gangways attached to such pits or tanks must have handrails and toe-board as further protection.

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H.

7.2

HANDLING & STORAGE OF MATERIALS, HAZRDOUS CHEMICALS, EXPLOSIVES & RADIO ACTIVE SUBSTANCES

First Aid Provision: The Emergency Shower and Eye Wash Station must be provided in chemical handling area. The persons working in that area must be familiar with operation and utility of this emergency facility. (Refer to Chapter – 4 for First Aid Information). In case of chemical contamination, the affected part of the body (e.g. eyes, face) must be thoroughly flushed with clean water and eyes should be washed with Eyewash solution. The medical assistance should be obtained as necessary. Any exposure to toxic chemicals through inhalation, skin absorption or ingestion shall require immediate medical attention and specialized medical treatment at hospital.

HAZRDOUS & TOXIC LIQUIDS, GASES, VAPOURS, FUMES & DUSTS: In a work area where toxic gases, vapours, dangerous fumes or dusts are likely to be found, the adequate ventilation shall be provided or alternatively exhaust appliances will be provided as near as possible to the source of origin. Special care shall be taken in the area prone to hydrogen sulphide hazard. A warning notice shall be posted at prominent location in the plant area to alert the personnel over there. (Refer to Appendix 14 for further information on H2S hazard.) A.

Handling Corrosive or Hazardous Liquids: A catch pits or bund walls shall be provided to contain the accidental spillage of a corrosive or hazardous liquid. Extreme care shall be taken handling, neutralizing or diluting acids or alkalis against splashing or exposure to heat emission. When corrosive or hazardous liquids or liquefied gases are being off-loaded from a vessel or tanker, warning notices shall be prominently displayed on either side of the discharging point. The road tanker shall be completely stationary and engine switched off while discharging such hazardous liquid. The electrical cables and conduits shall be adequately protected against corrosion caused due to probable exposure in areas, where corrosive liquid gases or fumes are likely to be found. The isolation valves or cock valves, which are not in regular use may cease to operate and should be subjected to periodic function test particularly for the line carrying corrosive liquid.

B.

Handling Acids or Alkaline Solutions: Acid carboys shall be stored in single tiers and never stacked one above other. The carboys should be lifted through the handle but not by the neck. The spilled acid shall be neutralized and washed away with water from a safe distance. The drums or carboys of acid shall never be decanted by applying pressure to the container. However the decantation may be done by applicable safe methods such as pouring, syphoning, hand pump or through discharge valve.

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A galvanized iron drums shall not be used for the storage or transportation of acid or alkaline solutions. The containers already open or contents partly used should not be transported. The acid resistant gloves and other protective equipment must be used while handling such containers. The overhead tanks containing acid or caustic solution shall be equipped with overflow pipe routed to a safe disposal or drain system where any spillage can be neutralised as per instruction in MSDS. The areas below the tank shall be barricaded to prevent unintended ingress. The tank or vessel containing such acids or alkaline solutions must have a vent line open to the safe location. (Refer to Appendix – 1 on Chemical Safety Data) C.

Handling Corrosion Inhibitors or Acidization Additives: All safety precautions against health hazard, reactivity, corrosive effect or fire & explosion risks shall be taken as stipulated in operating procedure & guidelines for such inhibitors and additives. It is always advisable to handle corrosion inhibitors or acidization additives in closed loop systems and as far as possible the use of open containers be avoided. The suitable personal protective equipment such as face shield, gloves and apron shall while handling these inhibitors or additives. In case of contamination to eyes, skin, or any other part of the body by such chemicals, the following first aid action is to be immediately taken: 1. Eyes: Wash out thoroughly with the Eyewash Solution and refer to hospital for further medical assistance. 2. Skin: Wash off thoroughly with soap & clean water and refer to hospital for further medical advice. 3. Clothing: Remove any contaminated clothing and follow the first aid procedure as mentioned above for affected skin. Clothing (including rubber boots) which has been in contact with the inhibitor or additive, shall be thoroughly cleaned with soap & water prior to using it.

7.3

SAFETY PRECAUTIONS FOR OTHER HAZARDOUS CHEMICALS: A. Material Safety Data Sheet (MSDS) for Hazardous Chemicals: Within the scope of this regulation, it is not feasible to provide a detail account of safety precautions for all the hazardous chemicals that may be handled in the operational area. However it is strongly recommended to refer the MSDS, manufacturer’s instruction or Health & Environment Team for any specific detail about the hazardous chemicals prior to its use. B.

Handling Drums of Sulphuric Acid: The drums containing Sulphuric Acid must not be exposed to direct sunlight. The key used for opening the drums should be fitted with protective guard plates. Moreover the drums containing

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C.

D.

HANDLING & STORAGE OF MATERIALS, HAZRDOUS CHEMICALS, EXPLOSIVES & RADIO ACTIVE SUBSTANCES

acids should not be transported until the bungs have been slackened to relieve excess pressure and then re-tightened. A suitable tipping device should be used for decanting drums and carboys. Blowing with compressed air to remove the contents of a drum or carboys is forbidden. Handling Wet, Dry or Reactive Chemicals: Wet, dry & reactive chemicals shall be segregated and stacked away from each other to prevent susceptible reactions in case of leakage or undesirable mixing. The defective container shall be removed from stock and the contents transferred to a proper container. Storage Facility for Oils & Lubricants: Oils & Lubricants shall be stored inside a designated storage area away from main stores. The storage area shall have proper drainage provision to contain the spillage. The store shall be well ventilated to dispose off any flammable vapours (released from Oil / Lubricants) heavier than air, which may settle at the floor level. Forced draft ventilation shall be installed if required to expel such obnoxious vapours. The electrical fittings and appliances installed in the store shall be suitable as per hazardous area classification.

7.4

E.

Storage of Paints: The paints shall be stored in designated places located at a safe distance from other storage facilities. The storage area will have suitable protection against the fire hazard. The stacks and bins shall be of reasonable size and placed with adequate spacing between them to reduce the risk of fire spread from one to another. Extreme care shall be exercised while handling Aluminium Powder to control potential fire & explosion hazard. The workers handling the paints shall be equipped with required personal protective equipment.

F.

Handling of Mercury: The safe handling of mercury requires good housekeeping, adequate ventilation, protective equipment and personal hygiene to avoid any poisonous effect. Any spilled mercury shall be picked up immediately through the use of a vacuum system. The areas where mercury is handled shall be equipped with temperature control system to prevent mercury vaporization at high temperature.

EXPLOSIVE MATERIALS: General: The explosives are used in Exploration, Drilling, Well Surveillance and Construction activities in the oil industry operations. The explosive materials will be handled by a duly authorised & specialist contractors engaged by the company for such operations. The contractor is responsible for purchase, storage, transportation and safe operations involving explosive materials; however KOC has the discretion to oversee the contractors’ safety performance and provision in this regard.

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HANDLING & STORAGE OF MATERIALS, HAZRDOUS CHEMICALS, EXPLOSIVES & RADIO ACTIVE SUBSTANCES

A comprehensive safety precaution & security arrangement shall be maintained at the site of explosive storage. Any unaccounted loss or missing of explosive items must be immediately notified to KOC as well as to the police for necessary investigation. It is essential to keep an updated stock position of explosive materials with the purpose to control receipt & dispatch of explosive items for work related activities. The storage facility shall be equipped with temperature & humidity control system to prevent early deterioration of explosives. . The offshore - installations, rigs, platforms and supply vessels have pyrotechnic items such as emergency signalling flares or rockets. These pyrotechnics must be stored separately away from other explosive materials. The signalling flares or rockets have a limited shelf life and any expired pyrotechnic should be returned to shore terminal for safe disposal. The operation of Tools such as Nail Guns or Rivet Guns, which utilises explosive cartridges, shall be strictly controlled in compliance to safety regulation in this regard. (Refer to Appendix 17 for safety information on this issue) 7.5.

EXPLOSIVES - STORAGE FACILITY: A.

Fire Prevention: 1. An explosive storage facility or premises enclosed by security fence is classified as "Hazardous Area" and accordingly safety regulations for such areas shall be strictly adhered. 2.

All safety precautions shall be taken to prevent any accidental fire or explosion in the storage. The entry a naked flame or any source of ignition is strictly probited into the explosive stores.

3.

The use of spark potential tools (e.g. steel hammer or drill machines etc.) and non-intrinsically safe equipment (e.g. electric lamps, torches, lighters, camera & battery operated appliances) inside explosive or detonator storage is forbidden.

4.

The storage facility shall be kept free from any grit or sand accumulation and a high standard of housekeeping shall be maintained.

5.

The storage facility shall be equipped with suitable & adequate fire extinguishers, heat & flame detectors as approved by Fire Team.

6.

Warning Notice, written in Arabic & English, indicating the prevalent Danger, Smoking Prohibition and Authorized Entry etc. shall be posted in the storage area with due approval from Fire Team. The notices shall be prominently posted at the location as hereunder: a. Fence & Enclosure Gates. b. Alongside the Security Fence. c. Storage Entrance & Containers

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B.

C.

HANDLING & STORAGE OF MATERIALS, HAZRDOUS CHEMICALS, EXPLOSIVES & RADIO ACTIVE SUBSTANCES

Responsibilities of Authorised Person for Explosives - Storage Facility: 1. A competent & authorized person shall be made Incharge for each magazine or explosive store. The concerned asset owner shall provide an updated list of such authorised & competent persons to the Fire Team. 2.

The Storage Incharge must personally supervise the receipt & dispatch of explosives, any maintenance work or activity inside the enclosed fence boundary. On no account this responsibility is to be delegated to another person without prior approval from the company.

3.

He will maintain a register detailing stock record and other relevant information as per format provided in Appendix - 17 of this regulation. The register shall be available with the explosive certificate holder and must provide the details as mentioned hereunder: a. Types & Quantity of explosives received. b. Details of explosive items issued and its purpose. c. Quantity of explosives used in each operation. d. Details of any misfired shots. e. Quantity of explosives returned to the stores. f. Details of explosive disposal & destruction of old stock.

4.

Copies of explosives certificates / permits and updated stock registers shall be forwarded to Fire Team.

5.

The record of pyrotechnics should be maintained in a separate register.

6.

He will ensure monthly inspection of explosive stocks with due involvement of civil defence authority.

Planning for Explosive Storage Facility: 1. Licensing, and Construction of Explosive Storage: A licence or permission, detailing type & quantity of explosive materials allowed for each storage facility or container, must be obtained from Civil Defence Authority prior to storing such explosives. The proposed storage location shall be approved by Fire Team in due consultation with Civil Defence Authority, who may advise on norms & standards for damage control issues in this regard. 2.

3.

F&S Regulations Chapter 7

Location: As a minimum requirement, magazines for permanent storage facility must be located at a distance of at least 100 meters from any other building, habitation, or place liable to be visited by company employees or public. Further more the proposed location must also be 270 meters away from thin traffic routes, 400 meters away from a heavy traffic zones and 500 meters away from a directional radio transmitters of 250 Watts. Security: a. Strict security shall be maintained in the explosive storage facility.

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b.

c.

d. D.

Explosive Storage Facility shall be enclosed by suitable fencing located at a distance of at least 15m from the building or containers. In addition to the main entrance, an emergency exit away from the main gate shall be provided to the fenced enclosure. The gate should be strong enough and secured with heavy duty locking arrangement. The asset owner and Civil Defence Authority shall keep a set of keys for each magazine or explosive storage. These keys shall be accessible round the clock and Police as well as KOC Fire Team shall be aware of its availability with the concerned officials. In the event of theft from explosive storage, the matter must be immediately reported to the police & respective area fire station.

Safety Precautions in Explosive Storage: 1. A licence / permit must be obtained from the Civil Defence Authority for each explosive storage facility. 2. The Storage facility shall be suitable from safety & security viewpoints type for the types & quantity explosives stored. 3. A person prior to entering such storage facility must take required precautionary measures such as wearing proper type of footwear (e.g. long neck rubber boots) to prevent contamination with grit. The boots with exposed metallic studs, nails or protectors should not be worn in explosive store. 4. The stores must be kept dry, scrupulously clean and free from grit materials. The sweepings dust from explosives store should be treated as explosives and remove for safe disposal as per procedure. 5. The boxes containing explosive materials shall be stacked on wooden shelves, which should be placed at least 15cm (6") way from the walls to facilitate air circulation. 6. The explosive material shall be stacked in issued ensuring the old items should go first to prevent deterioration or expiry of materials. 7. Any explosive, which not properly packed, shall not be allowed inside the storage. It is advisable to keep small quantity of explosives (maximum weight 5 kg) packed inside a stout wooden box with strong locking device. 8. The packing for explosive material or cartridge wrapping shall not be opened inside the storage facility. While issuing partial quantity from a complete package, the packing will be opened on suitable wooden bench kept outside the magazine storage facility. 2. A package already opened for issuing explosive materials should be kept separately from sealed packages. A package once opened should be used

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10.

11.

12.

13.

14.

HANDLING & STORAGE OF MATERIALS, HAZRDOUS CHEMICALS, EXPLOSIVES & RADIO ACTIVE SUBSTANCES with as little delay as possible. If the explosive material has not been utilized on the day it was issued, then original packaging should be folded over and the case properly closed to ensure maximum protection. The unutilised quantity of explosive materials shall be returned to the store under proper record in a stock register. The explosives returned should be inspected for safety prior to accepting in the stores. The open end of a detonating cord should be capped to prevent explosive falling from it on the floor. A floor contaminated with explosives is a potential source of explosion in case of frictional impact. The explosive should not be exposed to a damp environment, heat or direct sunlight. Any naked flame, spark or source of ignition shall not be permitted within 25m (80 ft) from explosive storage facility. Prior to authorizing any maintenance or modification work inside the explosive storage facility, all explosive materials will be removed to a safe & secure place and the store is properly cleaned. During such works the use of any spark generating tools is not permitted in the stores. It is advisable to use damp cloths in conjunction with the tools. The safety rules as applicable explosives storage facility shall be prominently displayed near the entrance (Refer to Appendix –17 for further detail).

E.

Detonator Storage: 1. Under no circumstances shall detonators be stored with any other class of explosives. 2. All detonators must be kept in a separated store as equipped as that of other explosive storage. Moreover any loose detonator shall not be allowed inside the storage facility. 3. Any electrical detonator shall be stored or removed from its primary packing or container taking all precautions against induced current hazards. 4. The safety rules as applicable to detonators storage shall be prominently displayed at the entrance of stores (Refer to Appendix-17 for further detail)

F.

Inspection Of Explosive Stores: 1. Team Leader - Stores Operations or his authorized representative should inspect each explosive storage facility at least every three months to ensure the compliance of relevant regulations in this regard. 2. Any explosive, that shows sign of deterioration, must be removed carefully & disposed off in accordance with manufacturers’ instructions & safe disposal procedure.

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3.

G.

7.6.

HANDLING & STORAGE OF MATERIALS, HAZRDOUS CHEMICALS, EXPLOSIVES & RADIO ACTIVE SUBSTANCES The date, time and observations of such inspections shall be recorded in the register at explosive stores under endorsement of Inspecting Authority.

Safe Disposal Of Explosives & Detonators: 1. Any explosive material, which is exuding liquid, should not be touched and manufacturer as well as disposal squad should be consulted for proper disposal as per procedure. The assistance from Fire Team and Civil Defence Authority shall be sought in this regard. . 2. Any explosive material (whether unused or returned), contaminated with water, dirt or any other element should be examined to ensure separation of detonators and blasting explosives. 3. Any unutilised or loose explosive material should be properly wrapped and safely stored to prevent contamination. 4. The unutilised or loose explosive materials should be consumed or disposed off within one week of its return to the storage. In any event contaminated material should not be allowed to accumulate over a long period.

TRANSPORTATION OF EXPLOSIVES: A. Portable Containers for Transportation of Explosives: 1. The minimum required quantity of explosives should be transported to the site in its original packing or inside a custom made containers. 2. It is strictly prohibited to transport any blasting explosives and detonators in the same container. The detonators should be carried separately. 3. The portable container alongwith its tight fitting cover must be of nonferrous material (such as leather, moulded rubber, plastics, wood or reinforced canvas) and strong enough for the purpose. However other attachment such as lock, rivets etc. shall be made brass. B.

Transportation of Explosives through Vehicles: The vehicles for transportation of explosive materials must be mechanically perfect in compliance with the Company regulations (Refer Chapter-17 for vehicles & Mobile Plant) and in addition the following mandatory requirements also be fulfilled: a. The driver of the vehicle shall be accompanied with one attendant, who has been trained in handling of explosive materials. No extra person is permitted to travel in a vehicle carrying explosive materials. b. It is strictly prohibited to carry lighter, matches or any source of ignitions in such vehicles. Moreover smoking is not permitted while transporting explosive materials.

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c.

d.

e.

f. g.

h.

i.

k.

l.

C.

The suitable and adequate number of fire extinguishers approved by Fire Team must be available in the vehicle for convenient access in case of emergency need. The vehicle shall have non-ferrous surface (such as wooden or tarpaulin covered surface) for placing boxes or cases of explosive materials. The boxes shall be adequately secured to prevent any movement or shock during transportation. The explosive items and detonators must be transported separately and shall not be carried in the same vehicle. No explosive should be carried in the driver's cab. No loose explosive shall be transported except appropriately packed in suitable receptacles. Extreme care must be taken while loading or unloading explosives. The boxes must not be dropped, jolted or dragged. The engine must be stopped during loading / unloading of explosives. The vehicle should have sufficient fuel for the journey prior to loading of explosive materials, as the refuelling is not permitted during transportation period. It is also not allowed to carry any flammable liquid / gas or other combustible materials such as oil soaked rags in the vehicle. As far as possible the vehicle carrying explosive materials should complete its journey without any break. However if journey break or halt cannot be avoided, it should be ensured that the vehicle is not parked in a built up area, near occupied buildings, or in proximity to overhead cables. The vehicle should carry two battery operated hand lamps of intrinsically safe design, which are duly approved by Fire Team. One of the hand lamps is fitted with red glass whereas the other one has clear glass for use after dark in event of a stoppage. The vehicle shall have clear sign posted to alert for explosive transportation. Additionally red flags should be hoisted at front and rear end of the vehicle. The vehicle should be escorted by police while travelling on highways and public road.

ACTION IN CASE OF VEHICLE BREAK DOWN / ACCIDENT: 1. No Fire Involved: a. One person either drive or his attendant will stay with the vehicle whereas other will inform police about the incident, location and the contents of the vehicle. b. The battery operated hand lamps (clear glass: at front end; & red glass; at rear end) will be fitted in the vehicle to illuminate in the dark alerting oncoming traffic. .

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c. 2.

7.7.

The respective area Fire Station and the Sponsoring Team shall be notified.

Fire Involved: a. Attempt to extinguish the fire and if possible remove small packages containing explosives or detonators to a safe place. b. One person either driver or his attendant will be stationed ahead of vehicle whereas the other will be at rear side to alert the oncoming traffic from both directions. c. Inform police or respective area fire station and request the passer-by to raise the alarm. d. Notify the sponsoring team as soon as possible.

SAFE USE OF EXPLOSIVE MATERIALS: A. Authorization: 1. Explosives shall not be handled, loaded or disposed except by a competent person / shot-firer, who is trained and experienced in all aspects concerning safe use of explosive materials. 2. The appointed shot firer shall be a competent person authorized to carry out jobs involving explosive materials. 3. The competent person shall be authorized in writing by the contractor responsible for the job in due agreement with sponsoring team. An up to date lists of all authorised personnel shall be forwarded to Fire Team also. B.

Precautions in Handling & Preparing Explosives: 1. The required quantity of explosive materials shall be withdrawn from the store or a temporary magazine for immediate work to be under taken. Any unused explosive must be returned to the store / magazine without delay. 2. It is strictly prohibited to carry lighter, matches or any source of ignition within 30 meters (100ft) from a box containing explosive materials or loose explosives. Smoking is also not allowed in such areas. 3. Any operation involving a source of ignition shall not be carried out at the site except by the authorized person designated for such jobs. 4. The danger zone must be clearly demarcated and shall remain so until the worksite supervisor / shot firer provides clearance for resuming normal operation after completion of jobs involving explosives. No person except those directly concerned with operational requirement shall be allowed within the danger zone until completion of the job and the area is declared safe by the worksite supervisor / shot firer.

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KOC F&S Regulations

5.

6.

7.

8. 9.

10.

11.

12.

13.

14.

F&S Regulations Chapter 7

HANDLING & STORAGE OF MATERIALS, HAZRDOUS CHEMICALS, EXPLOSIVES & RADIO ACTIVE SUBSTANCES The access to danger zone shall be controlled by guards / watchmen carrying red flags, whistles or bull horns posted at a safe distance to warn the people approaching the area. The work involving use of explosives must not be carried out under conditions of thunder, lightning, heavy rain, sand storms, high winds and inclement weather conditions. Only purpose made and duly approved electrical apparatus / equipment maintained in good working order shall be used to test circuits and fire the electrical shots. In the event of a misfire the correct procedures as outlined in paragraph (7.7.C) shall be followed. No excessive force should be used in the charging process or while inserting cartridges into a shot hole. It is to be ensured that the holes drilled to receive charges should be sufficiently large allowing easy passage to the cartridges. No ferrous element is to be inserted into a hole after a cartridge has been lowered into it. In case of tamping need, a wooden rod without any ferrous part, is to be used. The paper or plastics wrapping on explosive cartridge is provided to prevent ingress of any dirt, grit or rock and therefore should not be removed to facilitate charging of the shot hole. Any safety fuse shall be cut neatly and inserted safely into a detonator after blowing off any sawdust It is strictly prohibited to attempt removal of an obstruction within a detonator using a pin, piece of wire or similar implement. The fuse shall be secured to the detonator by nipping the latter with special pliers (crimpier) provided for the purpose. Extra care must be taken to prevent detonator end (containing mercury fulminate) being knocked, dented, pinched, or otherwise damaged during operations. To avoid the risk of a misfire, detonators should be inserted for at least two thirds of their length into the charge and when the later has a paper wrapping, the paper should be closed around the fuse or igniting wire and tied with twine. Electric detonators should be buried in explosives. The shot-firer must always keep the means to initiate the shot i.e. exploder handle, matches, in his possession until he is ready to fire the shot. All connections should be made by the shot-firer himself. The exploder handle and the shot firing leads are not to be attached to the exploder but just before the shot is to be fired & it must be removed immediately after use. Prior to a shot being fired, the shot-firer must ensure that: a) Clear and adequate warning has been given. b) All approaches in to the danger zone are properly controlled by guards with red flags. c) he and others have taken adequate cover.

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KOC F&S Regulations

15.

16.

17.

18.

HANDLING & STORAGE OF MATERIALS, HAZRDOUS CHEMICALS, EXPLOSIVES & RADIO ACTIVE SUBSTANCES When firing preliminary chambering or springing shots, at least 30 minutes must be allowed to elapse from the firing of a shot to the charging of the next shot in the same hole. The hole should be swabbed out with water if fuse firing is employed. The number of shots to be fired must be counted. If the number of explosions is less than the number of charges set for firing, precautions for misfires as per paragraph (7.7.C) must be adopted. A maximum of ten charges should be prepared and loaded for any single firing operation. On successful completion of all shots the shot-firer shall check the site of the explosion / debris to ensure the absence of cartridges / detonators or part of cartridges from misfired charges or cut offs. The all-clear signal shall be given by the Shot-firer only after confirming the area is free from explosive and fumes. Prior to authorization of any work involving use of explosive, the contractors shall provide a copy of field operating procedure to the sponsoring department and Fire Team. The field operating procedure shall clearly lay down safety precautions and steps for preparation & arming of explosives including action to be taken in the event of misfires.

C.

Misfires: 1. The shot-firer must be fully aware of the procedures to be adopted in the event of misfire. Each misfire must be treated carefully taking all precautions relevant to particular explosive and firing method being used. In the event of a misfire, all concerned persons at worksite must be warned of the incident and normal operation shall not to be resumed until clearance is given by competent person.. 2. If a shot misfires or does not explode at the intended time, no person should approach it until it is exploded or time interval (not less than 30 minutes for firing by safety fuse or not less than 10 minutes for firing by electricity) has elapsed. A charge, which has misfired, must not be unrammed, bored or picked out. 3. If it is essential to bore a hole near a misfired charge, extra care must be taken to prevent ignition of the unexploded charge. 4. After a second shot has been fired near the misfired charge, a thorough search for the unexploded charge must be made by the shot-firer before declaring the area safe for normal operations. All misfires record detailing circumstances, location and time of occurrence shall be maintained in the format as shown in - Appendix 17.

D.

Precautions Against Extraneous Electricity During Electric Shot Firing: Unless suitably protected, electric detonators may be accidentally fire due to electrical energy entering the shot-firing circuit from an outside source. Such source may be lightening, static electricity, stray current, galvanic electricity and

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HANDLING & STORAGE OF MATERIALS, HAZRDOUS CHEMICALS, EXPLOSIVES & RADIO ACTIVE SUBSTANCES

electromagnetic radiations from radar, radio, television, helicopters, etc. The Shot-firer or site supervisor for blasting operations must be familiar with such hazards prevalent in the area. Main Safeguards Include: 1. The electric detonators should be kept properly shielded inside packing or containers. 2. Suspension of any blasting operation during inclement weather conditions. (such as lightening, thunder, sand storms etc.). 3. Care to earth circuits, machinery and persons before making final connections to detonators. There might be static build-up resulting from weather conditions. 4. Handheld radio and portable transmitter are not to be taken within a range of 150 meters from site of operation. 5. All radio communication and equipment within a range of 150 meters will be switched off prior to any firing operations involving electrical detonators. 6. Any electrical detonator will not be stored or permitted within a range of 150 meters from a radio communication transmitter. 7.8

EXPLOSIVE ORDNANCE DISPOSAL (EOD): A.

The Danger: The Company faced a big challenge to clear a large amount of unexploded ordnances, which were found in all areas of Kuwait after liberation from the Iraqi invasion. Post liberation a programme of explosive ordnance disposal (EOD) has been led by Kuwait Ministry Of Defence (KMOD) to clear areas from dangerous unexploded ordnance. Although great progress has been achieved in respect of EOD clearances, however complete assurance for all operational areas within KOC premises cannot be guaranteed due to various factors such as - type of clearance utilised, variety of problems encountered at different situations including sand shifting, excavation works and oil lakes formed. It is to realize that EOD problem may diminish ultimately but will remain a potential threat for foreseeable period of time. Keeping such considerations in view, protective measures and safety aspects have been formulated, which must be implemented by all employees belonging to company or contractors. The adherence to such measures will reduce the risk pertaining to explosive ordnances.

B.

Precautionary Measures: The following precautionary measures shall be ensured to reduce the risk from unexploded ordnances: 1. No work shall be carried out till the area has been declared free from explosive ordnances. The clearance certificate for any area within the company remises shall be issued by Safety Team.

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KOC F&S Regulations

2. 3.

4. C.

The workers prior to deployment in the field must be made aware of prevalent danger due to possible presence of explosive device. The workers shall attend EOD familiarization programme conducted by Safety Team on request from sponsoring department. (Refer to Appendix 17 for EOD familiarization request). It is mandatory for company & contractors employees to attend EOD awareness session. It is advisable not to take any short cut while travelling in the oil field areas; rather only designated route should be followed.

EOD Certification: 1. It is not permitted to visit or carry out any work in the area, which has not been declared free from explosive device and EOD certificate has been issued for the same. 2. EOD certification shall be issued on printed format detailing the extent of clearance duly marked in the map or site plan. The verbal clearance in this regard will not be acceptable. 3. The clearance certificate issued by EOD contractors shall be approved by Kuwait Ministry Of Defence alongwith endorsement for quality assurance. These certificates shall be issued through Safety Team to the sponsoring department under a covering letter in this regard. 4. If the proposed work area has been previously issued EOD clearance and the sponsoring department has its record, then the work may proceed without any further certification. 5. In case of any doubt regarding EOD certification for the proposed work site, it is strongly recommended to seek clearance from safety Team by submitting standard request as per procedure. (Refer Appendix for EOD request)

D.

Action On Finding Suspected Unexploded Ordnance: Even in EOD certified areas, there is possibility of explosive presence due to shifting sand, excavations etc. The following precautionary measures shall be kept in view to minimize the dangers associated with discovery of suspected explosive ordnance: 1. Do not touch the suspected ordnance. 2. Stop the work immediately, clear the area and inform all personnel of the prevalent danger. 3. Note down the location of unexploded ordnance or suspected object, and place visible markers at a safe distance. 4. Inform respective area Fire Station immediately: •

Through Radio on KOC Fire Channel OR

•

F&S Regulations Chapter 7

By Telephone: Burgan Fire Station = 22221 / 22222 / 66669, 3986373.

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KOC F&S Regulations

WK Fire Station= 20348, 20320, 20278, 20276 NK Fire Station = 23100, 23111 and 3985197 •

7.9

Request EOD assistance.

E.

Oil Lakes: A major portion of oil lakes have been drained and the oil containment recovered, leaving layers of oil contaminated sludge, which solidifies over a period of time and makes it possible to access the oil lake areas. During fire fighting operations on burning oil wells, some of the oil lakes were covered with gatch to allow access. It is to be noted that remaining oil lakes are still a potential hazard and presence of explosive ordnance cannot be ruled out. Under no circumstances an attempt be made to enter or excavate within an Oil Lake. A formal EOD request should be submitted to Safety Team prior to any access or work in such areas.

F.

Minefields and Previously Mined Areas: Mines were laid around some oil field areas. Minefields and previously mined areas are normally fenced with barbed wire and danger sign posted. Most of these minefields have been already cleared however the possibility mines presence cannot be completely ruled out. Under no circumstances shall any attempt be made to enter or work within minefield or previously mined areas. In case of any doubt for location of minefield, Safety Team should be contacted for confirmation, advice and assistance. A formal EOD request should be submitted to Safety Team prior to any access or work in such areas.

G.

Off-Shore EOD Clearance: The Company has by and large completed EOD clearance in offshore locations under its jurisdiction. However due to various factors such as sand / slit coverage, or wind / tidal action etc. the presence of explosive device cannot be completely ruled out. Prior to any non-routine offshore activities such as, construction or dredging, a formal request for EOD clearance shall be made to Safety Team. (Refer Appendix – 17 for EOD Clearance request)

RADIO ACTIVE MATERIALS & IONIZATION HAZARD: A. General: There are various industrial activities such as non-destructive testing, detections system and parameters monitoring which involve use of radioactive source. It is well known that exposure to high doses of radiation may result in physical injury, malignancies, genetic effects and even death. The emissions are not detected by any of the human senses and the "dose" from successive exposures is cumulative. Damage can be caused in one of two ways, by general exposure of the body to radiation, or by ingesting or inhaling radioactive particles, which can then affect internal organs of the body.

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HANDLING & STORAGE OF MATERIALS, HAZRDOUS CHEMICALS, EXPLOSIVES & RADIO ACTIVE SUBSTANCES

It is therefore extremely important to control the use of radioactive source, based on three prevalent principals: • Use of radioactive source must be justified confirming a superior result in comparison to any other technique. • Exposure to radioactive source must be kept as low as achievable. • Dose limits for an individual must not be exceeded. In the state of Kuwait, Radiation Protection Department under Ministry of Public Health is the ultimate authority, which monitors the radioactivity standards applied in KOC. However in KOC the responsibility for all such matters rests "Radiation Protection Safety Officer" (RPSO) Inspection & Corrosion Team. The Company RPSO must be consulted on all matters related to radiography and he / she will advise on the appropriate safety procedures. [Refer to Appendix - 11 & Radiation Protection Manual issued by Standards Team in this regard]. Any radioactive substances brought for company requirement must be reported and registered with consent of RPSO prior to its arrival. A weekly statement of all radiography works duly logged by worksite supervisor and a monthly returns detailing Radiation Source Movement must be presented to Inspection & Corrosion Team. All reasonable steps must be taken to minimise the exposure of workers involved in radiography work. In any event the permissible maximum dose for each category of worker must not be exceeded. In all radiography activities, radiation dose meter and source retrieval equipment must be kept available for immediate use. These instruments must be under the control of a competent person approved by RPSO. The instrument must be functional tested and should have been calibrated within the last six months. The area where radiography activities is to be carried out must be barricaded and warning notice prominently posted (DO NOT ENTER – RADIOGRAPHY IN PROGRESS) incorporating the international radiation trefoil symbol at distance consistent with the defined "Supervised" area (Refer Radiation Protection Manual). The persons involved in radiography works must be qualified & certified for such jobs. All classified workers will wear a personal dose meter and complete the records as required by RPSO. The radioactive sources must be stored inside leak proof containers under locking arrangement and the storage are duly marked with radiation trefoil alongwith warning notice prominently posted at the entrance. The radioactive source shall be carried in purpose made containers, sufficiently shielded and robust for the required duty. The vehicle transporting such containers shall be appropriately marked displaying telephone number for contact in case of emergency. The storage facility and mobile containers will be kept fully operational and checked for leak testing after every 26 months or as required by RPSO.

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KOC F&S Regulations

HANDLING & STORAGE OF MATERIALS, HAZRDOUS CHEMICALS, EXPLOSIVES & RADIO ACTIVE SUBSTANCES

The carriage of radioactive sources by helicopter must conform to the requirements of ICAO Regulations, governing the transportation of hazardous materials by air. Similarly the carriage of radioactive source by sea must conform to International Maritime Organisation (IMO) rules in this regard.. B.

Sealed Sources: All sealed radioactive sources must be securely stored under lock & key and dose rates at the nearest point open to the access must not exceed that for an "Uncontrolled Area". (Refer to Radiation Protection Manual). A Visual or audible warning signals must be given whenever a sealed radiation source is being energised. The work involved in handling radioactive source must wear the suitable protective equipment such as rubber gloves, tongs, face shield etc. The radioactive source must not be handled with the bare hand.

C.

Unsealed Radiation Source: The work involving unsealed radioactive substances, carry potential hazard due to exposure by inhalation, ingestion or contamination in addition to the external radiation hazard. A procedure must be developed for such works dictating the control of activities within the "Supervised" or "Controlled" area. Moreover normal dose meter, radiation contamination monitors must be used to control any spread of contamination and also for checking workers into and out of the controlled areas. The suitable personal protective equipment like disposable overalls, gloves, goggles and respirator as required for the job must be worn. The work area shall have a hand washing facilities at the exit point. Any food will not be allowed and also eating, drinking & smoking is not permitted in a radiography-controlled area. The protective clothing and any other items which is contaminated must be sealed in suitable bags marked with radiation warning and safely disposed as instructed by RPSO. Emergency Action: The radioactive source is stored in container, which is two tiers sealed, pressure tested and normally present little hazard if the container is intact. However(i) In the event of source container accidentally broken, the following emergency action shall be taken: a. Clear all personnel from the immediate vicinity to a safe area and post warning notices. b. Do not touch the source and inform the concerned teams (i.e. respective area - Fire Station, HSE Team, Inspection & Corrosion Team) for necessary assistance. The services of professionals shall be sought to decontaminate the area and safe retrieval of the radioactive source. c. If possible, cover the exposed source with a tarpaulin, or plastic bucket to prevent dust being windblown. d. Do not wash down until decontamination personnel arrive.

D.

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KOC F&S Regulations

HANDLING & STORAGE OF MATERIALS, HAZRDOUS CHEMICALS, EXPLOSIVES & RADIO ACTIVE SUBSTANCES

(ii)

If fire occurs in the source storage area and it is not possible to extinguish the source, the following action will be taken, if the source container is damaged: a. Remove, if possible, the source from the fire area. If it is not possible, spray water to keep the source cool and prevent melting of the container shield. Such operations should be carried behind a protective cover to provide shielding from radiation. Keep at least 3 meters away from the container. b. When the fire is extinguished, leave the source at its location, post warning notices and seek expert advice.

(iii)

In case a radioactive source container is missing, the following action will be taken: (a) Begin an immediate search using whatever radiation detecting equipment is available. (b) If the source is not found within one hour, inform the police, the competent person, and notify the Ministry of Health. If a vehicle containing a source is missing, the police and the competent person must be informed immediately.

The most important action in all emergency cases mentioned above part (5) is to inform the Radiation Protection Dept., Ministry of Health before taking any actions. E.

7.10

Medical: Any classified worker must be medically examined including required blood test s before commencing employment for work involving radioactive source. Further medical examinations must be carried out at intervals of not more that 12 months. A new medical examination is necessary in case of exposure or suspected exposure to excessive radiation dose. The radiation dose record for all classified workers must be kept up to date & radiation dose relating to previous employment shall be also maintained in the individual’s record. The classified work may request medical department for a transfer record pertaining to radiation dose, when the individual leaves employment. In case of radioactive source leakage, all persons exposed or suspected exposed must be medically examined. The person exposed / suspected exposed to excessive radiation dose must report to Medical Department for thorough examination.

HOUSE KEEPING: All floorings, step ladders, stair cases, passages, gangways, and doors shall be properly maintained keeping free from any obstruction or potential trip hazard. The storage area or yard shall have adequate access for safe passage of mobile equipment (such as Forklift, Crane, Truck etc.) supposed to be deployed in the area.

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KOC F&S Regulations

HANDLING & STORAGE OF MATERIALS, HAZRDOUS CHEMICALS, EXPLOSIVES & RADIO ACTIVE SUBSTANCES

Any combustible materials (such as straw, wood shavings, woollen fibres, paper & plastic cardboards) used for packing purposes, shall be removed in suitable waste bins fitted with spring lids. These materials, if no longer needed, shall be removed for safe disposal. Any exposed or protruded nails from a scrap wood or timber shall be removed, or beaten flat before it is stacked or disposed off. Any spillage of chemicals or other liquid shall be appropriately neutralized, cleaned and disposed as per procedure. A.

Scrap: Scrap material generated due to work nature should not be allowed to accumulate on workbench, table or on the floors in the vicinity. It shall be regularly collected and placed in salvage bins or other receptacles for safe disposal. Any scrap material belonging to flammable or combustible category should be removed and disposed safely without delay.

B.

Laboratories Waste Disposal: 1. Waste Chemicals: Small quantities of acids or water miscible chemicals must be adequately and safely diluted before disposing in the laboratory drain. However the excess quantities must be neutralized and covered with sand for safe disposal. The area shall be washed with plenty of water after contaminated sand removal. 2. Waste Solvents / Samples: The solvent (if small quantity) may evaporate and the vapours should be allowed to escape through the fume hoods. However the large quantities of solvents must be safely drained in a chemicals disposal pit, which shall be periodically emptied by a vacuum tanker for disposal in the company-approved facility. The waste content of a disposable bottle must be emptied in the receptacle connected with chemicals disposal pit and the empty bottle shall be dumped in the waste bin. 3. Solid Chemicals: Any solid chemical waste, which is neither toxic nor hazardous, should be placed in the laboratory trash bin and disposed to the approved facility. However the disposal of materials, which are dangerous or may become dangerous if mixed with other item, must be handled as per manufacturer’s instruction and disposed off to the company approved facility. 4. Biological Waste: Biological wastes such as discarded bacterial count slides must be disposed off immediately after checking / tests. The glassware & other equipment containing microorganisms must be labelled as Biohazard and shall be sterilized or autoclaved before reutilization. Under no circumstances infectious material be consigned to inter departmental mails or messenger services. 5. Damaged Glassware: Any broken, chipped, cracked or damaged glassware shall not be used and should be discarded in the laboratory

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KOC F&S Regulations

6.

7.

8.

7.11

HANDLING & STORAGE OF MATERIALS, HAZRDOUS CHEMICALS, EXPLOSIVES & RADIO ACTIVE SUBSTANCES cans. Any sharp or broken edge, which do not hinder usage should be fire polished if necessary. The broken glass pieces should be removed from floors or workbench with the aid of a broom or brush but never with bare hands. Oily Rags & Refuse: Oily rags and refuse should be placed in a metal container with close fitting covers. These containers shall be emptied and contents properly disposed off on daily basis. Needles, Syringed, Sharp Edged Items: The waste needles, disposal syringes or sharp edged instruments should never be discarded in such a manner, which may cause harm to service workers. Cotton Waste: Any combustible materials such as cotton waste, oil soaked rags should always be deposited in a metallic receptacle with tight fitting lid.

C.

Pyrophoric Scale: The pipes, valves or fittings; which have been used for crude oil, unrefined distillate or gas and may contain pyrophoric Ferrous Sulphide scale; must not be placed in a salvage bin until those (pipes / valves / fittings) have been thoroughly cleaned & rendered safe. These lines, valves or fittings should be thoroughly washed and kept wet before opening or exposing to air. The open end should be immediately plugged with mud until blank flanges can be fitted. The spool piece no longer required should be plugged and removed to a safe area as quickly as possible. Subsequently the pipe interior should be thoroughly wet or filled with water and the pyrophoric scale removed should be buried immediately. Similar precautions should be adopted with all fittings removed from such pipes. While dismantling a pipeline, which has carried sour crude oil or gas, it is to be taken care that not more than one break is made at a time to avoid a through draught of air and possible explosion.

D.

Nails In Scrap Wood: The wood removed from packing, cases, shuttering, boxes or pallets etc. should have all nails removed or hammered flat before being disposed. All nails must be collected and should not be allowed to lie on the ground causing injury to the passer by. The injury caused by nails can be serious and requires immediate medical attention.

E.

Cleaning Tools & Machinery: It is not permitted to use petrol for cleaning tools & machinery rather a safe cleaning chemical should be utilized.

STACKING: All material stacking shall be properly organized to eliminate potential hazards due to congestion, obstacles or restrictions to the area. The material shall be stacked in such a way it does cause any overhanging towards one side or at the end. The material must be stacked on a sound and stable base with due consideration for safe approach, retrieval and arrangement of items. .

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KOC F&S Regulations

A.

De-Stacking of Materials: Most of the accidents, involving stacked material collapse, occur during the process of de-stacking. The following precautionary measures must be kept in view during such operations: 1. It is advisable to make one person responsible to supervise the destacking operations. 2. The supervisor for de-stacking operation should be familiar with stack erection and construction details. 3. The stack shall be taken down tier by tier, so that no part is endangered. 4. 5.

6. 7.

6. B.

HANDLING & STORAGE OF MATERIALS, HAZRDOUS CHEMICALS, EXPLOSIVES & RADIO ACTIVE SUBSTANCES

If tabular or other fencing are been built in or around the stack, it should also be dismantled and adjusted accordingly as the stack height decreases. If a crane is used, the slings shall be made up as near possible to, or on exceptionally large stacks, sufficiently near to the centre to allow ample clearance between sling load and edge of the stack. This precaution will also prevent the fouling of fence or other barricades as the load is taken away. Dunnage shall be collected as it is released and removed to a safe position away from the stack. If it is discovered that dunnage has broken during the life of the stack, this shall be taken as a warning for a serious fault that may exist and the matter shall be investigated. It is essential that the area around the stack, whilst work is being carried out, is clear of any material that will create a tripping hazard.

Segregation of Materials: Certain materials should not be stored together, or in close proximity with each other, for example. 1. Foodstuffs shall not be stored in close proximity to chemicals, toxic substance or materials with strong aroma. Many foodstuffs such as fats absorb aromatic gas easily. 2. Any oxidizing agent shall be stored away from wood shavings, straw, or other easily combustible material.

F&S Regulations Chapter 7

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Kuwait Oil Company

Fire & Safety Regulations

(K.S.C.)

DOCUMENTARY CONTROL OF HAZARDOUS WORK & WORK PERMITS

Chapter No. 8 June 2004

CHAPTER-8 DOCUMENTARY CONTROL OF HAZARDOUS WORK & WORK PERMITS Contents

Subject

8.1

Permit to Work Procedure ………................…………………

2

8.2

Responsibilities for Application & Authorization of Work. …

3

8.3

Nomination / Authorization of Personnel for Permit to Work…

6

8.4

Work Planning……………………...........................................

7

8.5

Types of Work Permits …........………...................................

7

8.6

Operation of Permit to Work System ....................................

7

8.7

Work Site Preparation.............................................................

12

8.8

Isolation, Lock off & Tag out....................................................

17

8.9

Gas Test for Work Permit ……..........................................

20

8.10

Fire Protection During Work ...............................................

21

8.11

Permit for Wireline Operations .............................................

21

8.12

Permit for Shared Area ……………………………………

22

Page

ATTACHMENTS Work Permit Formats:

F&S Regulations Chapter 8

• • • • • • •

Cold Work Permit Hot Work Permit Radiography Work Permit Confined Space Entry Permit Vehicle / Mobile Plant Entry Permit Excavation Notifications Electrical Work Certificate

June 2004

Page 1

KOC F&S Regulations

DOCUMENTARY CONTROL OF HAZARDOUS WORK & WORK PERMITS

CHAPTER - 8 DOCUMENTARY CONTROL OF HAZARDOUS WORK & WORK PERMITS 8.1

PERMIT TO WORK PROCEDURE: 8.1.1 INTRODUCTION: The ‘Permit to Work’ (PTW) Procedure is a formal written system that utilises a document (Work Permit) to control work by means of potential hazard identification and risk assessment. The work permit is also a means of communication among various Supervisors or their representatives belonging to Operations, Maintenance, Sponsoring Teams & Contract personnel, who are involved in work preparation and / or its execution. The issuance of Work Permit does not, by itself, make a job safe. Safety can only be achieved by those preparing the work & those carrying out the work. To ensure the Permit to Work System is effective DO NOT ATTEMPT TO BYPASS IT. The system is intended to ensure personnel & environmental safety as well as plant & equipment integrity. The work permit is not simply a permission to carry out the job; rather it is a cornerstone for a safe system of work, which determines how that job can be carried out safely. A work permit is not just an exercise in form filling. Your signature on Work Permit confirms your responsibility towards the safe preparation and execution of work. If you are unsure of any instruction on a Work Permit or in any doubt regarding a procedure, STOP & ask your immediate Supervisor for 8.1.2

OBJECTIVE OF PERMIT TO WORK SYSTEM: To ensure - A co-ordinated, communicated & controlled safe system of work. - All work carried out in Company premises are recorded. - Continuous improvement of PTW system through audit & revision.

8.1.3

WORK COVERED BY WORK PERMIT: Work shall not be carried out unless: • It has been approved either by a Maintenance Work Order, Routine Maintenance Work, Planned Corrective Work, Preventive Maintenance Schedule, & Plant Modification Approval. All other works not defined above must be approved & agreed by the Permit Issuer. However work of a routine operational nature does not require permit authorization. • The work is permitted under the MMMS Work Order. • The work has been planned and agreed twenty-four (24) hours in advance, or is of a breakdown nature or priority unplanned work which requires immediate action.

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KOC F&S Regulations •

8.2

All works have been properly authorized. All works, those are not of routine operational nature, in any area require a Work Permit with the exception of emergency safety work that is either ‘ loss of life actual’ or ‘loss of life potential. In the event of such situations, the Permit Issuer or the senior most KOC personnel available at site is authorized to verbally allow the work to commence immediately, and informing the asset owner subsequently. Work permits shall be prepared as soon as practical to cover the work being carried out. In case of such ‘Emergency Work’, it must be recorded in Operation Log Book & signed by the Permit Issuer.

RESPONSIBILITY FOR APPLICATION & AUTHORIZATION OF WORKS: A. Permits Applicant: An appropriate Work Permit shall be raised by Permit Applicant for any work within a RESTRICTED or HAZARDOUS AREA and shall be submitted for authorization to the respective Permit Issuer in whose area of control the work is to be carried out. A Permit Applicant: • Is a member of the sponsoring department representative (such as Maintenance, Projects Management or Major Projects etc.) who will initiate the work. • Is nominated in writing by the respective Team Leader on the recommendation of the Permit Applicant’s line supervisor. • Must have the technical competence to execute the work with due consideration to identify the potential risks / hazards associated with the work and its prevention techniques. • Must have detailed knowledge of the Permit to Work System. The appropriate permit shall be raised by the following listed authorities / personnel belonging to Company (KOC) or the Contractors depending upon the criticality of the work and its associated hazard: S. No. 1

Work Category Cold Work Permit & Hot Work Permit

2

Cold Work Permit

F&S Regulations Chapter 8

Nominated Permit Applicants Snr. Engineer, Engineer, Maintenance Supervisor, Snr. Foreman, Foreman, Incharge Mechanic. Snr. Mechanical Technician, Snr. Instrument Technician, Service Engineer, Foreman, Lead Instrument Technician, Lead Mechanical Technician, Lead Electrical Technician, Supervisor Incharge Electrician, Snr. Mechanic, Snr. Electrician, Electrician, Mechanic, Foreman, Chargehand, Mechanical Technician, Instrument Technician,

Company or Contractor KOC or Service Contractor

KOC or Service Contractor

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DOCUMENTARY CONTROL OF HAZARDOUS WORK & WORK PERMITS

KOC F&S Regulations 3 4 5

Radiography Work Permit Vehicle / Mobile Plant Entry Permit Confined Space Entry Permit

Electrician Certified Radiographer

KOC or Contractor

Vehicle’s Driver or Mobile Plant Operator

KOC or Contractor

Snr. Engineer, Engineer, Maintenance Supervisor, Snr. Foreman, Foreman, Incharge Mechanic.

KOC

The authority to raise the appropriate permit for service contract personnel shall be approved by the Sponsoring Team and the approved list shall be copied to the Fire Team & respective area Asset Operating Team for reference and cross check. KOC supervision will be mandatory in case the service contract personnel are not approved for raising the appropriate permit. The permit applicant shall comply with the following preparatory actions while raising a permit: • All the required information as stipulated in the Permit must be entered before the permit is submitted for approval and authorization. • Any required preparatory work must be stipulated on the permit application. • All personnel under his responsibility must be advised of their responsibilities under Work Permit System. • No job can begin until he is satisfied that the Worksite Supervisor fully understands his responsibilities under Work Permit System. • The safety gears and appliances required for the work must be available. B.

Permits Issuer: The responsibility for authorizing work permits rests with the Asset Operating Team responsible for the operation of the facilities. The respective asset operating - Team Leader (in whose area of control the work is to be carried out) can delegate the responsibility of permit authorization to their subordinates, provided that they have a complete overview of all operational activities and also have a detailed knowledge of the ‘Permit to Work System’. The following table, which is for guidance only, lists authorities or sub-ordinates who might be nominated in writing as Permit Issuers by their Team Leader in compliance to job competency and the nature of work:

S. No. 1

Teams / Groups Export Operations

2

Marine Operations

F&S Regulations Chapter 8

Nominated Permit Issuers

Remarks

Shift Supervisor, Senior Engineer, Terminal Supervisor, Engineer, Controller, Operator Meter Test, Operator Port Captain, Harbour Master, Pilot, Supervisor, Foreman

Operator Meter Test is authorized to issue Hot Work Permit also; whereas other Operators can issue cold work permit only. Foreman is authorized to issue Cold Work Permit only

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KOC F&S Regulations 3

Marine Services

4

Production Operations

5

Drilling Operations Electrical Maintenance

6

Snr. Marine Engineer, Marine Maintenance Engineer, Engineer Port Services, Supervisor, Foreman, Assistant Foreman, Snr. Technician Production Supervisor, Production Controller, Operator – I, Operator II Drilling Supervisor, Company Man Electrical Supervisor

Asstt. Foreman & Snr. Technician are authorized to issue Cold Work Permit only Operator- II is authorized to issue Cold Work Permit only

For electrical substation such as B1 & B2 and Ahmadi distribution

The PERMIT ISSUER is responsible to ensure that: • All hazards associated with the proposed work have been identified. • Before any work begins, the worksite is safely prepared, examined and all specified precautions have been taken. • Work permits that may interact or affect one another are cross-referenced clearly. • The worksite is examined to ensure that it is in safe & acceptable condition o When the work is suspended o Before restarting the work o When returning to normal operation • The shift change handover procedure is properly followed and permit endorsement and transfer of responsibilities have been completed. Work of an urgent nature may continue during the shift change period provided agreement has been obtained from the asset owner in advance. • Prior to closing or cancelling a work permit any precautions and isolations have been withdrawn and the system returned to normal operation. • When work is completed and the work permit is signed off the Permit Issuer closes the work permit and returns the equipment to operation. C.

Worksite Supervisor: The Worksite Supervisor shall be a person authorized in writing by the Sponsoring Team’s representative to supervise the work. The Worksite Supervisor is responsible to the Permit Applicant for all aspects of safety related to work and the work party. . He must have a detailed knowledge of the Permit to Work System. The Worksite Supervisor can be a person belonging to Company (K.O.C.) or Contractor as deemed suitable in the opinion of Sponsoring Team considering the criticality of work & its associated hazards. The Worksite Supervisor shall ensure: He has detailed working knowledge of procedures related to his work activity. He does not start any job requiring a work permit until it is authorized & issued.

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KOC F&S Regulations

He understands the limitations and restriction of the work permit in order that work may proceed safely. All members of the work party adhere to safe working practices and are fully conversant with the limitations, restrictions and hazards involved. All precautions specified in the work permit are taken. He does not leave the work site during Hot Work, Vessel Entry, Radiography and Excavation Work. Permission is obtained from the Permit Applicant and the Permit Issuer to leave the worksite during performance of Cold Work. The work permit is endorsed as necessary and responsibilities are passed to the oncoming worksite supervisor at the shift change handover. The job described on the work permit is completed and the worksites as well as equipment are left in a safe condition. On completion of the job the work permit is signed off and passed to the Permit Applicant & Permit Issuer for the equipment to be returned to the asset owner. The original work permit is prominently displayed at worksite at all times during the work. 8.3

NOMINATION / AUTHORIZATION OF PERSONNEL FOR PERMIT TO WORK:

All the personnel associated with Permit to Work System shall fulfil the following competency requirements before being authorized for their stipulated role: •

In addition to his pre-requisite educational qualification and experience for the job, he must have detailed knowledge of the ‘Permit to Work System’.

•

He must have successfully completed training on the ‘Permit to Work System’ and have passed the qualifying test (written as well as oral) relevant to his role.

•

The concerned sponsoring team, which has ultimate responsibility for safe execution of work in their area of jurisdiction, shall arrange such training on PTW and qualifying tests for respective workers as per their stipulated role. Once the concerned employee or contractual worker successfully qualifies in the PTW Test; he will be issued a laminated authorization card (as sampled below) by the concerned Sponsoring Team:

•

•Authorized as: (Tick mark the relevant

Ref No. Date:

Kuwait Oil Company (K.S.C.)

Work Permit Authorization Card Name: Designation: Id. No. Company / Contractor: Sponsoring Team:

Front View

F&S Regulations Chapter 8

& cancel the rest)

(…) Permit Applicant (Hot / Cold / Radiography / Confined Space / Vehicle Entry)

(…) (…) (…) (…)

Permit Issuer (Hot / Cold / Radiography / Confined Space) Worksite Supervisor (Hot / Cold / Confined Space Entry) Gas Tester Competent Electrical Person (HV / LV)

•Valid till: • Authorized By: a) b)

Designation: Signature:

Rear View

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Page 6

KOC F&S Regulations •

DOCUMENTARY CONTROL OF HAZARDOUS WORK & WORK PERMITS

The test questionnaires for each category of authorization shall be provided by the concerned sponsoring Team. A sample of questionnaires on Permit to Work has been provided by HSE Group.

The cardholder may get the Work Permit Authorization Card revalidated on its expiry (every 2 years) after completing again the required training and testing

8.4

WORK PLANNING: An essential requirement for safe & efficient administration of the Work Permit System is comprehensive forward planning. A work permit meeting shall be held daily on each location to define: • The precise work to be performed (if possible) & sub-sequential execution of work. • The tools and equipment required and any necessary safety procedures including isolation need identified with risk involved. • The area, system and equipment to be worked on and any actual or potential hazards that may arise. • Whether the work shall affect any other area, system or equipment either adjacent or remote. The timing of this meeting (usually 24 hours in advance of the planned works) shall be decided locally, and as minimum shall involve the Permit Applicant, Permit Issuer, Worksite Supervisor and area Safety Officer (if available). Breakdown and priority unplanned work may necessitate immediate action.

8.5

TYPES OF WORK PERMITS: The Permit to Work System incorporates the use for 6 types of Work Permits as mentioned below: • Cold Work Permit • Hot Work Permit • Radiography Permit • Vehicle / Mobile Plant Entry Permit • Confined Space Entry Permit • Excavation Notification Note: i) A spading / blanking list is mandatory for Vessel / Tank Entry Permits). ii) Excavation Notification is valid with supporting Work Permit only.

8.6

OPERATION OF PERMIT TO WORK SYSTEM: 8.6.1 Work Permit validity: • Hot / Cold / Radiography: Maximum duration seven consecutive working days from the date of issue, however the permit is to be re-endorsed in case of shift change, transfer of responsibility or work suspension. • Confined Space Entry Permit: One continuous work shift or part thereof; however the permit is to be re-endorsed in case of crew change, transfer of responsibility or work suspension. .

.

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•

Vehicle / Mobile Plant Entry Permit: Valid for one continuous work shift for Vehicle entry, whereas for Mobile Plant Entry it is valid for maximum 7 consecutive working days from the date of issue. However the permit is to re-endorse in case of shift change, transfer of responsibility or work suspension.

•

Excavation Notification: Maximum 90 days from the date of issue or less as stated in the permit

(N.B: The validity period for Cold Work Permits pertaining to the works (such as minor construction,

maintenance or renovation) in a non – hazardous area can be extended for a maximum period of one month with due approval from the asset Team Leader)

8.6.2

Work Permit Application: All identified work must be authorized and planned prior to work permit application. The Permit Applicant shall raise the appropriate work permit with a full description such as: o The Worksite o The Equipment to be worked on o The exact nature & scope of work (supported with sketches or drawings if available) o Special tools or equipment that may impact on safety at the worksite. The Permit applicant shall to the best of his knowledge complete the relevant sections on the work permit and present it to the Permit Issuer for review and authorization.

8.6.3

Work Permit Authorization: The Permit Issuer shall review the work permit and any supporting documentation and complete the appropriate sections. He shall arrange for equipment preparation e.g. depressurising, draining, flushing, purging and any process, mechanical, safety and electrical isolations. When he is satisfied that the worksite has been safely prepared and safety precaution put in place, he shall authorize the work to proceed. It is to be ensured prior to authorizing the permit that only work identified on the work permit shall be carried out on and no account can any deviations to the agreed workscope take place without a new permit being written.

8.6.4

Work Permit Issuance: The Worksite Supervisor assigned by the Permit Applicant shall sign to acknowledge he understands and accepts the work permit & associated worksite responsibilities. •

The Worksite Supervisor shall then obtain the first endorsement for the work to proceed from Permit Issuer.

•

No amendment to the work permit is permitted without the approval of the Permit Issuer. Mistakes must be crossed out with a single line and initialled by the Permit Applicant and Permit Issuer. Any overwriting or correction

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KOC F&S Regulations

fluid on the Work Permit immediately invalidates it and it shall be cancelled immediately. •

If a work permit has all the endorsements complete but the isolation and work are to continue, a new permit shall be raised. The new permit number shall be deleted and the previous number annotated on it thus preserving the original isolation tags. The new work permit must be applied for and authorized following the normal procedure.

•

Similarly if the number of isolations required are more than the number of endorsement boxes provided in the work permit (referred to as original), a new permit shall be raised with the new permit number struck out with a single line and replaced with the original work permit number so that all the isolation tags as per original work permit are preserved. Each work permit endorsement from the Permit Issuer is only valid for a maximum of one shift (12 hours). Work extension to the next shift must be endorsed by the oncoming Permit Issuer and Shift Controller. If the work permit endorsement boxes have all been completed then a new work permit must be raised.

•

8.6.5

Transfer of Responsibilities: Permit Issuer: All work permits must be presented for transfer of authority to the oncoming Permit Issuer immediately upon his arrival at the permit control centre Permit Applicant: As above Worksite Supervisor: Work must stop if he leaves the site unless a substitute authorized by the Permit Applicant & Permit Issuer is present.

8.6.6

Cross - referencing: All work permits associated with the same work must be cross-referenced by mentioning the work permit number in the box provided on each permit.

8.6.7

Work Permit Suspension: In the case of a dangerous situation at the worksite or adjacent facilities all work must stop immediately and shall not recommence until worksite is declared safe & subsequently the permit is endorsed by the Permit Issuer. In such situations (such as fire or gas leak) the workers on hearing the dangerous situation alarm, shall vacate the area after making the worksite safe and will proceed to the designated assembly point for mustering and further instruction. The Permit Issuer, Permit Applicant and personnel from Fire Team / HSE Team / HSE Group are authorized to stop the work in the event of a work permit violation, unsafe acts or unsafe conditions. Any person can advise to stop the work if they observe any hazard or potentially hazardous condition. Any unsafe or hazardous condition must be immediately reported to the Permit Issuer, Permit Applicant and the respective area HSE

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KOC F&S Regulations

Team as well as Fire Station. If on investigation it is determined that the work permit is to be suspended the Permit Issuer must be informed immediately. Any suspended work permit shall be endorsed ‘S in Box 10 (Shift Change Endorsement Box) of that permit and be kept in the custody of the Permit Issuer under the suspended work permit file. A work permit can be suspended for a maximum of 5 days or until the expiry of its validity period (whichever is sooner) in which case the work permit must be cancelled and signed off. Either a new work permit shall be raised or the system and equipment placed in long-term isolation as appropriate. 8.6.8

Closing a Work Permit: On completion of the work the Worksite Supervisor shall check the worksite and ensure all tools & equipment have been removed as well as housekeeping completed. He will inform the Permit Applicant and both shall sign the work permit signifying hand-back of the equipment. The Permit Applicant is responsible for satisfactory hand-back of the worksite. The Permit Issuer shall ensure the area is acceptable prior to signing to accept the hand-back of the area and equipment. The Permit Issuer can allow de-isolation of the equipment. The Permit Issuer shall ensure that all isolations are removed, the system and equipment purged and aligned as necessary. He shall then sign to close the work permits and allow the equipment to be re-instated. .

8.6.9

Work Permit Distribution: Work Permits will be made out in four copies: •

The original will be kept by the Worksite Supervisor for worksite

•

1st copy of all permits (except Cold Work Permit) will be forwarded to Fire Team by the Permit Issuer prior to Job commencement or respective area Fire Station is notified and subsequently 2nd copy is forwarded to Fire Team within 48 hours from the permit authorization.

•

2nd copy shall be kept with the Permit Applicant.

•

3rd copy shall be retained by the issuing authority.

After successful completion of the work and permit closure as per procedure, the original shall be kept on record with the Permit Issuer whereas the 2nd copy shall be retained by the Permit Applicant, for a maximum period of 6 months before it is sent to Dead Record Room for archiving. If an accident or incident occurs associated with a work permit, the original copy of the work permit shall be attached to the incident report and a copy retained on the file A Flow Diagram on operation of Work Permit System is displayed on next page for convenient reference F&S Regulations Chapter 8

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DOCUMENTARY CONTROL OF HAZARDOUS WORK & WORK PERMITS

KOC F&S Regulations Need for Work Identified

WS Starts Work

PA raise appropriate permit PA or WS checks if any changes to permit signatories due to shift change PA & PI specify isolations & precautions in relevant boxes

No

Any Change Yes PA or WS stops the work, housekeep & return the permit to oncoming PI

PI considers if work conflicts with other Permits Oncoming shift endorse the permit confirming safety precaution in place

Yes No PI holds the permit or suspends other permits

No Refer to PI

Permit Endorsed

No

Yes

PI considers if adjacent operations affected

No

WS resumes Work

Yes

Is the work going on but the permit has expired?

PI holds the permit or suspends other permits

No

PA raises new permit cross referencing existing one

WS completes the work & housekeep the worksite

PI decides if the risks to personnel & assets have been assessed

Yes

WS informs PA

PA liaises with PI to visit the worksite Yes PI ensures for required isolation, equipment preparation & gas test

No

Is the work complete? PI cancels permit & records for Long Term Isolation

Is the work onYes hold? PI authorizes the permit to proceed after confirming isolations & safety precautions PA accepts overall responsibility for the work & signs

F&S Regulations Chapter 8

WS accepts responsibility for safe performance of work & signs

Yes No WS & PA signs the permit to handover the equipment to asset owner

June 2004

PI & PA

Page 11arrange PI or his delegate visit the worksite to confirm the equipment can be returned to service

for deisolation

KOC F&S Regulations 8.7

DOCUMENTARY CONTROL OF HAZARDOUS WORK & WORK PERMITS

WORKSITE PREPARATION: It is the responsibility of the Permit Issuer to ensure the safe preparation of the worksite. When deemed necessary by the Permit Issuer, a formal Plant and Equipment Preparation Procedure shall be prepared prior to work commencing making reference where necessary to any simultaneous Operation procedures. The equipment to be worked on shall be isolated from all sources of energy (such as electrical, mechanical, hydraulic & pneumatic etc) and prepared as per the job requirement (such as depressurisation, de-contamination, flushing & purging etc.) to confirm safety & integrity of worksite. The Permit Issuer in liaison with the Permit Applicant shall mark up P&IDs in conjunction with detailed valve isolation, vent or drain valves open details (Mandatory for all vessel entry & process isolation). The possible impact of the work on the surrounding area must be assessed and care taken NOT to issue a work permit which could impact on the safety conditions for other work permits in the area. Based upon the detailed work description, the hazards shall be assessed and the required precautions to be taken to enable the work to proceed safely shall be indicated on the work permit. 8.7.1 Cold Work: Any work that does not involve a source of ignition or naked flame or does not have spark-generating potential is classified as Cold Work. The performance of cold work shall require, but is not limited to the following precautions: •

If a gas test is required, it shall be carried out immediately prior to the commencement of work, and, if the work party has left the worksite, immediately prior to re-commencement of the work.

•

If continuous gas monitoring is required, the Worksite Supervisor and the person performing the work shall ensure that the portable gas detectors remain charged and in working order.

•

The Worksite Supervisor shall ensure that all personnel under his control strictly adhere to the constraints of the work permit i.e. Work Description, Equipment / Area / Terms & Conditions / Restriction of the work permit.

•

The Worksite Supervisor must remain at the worksite during performance of the work. Should the Worksite Supervisor require leaving the worksite, he must make prior contact with the Permit Applicant & Permit Issuer advising the reason & duration, he will be absent from the worksite. The Worksite Supervisor can leave the worksite only if the Permit Applicant & Permit Issuer agrees it. This privilege applies only to Cold Work permits

8.7.2 Hot Work: Any work, which involves the use of naked flame or a source of ignition or spark generating potential, capable of igniting a combustible or explosive material, is classified as Hot Work. Prior to any hot work being authorized, the Permit Issuer must consider the following points: F&S Regulations Chapter 8

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KOC F&S Regulations

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•

Can the work be removed to a safe location?

•

Is it essential for Production or Safety reasons to perform the work during operation of the plant? Can the work be deferred until a shutdown or partial shutdown?

•

Have the workscope and potential hazards been discussed among the Permit Applicant, safety personnel (if available) Permit Issuer and worksite supervisor.

•

No Confined Space Entry Permit shall be issued for the same vessel / tank / enclosure where a hot work is in force. (Refer to Chapter – 11 of Fire & safety Regulations for precautions during hot work inside the tank)

•

Paint spraying and hand painting are not permitted during performance of the hot work.

•

Cold work permits likely to cause a gas release must be suspended.

•

The Permit Issuer & Permit Applicant shall make regular site visits during the work.

•

Total isolation from flammable or toxic gas / liquids must be achieved by either: o Physical disconnection. . o Blanking / Spading (using correctly rated blind / spade) o Double isolation valve with bleed valve in between. o Any combination of the above as deemed necessary by Permit Issuer & Permit Applicant. It may be necessary to raise a Cold Work permit for this preparatory work. The Permit Issuer shall assess this after discussion with Permit Applicant.

• •

Before any hot work can begin, the Permit Issuer must ensure the equipment is free of liquid / gas by: o Depressurising o Draining o Venting o Purging & flushing o Any combination of the above

•

During hydrocarbon venting to atmosphere, any hot work permit at the location must be suspended.

•

The hot work site must be free of hydrocarbons and combustible materials e.g. sludge, scale, deposits etc.

•

The worksite shall be gas tested and certified as being gas free by an authorized gas tester. The maximum LEL (Lower Explosive Limit) permissible for authorized hot work is 0% LEL. If the work generates spark or chippings, the work must be suitably confined.

•

•

F&S Regulations Chapter 8

If the work is above access ways, precautions must be taken to ensure that no sparks or hot metal can fall below. Additionally the area beneath the worksite must be barriered off and warning notice posted in English & Arabic.

June 2004

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KOC F&S Regulations •

8.7.3

Mobile plant and equipment shall not be sited in hazardous or non-hazardous locations unless it meets the safety requirements specified for its area of operation. Radiography Work: Any work that involves the use of a radioactive source, shall be covered by a Radiography Permit. The transportation, control and handling of radioactive isotopes must be in compliance with Radiation Protection Manual, KOC Fire & Safety Regulations (Chapter – 7) and Kuwait Ministry of Health Regulations in this regard. Precautions that must be adhered to include but are not limited to: • The Permit Applicant shall raise a Radiography Work Permit. Where possible this work shall be scheduled during mealtimes or night shift. • • • •

•

•

8.7.4

DOCUMENTARY CONTROL OF HAZARDOUS WORK & WORK PERMITS

The radiography work permit shall be endorsed for a maximum of seven days. A three-dimensional control area shall be designated and marked by barriers. Prior to commencement of radiography, all other work permits within the controlled area or as specified by the Permit Issuer, shall be suspended. Identified UV detectors shall be over-ridden and recoded in the work permit. A Public Address (PA) announcement (if available) shall be made 30 minutes prior to radiography commencement advising all non-affected personnel to make safe their work place and vacate the area. A further P.A. announcement (if available) shall be made five minutes prior to radiography commencement advising non-affected personnel to vacate the area immediately. The Radiographer & Assistant Radiographer shall check the area to ensure all non-classified personnel have vacated the area. Then final P.A. announcement (if available) shall be made advising the radiography is commencing.

Confined Space Entry Permit: Any enclosure having a limited means of entry & exit and not designed for continuous occupancy is defined as a Confined Space. Examples include (but are not limited to) the following: i. Process vessels, tanks, bins, stacks, large pipe, ducts, pits, and vaults. ii. Any enclosure where the presence of air contaminants may be harmful to a worker and prevent his ability to escape unaided. The following are the minimum precautions that must be taken. They apply even when a person’s head is inserted into the confined space for the purpose of a quick visual inspection. These requirements are applicable to all process and utilities systems irrespective of service: • Entry to confined space can only be authorized by the Permit Issuer. At the start of each shift, a new confined space entry permit must be issued in due consideration of precautionary measures required as per procedure detailed in Appendix – 6 (Confined Space Entry Procedure)

F&S Regulations Chapter 8

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KOC F&S Regulations

DOCUMENTARY CONTROL OF HAZARDOUS WORK & WORK PERMITS

•

The Permit Issuer & Permit Applicant must make regular site visits during the work. The worksite supervisor shall be fully aware of the confined space entry procedure and the Permit to Work System.

•

The confined space must be positively isolated from all processes & utility systems by blanking, spading or disconnection. Where disconnection is employed as a means of isolation, the lines shall be blanked. Isolations must be achieved as close to the confine space as possible, preferably on the nozzles. If this is not achievable then the next nearest point of isolation will be selected. If the confined space is equipped with a source of electrical power, an electrical isolation must be carried out and ensured that the confined space & equipment to be used are earthed prior to the issue of entry permit. The confined space must be tested for oxygen levels, flammable vapor and toxic gases prior to entry and at a minimum every 6 hours subsequently. If the confined space is vacated a new gas test shall be performed prior to reentry. A portable gas monitor must also be sited for continuous monitoring.

•

•

•

•

When determining the criteria for confined space entry without breathing apparatus, the associated hazards due to sludge, scale and deposits must be considered. These residues can contain and emit dangerous levels of vapor. Pyrophoric Iron Sulphide may also be present and the danger of ignition if allowed to dry out and be exposed to oxygen must be considered.

•

A standby man shall be stationed at each confined space entry point. He shall be equipped with a portable radio and must keep visual contact with personnel working inside the confined space.

•

The standby man will inform Control Room each time the confined space is entered or vacated & all entries as well as exits will be recorded in CCR log book. Additionally the standby shall also keep a record of personnel’s entry / exit at the worksite. In case of emergency inside the plant, the confined space entry must stop immediately. The standby man shall advise the Control Room by radio, when the personnel inside the confined space have vacated, the site shall be made safe and the personnel shall proceed to muster.

•

•

If an emergency occurs within the confined space, the standby person must not enter it until rescue team arrives. It is the responsibility of standby man to summon aid immediately by contacting the Control Room through radio or other available means of communication.

•

Personnel working inside the confined space will be given a rest period at each 30 minutes intervals, or more frequent depending upon prevailing conditions.

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KOC F&S Regulations

8.7.5

8.7.6

•

Generally not more than two persons will be allowed to work at a time in a confined space. The area around the confined space must be barriered off and warning sign posted in English & Arabic.

•

As and when needed the opinion and assistance from HSE personnel may be sought to ensure the safety aspects of a confined space entry

Vehicle / Mobile Plant Entry Permit: Any Vehicle or Mobile Plant will not be allowed to enter into a hazardous area except under duly authorized Entry Permit subjected to inspection & authorization by the Permit Issuer. However the vehicle entry to a Tank Farm will require a permit only if it enters the plant area (such as bund wall) to carry out specific work / activity duly authorized by asset owner. •

The vehicle or mobile plant required to enter inside a hazardous area under duly authorized entry permit must also have approval from KOC Transport Operation Team to confirm its suitability, safety & integrity. (Refer to Appendix – 8 for further detail).

•

The mobile plant (such as air compressors, welding machines, primus stoves, tar boilers & Diesel Engine Generator etc.) must have at least two fire extinguishers duly approved by Fire Team.

•

The validity of entry permit for the Vehicle will be one continuous workshift whereas for Mobile Plant, it will be valid for 7 consecutive days from the date of issuance. It is to be noted that the permit is valid for entry only; however for carrying out any work, a separate appropriate permit is to be authorized as per procedure.

•

The entry permit needs to be endorsed by on-coming shift after carrying out necessary gas test.

Excavation Notification: Excavation Notification is not a permit to work but a document to notify the concerned authorities, which have responsibility and jurisdiction for safety & integrity of aboveground and underground services existing at the proposed site of excavation. An Excavation Notification is required for all excavations regardless of the depth. The Excavation Notification shall be raised by the respective supervisor or engineer and must be endorsed by all concerned parties. •

An Excavation Notification must be supported by a primary work permit duly authorized by the permit issuer. A Cold Work permit shall be additionally required where only hand excavation tools are to be used. Whereas for excavations work using powered tools (such as mechanical excavator, back hoe, shovel, loader etc) will need a duly authorized Hot Work Permit if work is to be carried out in a hazardous area. Mechanical excavation is not allowed inside the plant or facility or within 5m radius from any underground facilities.

F&S Regulations Chapter 8

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KOC F&S Regulations

8.8

DOCUMENTARY CONTROL OF HAZARDOUS WORK & WORK PERMITS

•

For excavations below 1200mm, a Confined Space Entry Permit is required and in some circumstances gas free certification also. (Refer Chapter–18 for further detail on Excavation)

•

A drawing or sketch of the proposed excavation site (showing above & underground services) must accompany the Excavation Notifications to enable the affected disciplines to check and specify precautions & hazards prior to signing the approval.

•

If a buried cable or pipeline is encountered during excavation, the work must stop immediately and the Permit Issuer informed. The Permit Issuer shall liase with the Permit Applicant to decide best course of action.

•

The Excavation Notification is valid for a period of 90 days from the date of issuance or as stated in the permit.

•

The Excavation Notification should be linked and cross referenced with KOC Recommended Practice (KOC - L - 002) for clearance requirements on buried pipelines, cables and other underground services.

•

The respective supervisor or engineer initiating the Excavation Notification must ensure that the proposed excavations / trenches will not obstruct the movement of emergency vehicles (such as fire tender, ambulance etc) to the worksite

ISOLATION, LOCK OFF & TAG OUT: Isolation, lock off and tag are an integral part of the “Work Permit System”. If plant or equipment is specified as requiring isolation as a condition of work permit, then the required isolation (such as Electrical, Mechanical, Instrument & Telecommunications) must be identified by the Permit Applicant and mentioned in the appropriate section of the work permit. The isolation shall be carried out by nominated & authorized personnel only and the isolation detail must be entered on relevant sections of the work permit. If isolations require ‘Locking Off’ then the official Company padlocks clearly stamped with an individual ID number must be used. If the padlocks cannot be installed, other immobilizing device (as specified by the Permit Issuer) can be used. Each isolation point (such as padlock, immobilizing devices or spades/blinds/blanks) and any vent or drain which has been opened or closed must have an isolation tag attached clearly.

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. 8.8.1

Mechanical Isolation: The type of isolation used shall depend on the level of risk associated with the work to be performed. (a) Positive Isolation; physical disconnection and blanking of open ends; the turning of spectacle blind; the insertion of spades between flanges or the replacement of a spacer with a line blind. Blanks, spades (blinds), bolting and gaskets shall conform to the piping specification for the equipment. (b) Double block & bleed, valve isolation is the industry standard for isolating a valve. The effectiveness of isolations must be tested and proved. If an isolation valve is passing, it may be necessary to shut additional valves or take further plant and equipment out of service

8.8.2

Electrical Isolation: Prior to authorizing a ‘Work Permit’ it is essential to ensure that the equipment to be worked on is safe and electrical power isolated for the safe conduct of authorized work. The requirement for electrical isolation shall be specified by the Permit Issuer in liaison with the Permit Applicant. The authorized Electrical person as appropriate completes the electrical isolation and enters the detail on Work Permit subsequent to discussion with the Permit Issuer. The authorized electrical person shall hand over the padlock key to the Permit Issuer for safe custody. Once electrical power is isolated for any equipment and the Work Permit issued, such equipment must not be made live or electrically de-isolated until work has

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DOCUMENTARY CONTROL OF HAZARDOUS WORK & WORK PERMITS

been completed, the permit returned to the issuing authority, the work site, equipment and system have been checked and clearance has been granted by the Permit Applicant and Permit Issuer. It is strongly recommended for the authorized Electrical Person (from KOC) to raise an ‘Electrical Isolation Certificate’ in the format as provided in Appendix – 10 (Electrical Work Safety), giving all the specified details. The certificate should be attached to the respective Permit as an additional check prior to commencing the work as well as for convenient reference while de-isolating or commissioning the equipment.

8.9

8.8.3

Instrumentation Overrides: The requirement and implementation of instrumentation overrides, defeats and inhibits (such as inhibiting - equipment safety switches, ESD switches, Fire & Gas detectors, plant alarm system etc) for safe work execution shall be the responsibility of the Permit Issuer in liaison with the Permit Applicant. The necessary detail such as inhibited device tag number, equipment number and instrumentation overrides or defeats shall be clearly recorded in the respective isolation / de-isolation box of Work Permits and these overrides and defeats shall be authenticated by the concerned authority in this regard. It is also advisable to record such overrides separately in the Control Room logbook to prevent inadvertent removal or normalization of inhibited switches. The process and equipment protection alarms (on DCS or Plant Shutdown System as well as Fire & Gas Detection panel) due to such overrides shall be checked and corrective actions taken before normalizing the inhibited switches or device to rule out the possibility of any adverse affect on the system or facility in the plant.

8.8.3

Long Term Isolation: If work is completed or suspended beyond the work permits period of validity, but the worksite requires continued protection of an electrical, mechanical or instrument system isolation, it shall be indicated in the work permit stamping ‘LONG TERM ISOLATION’ in bold letters. Such longterm isolation must be recorded in the Control Room Log Book and widely brought to the notice of all concerned supervisors in the plant or facility.

GAS TESTS FOR WORK PERMIT: Gas testing is essential prior to and during any work activity that may expose personnel to risks from fires, explosions, chemical or other toxic substances. The

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methods and equipment used for testing atmosphere must be selected with regard to contaminants, which are or may be present at the worksite. In oil & gas industry, gas tests are carried out to determine the presence or absence of the following gases: • • • •

Oxygen (deficiency or enrichment) Flammable Gases (Usually hydrocarbon) Hydrogen Sulphide (H2S) Other toxic substances (such as welding fumes, chemicals, solvents or dusts)

Personnel must be fully trained to understand the methods, equipment and procedure for frequent monitoring throughout the work duration. Even if a particular atmosphere has been declared safe, continued monitoring is necessary particularly for Hot Work & Confined Space Entry to ensure that it remains safe during the entire work period. Gas tests should be conducted each day or shift prior to starting the work activity, and always after any break or interruption of work. In special circumstances (such Confined Space Entry, Hot Work) the frequency of such gas tests can be mentioned in the work permit. Gas tests are mandatory prior to authorizing any – Hot Work, Confined Space Entry and Vehicle / Mobile Plant Entry - permits and may also be required sometimes for cold work permits as well as excavations notifications depending upon potential hazards. Gas tests must be carried out by an authorized gas tester & test results must be recorded in the appropriate section of the work permit. If the work has not started within 2 hours from the time of a gas test, the gas free certification will become invalid and a new test must be carried out. All gas detectors must be checked, inspected and tested prior to use. Depending upon the type and nature of contaminants, tests should be conducted by certified personnel using specific instruments. This is necessary to ensure accuracy in the testing and in the interpretation of test results. As and when needed the opinion and assistance from HSE personnel can be sought to ensure the gas test certification. In case of Confined Space Entry, the initial tests for flammable vapour, toxic gas and oxygen deficiency should be made from outside the confined space, using a long probe. If the initial tests indicate a concentration above the permissible levels, further gas freeing and tests will be necessary until the gas concentration falls within permissible limits. For testing of flammable gases & vapours, electronic monitor or detector tubes should be used. Portable gas detectors are used to determine the concentration of flammable gas, whereas detector tubes may be used to identify a particular gas and find out approximate concentration.

8.10

Tests for Hydrogen Sulphide should be conducted using detector tubes or an electronic sensing & measuring device. Personnel conducting H2S tests must always wear self – contained or air supplied breathing apparatus preventing exposure to toxic environments. FIRE PROTECTION DURING WORK: A. Where the hot work is to be carried out in a hazardous area, a minimum of two fire extinguishers (of capacity 9 Kg Monnex or 12 Kg DCP) shall be available within 7.5 meters from each hot / flame / spark potential work location.

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KOC F&S Regulations B.

C. D.

E. F.

G.

H.

8.11

Additionally there shall be a 2 ½ " diameter duly pressurized water hose capable of reaching a minimum distance of 30 meters from the hot work location. The firewater hose shall be properly connected to nearby fire hydrant and a continuous flow of water shall be maintained through the delivery nozzle (fitted with shut off valve) while hot work is in progress. Fire Team may be requested to provide additional support or equipment depending upon the criticality and hazardous nature of work. One person may be deployed for directing water from the hose to the area where sparks or hot debris may fall. It is also recommended to deploy a fire watch for all hot work activities. While working at heights, a tarpaulin soaked with water shall be provided in order to kill falling sparks and to prevent scattering on to other unprotected areas. The worksite supervisor shall ensure that no combustible material or refuse is collected adjacent to the work area. The worksite shall be kept clean, tidy and free from obstruction. In case the General Alarm or Fire Alarm is sounded, all work will immediately cease, machinery stopped and worksite made safe prior to reporting at assembly point for further instruction. The firewater hose shall also be isolated from the hydrant before leaving the area. Any pyrophoric refuse shall be made wet and disposed of immediately according to approved KOC waste management procedure. The equipment and components contaminated with combustibles such as pyrophoric material shall be always kept wetted with water.

PERMIT FOR WIRELINE OPERATION: All wireline operations require a ‘Permit to Work’. Wireline activity can be permitted at night only if the Permit Issuer agrees with the Workscope and is satisfied all potential hazards have been considered and adequate precautions taken. The Permit Issuer shall take into account the adequacy of lighting at the worksite for the job to proceed safely. The following procedure will apply for wireline activities at Wellhead locations: • • • •

•

8.12

DOCUMENTARY CONTROL OF HAZARDOUS WORK & WORK PERMITS

In normal operations a Workscope must be received by the Permit Issuer 24 hours prior to commencing of wireline activities. The representative from Well Surveillance Team shall be the Permit Applicant and is also responsible for all downhole technical aspects of the wireline program. The Permit Issuer in liaison with the Permit Applicant shall ensure the isolation and preparation of the worksite as specified on the permit. When the work is completed, the Permit Issuer shall ensure that everything is in order at the wellhead location before reinstating the well back to production. For further detail refer Chapter – 21 on “Oil well Drilling, Workover, Exploration & Wireline Activities”

PERMIT FOR SHARED AREA:

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DOCUMENTARY CONTROL OF HAZARDOUS WORK & WORK PERMITS

The permit for worksites shared between KOC and other external agencies (such as KNPC, MEW, Municipality etc.) shall be routed through the Local Relation Team to the respective area asset owner for either endorsement or authorization of the permit. Local Relation Team will act as the contact medium for external agencies whereas the permit application, endorsement and authorization will be the responsibility of respective asset owners

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ATTACHMENTS .

(WORK PERMIT FORMATS)

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Kuwait Oil Company (K.S.C.)

Fire & Safety Regulations

COMPRESSED AIR EQUIPMENT, BREATHING APPARATUS, GRIT BLASTING & HIGH PRESSURE WATER JETTING

Chapter No. 9 June 2004

CHAPTER - 9 COMPRESSED AIR EQUIPMENT, BREATHING APPARATUS, GRIT BLASTING & HIGH PRESSURE WATER JETTING Contents 9.1

9.2

9.3

9.3

Subject

Page

COMPRESSED AIR EQUIPMENT...

2

A.

Mobile Air Compressors.................................................

2

B.

Permanently Installed – Plant Air Compressors.......................... 2

C.

Compressor in Refrigeration Plant.......................................

2

D.

Air Receivers & Air Drier ...............................

3

E.

Pneumatic Tools......................................................

3

BREATHING APPRATUS …………………………….

4

A

Self Contained Breathing Apparatus………………………..

4

B

Air Supplied Breathing Apparatus …………………………

4

COMPRESSED AIR CAPSULE .........................................

5

A.

Air supply...............................................................

5

B.

Register..................................................................

6

C.

Medical Requirements...............................................

6

D.

Compressed Air Chamber ...................................................

6

E.

Welfare...................................................................

7

GRIT BALASTING & HIGH PRESSURE WATER JETTING...

7

A.

Grit Blasting ............................. ………………………………. 7

B.

High Pressure Water Jetting........................................

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June 2004

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COMPRESSED AIR EQUIPMENT, BREATHING APPARATUS, GRIT BLASTING & HIGH PRESSURE WATER JETTING

KOC F&S Regulations

CHAPTER - 9 COMPRESSED AIR EQUIPMENT, BREATHING APPARATUS, GRIT BLASTING & HIGH PRESSURE WATER JETTING 9.1

COMPRESSED AIR EQUIPMENT: A.

Mobile Air Compressor: The use of a mobile air compressor is not permitted in Zone-0 & Zone-1 hazardous area and discouraged in Zone-2 area also. The deployment, mobilization & operation of a mobile air compressor in Zone –2 shall be covered by duly authorized Hot Work Permit subject to equipment’s suitability for the hazardous area classification. As far as practicable the effort shall be made to deploy & operate mobile air compressor in an unclassified area. Prior to start up, the machine operator must carry out the safety checks as recommended by the manufacturer. The air carrying hoses must not be uncoupled when pressurized. All hoses used in conjunction with mobile compressor are to be maintained in good condition and shall be suitably protected from probable damage by vehicles or plant in the area.

B.

Permanently Installed Plant Air Compressor: The plant air compressor shall not be installed in Zone-0 or Zone-1 areas and shall be avoided in Zone – 2 hazardous area also. The following safety precautions must be kept in view for plant air compressor:

C.

•

The equipment & machinery shall be suitable for the hazardous area classification.

•

The air intake must be drawn from and exhaust disposed off (if prime mover is a diesel engine) to a NON-HAZARDOUS AREA.

Compressor In Refrigeration Plant: In addition to applicable requirements as mentioned above, the compressor installed in refrigeration plant, shall be located in a well ventilated room with clearly marked escape routes, entrance and exits. Any adjustment and calibration to relief valves & cutouts shall be carried as per manufacturer’ procedure subsequently certified by Inspection & Corrosion Team. Any maintenance work on air compressor in refrigeration plant, shall be carried out with due authorization of appropriate work permit under proper planning and procedure. The required precautionary measures must be complied against the potential hazards. The availability of approved fire extinguishers, personal

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COMPRESSED AIR EQUIPMENT, BREATHING APPARATUS, GRIT BLASTING & HIGH PRESSURE WATER JETTING

KOC F&S Regulations

D.

protective equipment, evacuation plan and assembly point must be insured prior to commencing the work. Air Receiver & Air Drier: The plant & instrument air receiver & air drier package must conform to respective engineering specification and code of inspection. The equipment shall be clearly marked with Maximum allowable working pressure (MAWP), and rated capacity, identification number and date of inspection. After any modification, major repair or adjustment in safety valve the equipment shall be certified by Inspection & Corrosion Team before putting it into service. The air receiver, vessel as well as drier shall be protected against undesirable high pressure & temperature as applicable. The safety valves on such equipment shall be tested by Inspection & Corrosion Team as per procedure & schedule in this regard. (Refer Chapter-19 for further detail).

E.

Pneumatic Tools: A variety of tools such as hammers, drills, saws, vibrators, lighting units are powered by compressed air. The safety precautions as hereunder shall be kept in view while operating pneumatically powered tools:

9.2

(i)

Pneumatic hammers shall be equipped with a suitable silencer or muffler.

(ii)

The air pressure must not exceed the maximum rated pressure for the equipment.

(iii)

The hose, coupling and connector to be used on a pneumatically operated tool must be safe, suitable and rated for the maximum allowable pressure.

(iv)

The hose must never be uncoupled from the pneumatic tool under pressurized condition.

(v)

The air supply hoses must be adequately protected against probable damage from vehicle or plant in the area. (Refer Cahpter-15 “Power & Hand Tools” for further detail.).

BREATHING APPARATUS: There are numerous jobs that require the use of respiratory protection such Breathing Apparatus. Some of these jobs involve exposure to chemicals, dusts, vapours, fumes and toxic substances like H2S, SO2 & CO2. The nature and duration of potential exposure will dictate the type of Breathing Apparatus that must be used. The workers must have adequate training to understand the need and use of breathing apparatus. The training shall include pre-donning inspection of the equipment, donning & removal of the equipment and post use maintenance & cleaning.

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COMPRESSED AIR EQUIPMENT, BREATHING APPARATUS, GRIT BLASTING & HIGH PRESSURE WATER JETTING

KOC F&S Regulations

It is to be noted that a person’s ability to communicate is limited when wearing a breathing apparatus. The breathing apparatus shall be equipped with portable radio attachment for communication while wearing it. The quality of air in Breathing Apparatus shall be regularly checked conforming to health and hygiene requirement. A.

Self Contained Breathing Apparatus (SCBA): It is used where there may be: • • • •

High concentration of toxic substances. Oxygen deficient atmosphere. Levels of toxic smoke. Environments considered hazardous to life.

The SCBA must consist of a full-face mask, a flexible breathing tube, a regulator, an air supply cylinder and a harness assembly. It is to be noted that the amount of air available to the user is limited by the size & capacity of air storage cylinder. The consumption of breathing air will also depend upon the metabolic and physical state of the user. After each use, SCBA must be cleaned, disinfected, recharged with air and returned to storage area in ready to use condition. The apparatus must be frequently inspected to ensure that the air pressure is adequate and that the regulator, facemask & harness are in good ready to use condition. (Refer Chapter-4 on Personal Protective Equipment). B.

9.3

Supplied Air Breathing Apparatus: If the supply for the longer period is required, it is preferable to use a supplied air breathing apparatus, connected to a continuous air supply source through flexible hose & regulator. All supplied air breathing apparatus must be fitted with a small cylinder of breathing air to allow the user to breathe in the event that the normal air supply is lost or fails. In case of emergency such as entrapment or entanglement the user must disconnect the air supply line and turn on the egress cylinder before attempting to escape.

COMPRESSED AIR CAPSULE FOR PROFESSIONAL DIVERS: The following safety precautions must be kept in view for a Compressed Air Capsule pertaining to professional divers’ preparatory arrangement prior to deep diving operation: (i)

Main-locks are to be kept in a clean and dry atmosphere. The appliances & gadgets (such as pressure gauge, clock, pressure regulators, throttling valves & relative humidity indicator etc.) must be maintained in good condition.

(ii)

A safety checklist shall be posted near each main-lock indicating precautions to be taken during compression / decompression and post decompression period.

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COMPRESSED AIR EQUIPMENT, BREATHING APPARATUS, GRIT BLASTING & HIGH PRESSURE WATER JETTING

(iii)

The worker deployed to work in compressed air enclosure must have experience & valid certification from approved agency for suitability under environmental condition.

(iv)

Any work for compressed air capsule must be constantly supervised by a competent person.

(v)

The door between working chamber and the main-lock leading to lower pressure enclosure shall be kept open when any person is inside the chamber and the lock is not in use.

(vi)

Main-lock on the access to working chambers where pressure exceeds 10 psi, are not to be used for the passage of plant and materials other that hand tools or equipment carried by workers passing through the lock.

(vii)

The capsule attendant shall control the rate of compression and perform all decompression activity.

(viii)

The workers shall not stay inside pressurized chambers if relative humidity exceeds 26.70C (800F) except in case of essential requirement with approval from the Medical authority.

(ix)

Similarly the workers shall not be deployed inside a compression chamber exceeding 50-psi pressure except in an emergency case with due approval & supervision of medical authority.

A.

Air Supply: The air supply plant shall be continuously supervised by a competent person while the persons are working in compressed air environment. The air supply plant shall be of adequate capacity to deliver the required quantity of air such as 10 CFM per person working inside the chamber. The chamber shall be equipped with facility for hyperbaric oxygen also. The supply air must be clean, hygienic and free from impurities such as smoke, toxic vapour, foul odour, flammable or corrosive gases etc.

B.

Register: The capsule attendant shall maintain a register when persons are deployed to work in pressure exceeding 18 psi. The attendant must record enclosure pressure when a worker enters or exits the capsule alongwith the time taken to decompress.

C.

Medical Requirements: No person is permitted to work in compressed air unless certified & declared fit by Medical authority.

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June 2004

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KOC F&S Regulations

COMPRESSED AIR EQUIPMENT, BREATHING APPARATUS, GRIT BLASTING & HIGH PRESSURE WATER JETTING

The fitness certificate for working inside compressed air chamber shall be valid for a period not exceeding six months. It becomes invalid if the person be incapacitated from work for any reason during that period. Each person certified as medically fit to work inside compressed air chamber must have a personal record, maintained by Medical Group detailing general health condition, medical examination results and of the amount of time spent in compressed air environment. The latter information is recorded at the place of work by the capsule attendant. Each person working inside compressed air chamber at a pressure above 18 psi must be provided with an identity tag to be worn for immediate notice in case the individual falls ill after leaving the work. The label or tag must have information such as place of work, condition of work (i.e. compressed air chamber) and emergency contact number for KOC Medical Group. Medical Group must be notified for any activity where work nature involves compressed air chamber above 18 psi pressure. The controlling team shall also inform medical group on completion of compressed air operations. D.

Compressed Air Chamber or Capsule: The compressed air chamber must be approved by Medical Group if the pressure inside the capsule may exceed 18 psi. Moreover a dedicated capsule (compressed air enclosure) shall be kept for medical treatment of personnel engaged for working in compressed air environment. The capsule shall have two compartments so that lit can be entered while still under pressure. Each capsule shall be provided with a couch, blankets, garments as recommended by Medical Group. It shall also have a window through which persons in either compartment can be seen from outside as well as an efficient communication is possible from outside as well as between compartments. The capsule attendant shall have adequate training in first aid and must remain present near the capsule when the work in compressed air environment is under progress.

E.

Welfare facilities inside the Capsule: The worker / diver shall be provided with essential facilities such as wardrobe, clothing, wash room, and change room etc. Such facilities shall be provided for workers remaining on site after decompression for at least one hour. However if the persons have been working in compressed air pressure of 40 psi or above, they must have adequate rest accommodation for at least 1½ hour after decompression. Arrangements shall be made for provision of food and drinks as recommended by Medical Group.

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COMPRESSED AIR EQUIPMENT, BREATHING APPARATUS, GRIT BLASTING & HIGH PRESSURE WATER JETTING

KOC F&S Regulations

9.4

GRIT BLASTING & WATER JET CLEANING: A. Grit Blasting: Grit blasting is permitted in Hazardous Areas, only when following conditions are fulfilled. •

The pipe work or process vessel to be grit blasted, shall be isolated and depressurized.

•

Grit blasting must be authorized under hot work permit with all required safety precautions in vogue.

A.1. Precautions During Grit Blasting: The precautionary measure must be kept in view prior to commencing grit-blasting activities: (i)

The permit applicant & permit issuer must ensure that the requirement of grit blasting is fully justified and can not be delayed until a facility shutdown period.

(ii)

Both permit issuer & permit applicant shall inspect the work site prior to and regularly during blasting to ensure that sufficient protective measures have been taken to protect cable runs, gas detection heads, instrumentation & operating equipment in the immediate grit blasting area, and to satisfy themselves that the work is being carried out safely.

(iii)

An authorized gas tester shall carry out a gas check at the work site prior to grit blasting as well as continuous gas monitoring is recommended during the entire work period.

(iv)

Suitable barrier must be erected around the grit blasting area and warning signs indicating “grit blasting in progress” must be posted around barrier.

(v)

Only personnel associated and involved in grit blasting activities shall be permitted to enter the cordoned off area. Suitable sheeting must be erected to eliminate the possibility of personnel being struck by grit material.

(vi)

All gas cylinders within the cordoned of area must be removed from the vicinity or where this is not possible extra protection from grit material impact must be accorded.

(vii)

Any paint spraying activity at the location must cease prior to grit blasting

(viii)

All pipework / equipment to be grit blasted must be adequately bonded to earth to prevent the build up of electrical charges on any process equipment. This requirement applies equally to contractor’s pots, hoses and compressors.

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June 2004

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KOC F&S Regulations

B.

COMPRESSED AIR EQUIPMENT, BREATHING APPARATUS, GRIT BLASTING & HIGH PRESSURE WATER JETTING

(ix)

The blast gun must be fitted with a dead man’s handle, which must be checked for correct operation prior to starting grit blasting.

(x)

The contractor performing the grit blasting must nominate a competent supervisor to oversee all grit blasting activities. The designated supervisor must: • Be continuously present during grit blasting and not be involved in any other task or duties. • Know the location of fire fighting equipment in the area & how to use. • Know how to immediately shutdown grit blasting equipment in case of any emergency situation.

(xi)

The workers must use suitable personal protective equipment against exposure to dust and other health hazards.

(xii)

The spent grit shall be recovered and safely disposed off to company approved waste disposal facility

(xiii)

The following minimum fire fighting equipment shall be kept available at grit blasting site in working order: • Two pressurized water hoses run out & tested. The fire hoses are to be taken from separate hydrants in order to approach from two directions. • Two suitably positioned portable type fire extinguishers. • At least one gas detector near grit blasting location and another at compressor site.

High Pressure Water Jetting: High pressure water jetting refers to cleaning with water jets at pressures greater than 2000 psi and up to around 20,000 psi. Such equipment is very effective for removal of coatings & scale as well as in metal cutting although extremely dangerous if not used carefully. Jetting equipment shall be handled by competent persons only taking following minimum precautions: (i)

The work site shall be cordoned off and warning site shall be posted at safe distance to alert the persons from prevalent danger.

(ii)

The number of workers shall be kept as minimum as possible and each worker must be made aware of potential hazard taking extreme care during the work.

(iii)

It is to noted that personal protective equipment can be affective against water spray and flying particles, but not against the direct impact of the jet itself.

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KOC F&S Regulations

COMPRESSED AIR EQUIPMENT, BREATHING APPARATUS, GRIT BLASTING & HIGH PRESSURE WATER JETTING

(i)

The worker must wear the required personal protective equipment such as PVC suit, hand gloves, safety boots, earmuffs, safety goggles or face shield and safety helmet.

(ii)

The injury caused due to water jetting may damage inner tissues although not visible at surface and must be referred to the hospital for treatment.

(iii)

The equipment and its accessories shall (such as hose, couplings & connecters) shall be suitable for pressure rating of the system and maintained in accordance with manufacturers instructions. The pump shall be equipped with a relief valve or regulator set at 10% above the rated working pressure of the weakest component in the system.

(iv)

The connector and couplings for joining different length of hoses must be suitable for sustaining the pressure implied.

(vii)

The equipment & accessories shall be inspected for quality assurance as per Inspection & Corrosion Team requirement in this regard.

(viii)

If the equipment is assembled from separate components immediately before use, then a pressure test shall be conducted prior to operation; at a pressure not exceeding rated working pressure of the weakest component.

(ix)

A failsafe trigger must be provided on the jetting gun.

(x)

Water quality shall be preferably potable water and shall not contain any undesired chemicals, hazardous substances, free silica, toxic material or oil.

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Kuwait Oil Company

Fire & Safety Regulations

(K.S.C.)

BOILERS, PUMPS AND ELECTRICAL SAFETY

Chapter No. 10 June 2004

CHAPTER -10 BOILERS, PUMPS AND ELECTRICAL SAFETY Contents

Subject

Page

10.1

BOILERS......................................................................

2

A.

Safety Valves..........................................................

2

B.

Water Level Gauges.................................................

2

C.

Fusible Plugs..........................................................

3

D.

Inspection & Certificates...........................................

3

E.

Insulation..............................................................

3

F.

Isolation...............................................................

3

G.

Ventilation............................................................

3

H.

Repairs................................................................

3

I.

Testing.................................................................

4

J.

Chimneys..............................................................

4

K.

Operation.............................................................

4

10.2

PUMPS........................................................................

4

10.3

ELECTRICAL SAFETY..................................................

5

Supply...........................................................................

6

F&S Regulations Chapter 10

June 2004

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KOC F&S Regulations

BOILERS, PUMPS AND ELECTRICAL SAFETY CHAPTER - 10

BOILERS, PUMPS AND ELECTRICAL SAFETY 10.1.

BOILERS: The failure of boilers is often caused by; insufficient amount of feed water, defects in water feeders, faulty water level indicators, improper work practice and contaminated water condition. It is mandatory that the Boiler Operators should have special training and must be fully conversant with safety rules & standard code of practices about boiler & its auxiliaries. A boiler shall neither be operated beyond the maximum certified pressure nor beyond the period specified on the valid inspection certificate. This regulation is intended in reference to industrial & commercial type steam generating boilers in the Company. A.

Safety Valves: On every safety valve the following information should be displayed in addition to the usual technical data.

a.

Set Pressure with units.

b.

Date of Calibration & due date of inspection.

c.

Tag No. & Vessel / Line No.

d.

Inspection Authority for setting valves pressure

The copy of the test certificate shall be available with the concerned asset owner and Inspection & Corrosion Team. The safety valve shall be re-calibrated before the due date of inspection. Each Boiler shall have at least two safety valves. The safety valves should be locked, and where applicable ferruled, so that unauthorized personnel cannot tamper with them. The safety valves and the lines should be adequately sized to ensure proper relief from the vessel being protected. B.

Water Level Control & Gauges: The water level gauges should have sufficient illumination for easier & convenient visibility of water level inside the boiler. Tubular level gauges should be fitted with stout glass guards as a safety protection against accidental bursting of gauge glass. Moreover the stopcock should be fitted at both ends level gauges to facilitate its isolation from the boiler for operation and maintainability need. The level gauges should also be fitted with a test cock at the bottom.. The water level control system should be thoroughly inspected & overhauled at the time of annual survey and additionally tested as & when required to assure its reliability.

C.

The internal flue type Boilers shall have fusible type Heat Detectors fitted in its immediate vicinity for heat detection and relevant control action.

Fusible Type Heat Detectors:

F&S Regulations Chapter 10

June 2004

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KOC F&S Regulations D.

BOILERS, PUMPS AND ELECTRICAL SAFETY

Inspection and Certificates: The routine inspection should be carried out on daily basis for checking early signs of defects and malfunctions. Any maintenance work to be carried out inside combustion chamber, gas carriers / tubes or in the pressure vessels itself, must be authorized under relevant WORK PERMIT. The asset owner must keep a record of all inspection & maintenance activities carried out on the boiler with due endorsement by Inspection Authority.

E.

Insulation: Adequate thermal insulation shall be provided and moreover the insulation should be in good condition to protect operators from inadvertent hot burn.

F.

Isolation: Before a boiler is entered for inspection or maintenance, it must be positively isolated from all steam as well as water lines, preferably by removal of pipe spool adjacent to the boiler whereas open end of the line is blanked off. If it is not feasible, then the relevant isolation valves must be securely closed, locked, spaded or blanked ensuring that these valves are not passing. Similarly before entry into combustion chamber, fuel gas / oil supply lines must be disconnected and blanked off (Refer Chapter 8 on Vessel Entry Permit).

G.

Ventilation: Before entry to a boiler or combustion chamber, sufficient time must be allowed to elapse after opening up the manhole to facilitate thorough ventilation, breaking of vacuum and expulsion of gases. The atmospheric testing of the confined space for flammable gas, toxic vapour and oxygen deficiency must be carried out. It is essential to maintain good ventilation during the period while the personnel are working inside the boiler or combustion space. Continuous ventilation will be essential during hot weather condition or when welding or work of a strenuous nature is being done inside the confined space. The ventilation of combustion space whether natural or forced, will give rise to objectionable dust; the personnel working inside must wear protective goggles & dust masks. (Refer to Vessel & Confined Spaces Entry Procedure Appendix 6).

H.

Repairs: Any failure or suspected defects must be immediately reported to Boiler Surveyor. Before carrying out any repair work on pressure carrying part of the Boiler, the Surveyor must be consulted and the repair work done up to his satisfaction.

I.

Testing: The boiler must be hydraulically tested up to a pressure as stipulated by the Surveyor prior to steaming the boiler. The boiler Surveyor may require subsequent hydraulic tests following repairs or in the course of re-certification. New Safety valves, high & low

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KOC F&S Regulations

BOILERS, PUMPS AND ELECTRICAL SAFETY

water level alarms, blow down valves; water level gauges and instrumentation fittings, which may be taken into service, must be tested & approved by the boiler surveyor prior to installation.

J.

Chimneys: The upper stakes of a steel chimney should be examined for corrosion in accordance with shutdown philosophy or specified due inspection. The personnel engaged to work on chimney must be trained on precautionary measure for working at height. The required safety harness must be used while working at height. The repair work in chimneys should not be permitted during inclement weather conditions such as severe heat or cold, high winds, rain and dust storms.

K.

Operation: The operating procedures shall be developed enlisting stipulated actions for normal, critical and emergency situation. Care should be taken while charging the pipelines with steam, and all the by-pass valves on the steam traps should be kept open to avoid water hammering, which may cause extensive damage to the piping and instrument fittings.

10.2.

PUMPS: Every effort is to be made to prevent leakage from pumps handling gaseous or volatile liquid products. Such leakage from a pump may cause fires or release toxic vapour. The leakage from pump glands must not be allowed to collect on floors & should be drained away to a disposal pit. The gland leakage from a pump handling oil must be routed to a proper drainage system or to disposal sump at a safe location. Any abnormal or excessive leakage from the pump must be brought to the notice of concerned maintenance supervisor for immediate remedial action. In case of over-heating, the pump must be shut down immediately, unless it is vital to the safety of the process plant. Under such circumstances the pump must be kept running till process can be shut down safely. Sufficient ventilation shall be maintained inside a pump – house with pumps handling petroleum or other hazardous product. All repair work on a pump located in RESTRICTED AREA shall be authorized under appropriate WORK PERMIT. The mechanical guard protecting shafts, coupling, and other moving parts, should be maintained in good condition and it must not to be removed while the pump is running. Any portable pumps shall not be used within Zone - 0 & Zone-1 whereas it may be used in Zone 2 under hot work permit authorization. Electrical Maintenance should approve an electrically powered pump alongwith associated cables & fittings, prior to its use in operational area. Moreover any portable pump must have a check valve & pressure gauge on its discharge line. Before starting a pump, all valves on the suction and charge lines should be in the correct mode, including lines, joints & supports are in good condition.

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BOILERS, PUMPS AND ELECTRICAL SAFETY

When a pump powered by diesel run prime mover is used, then the diesel engine must comply with safety requirements as stipulated in Chapter 1 & 17 for diesel engines and mobile plant. Portable pumps used for emptying the storage tanks must be located outside the bund wall, except where the tanks containing heavy sludge require the pump to be located within the bund wall periphery, in such case the pump must be placed not nearer than 8 meters (26 feet) from the tank. The pump unit must be kept in ready to run condition prior to opening any manhole covers of the tank. The pump unit should be positioned up-wind of the open manhole. There should be frequent gas monitoring in the area adjacent to the pump. Pumps should be bonded & grounded properly to eliminate static electricity hazard. 10.3.

ELECTRICAL SAFETY: No electrical work shall be carried out except with due authorization under appropriate Work Permit. The competent person approved by the relevant Maintenance Team can carry out electrical work. All electrical works must be carried out in a safe manner with full compliance to KOC "Safety Rules - Electrical Power System & High Pressure Apparatus"(Refer Appendices10). All electrical work must be covered by an appropriate WORK PERMIT under proper lock out and tag out procedure for safe execution of work. On completion of the electrical work, the maintenance authority shall inspect the installation to ensure the quality of materials and proper rating of devices used. Finally clearance certificate shall be issued upon confirmatory physical examination for unusual conditions such as hot joint, overheating, insulation, termination etc. Competent, qualified and approved personnel shall carry out testing and energizing of the equipment. Before testing and energizing the equipment, all necessary precautions shall be taken to ensure the safety of personnel and equipment. No crane, hoist or scaffoldings etc., shall be used or erected near overhead power lines without a WORK PERMIT duly authorized by concerned Maintenance Team. The presence of underground electrical cables must be determined before any excavations work is taken up. The excavation notification must be authorized & endorsed as per company procedure. All portable electrical equipment must be approved by the Maintenance Team and shall used as per suitability for the relevant area only. The First Aid instructions about emergency resuscitation (in case a person is rendered unconscious due to electrical shock) shall be posted in all electrical sub-station as well as at other points as considered desirable by Maintenance Team or Medical Group. In the event of a person being rendered unconscious due to electrical shock, the victim should be removed safely away from the electrical source and immediate artificial respiration be given by a trained personnel and Medical assistance called without delay. All electrical equipment shall comply with Hazardous Area Classification as stipulated in KOC standard KOC-G-002. Supply:

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Any interruption of electrical supply due to the blowing of fuses, mal-operation of cut-outs or any other defects must be reported immediately to the concerned Maintenance Team or the Company's approved electrical contractor. Any damage to electrical equipment, which might occur without interrupting the supply must be reported to the concerned Maintenance Team immediately. Damaged equipment must not be touched until the isolated by the maintenance personnel. In the event of fire on electrical panel or equipment, the electric power supply must be isolated and suitable fire extinguisher shall be used to extinguish the fire by the person available at site.

F&S Regulations Chapter 10

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Kuwait Oil Company (K.S.C.)

Fire & Safety Regulations CRUDE OIL - STORAGE TANK, PIPELINES & OIL SPILL

Chapter No. 11 June 2004

CHAPTER -11 CRUDE OIL - STORAGE TANK, PIPELINES & OIL SPILL Contents

Subject

Page

11.1

Storage Tank Hazards For Cleaning & De-sludging. ………

2

11.2

Additional Hazard For Floating Roof Tanks…………….

3

11.3

Safety Aspects In Tank Preparation For Cleaning & Desludging.

5

11.4

Precautions For Entry Upon Floating Roof Tank……….

9

11.5.

Precautions For Descent Onto External Floating Roofs…………

10

11.6.

Precautions For Descent Onto Internal Floating Roofs…………

11

11.7.

Safety & Rescue Equipment……………………………………….

12

11.8

De-Commissioning Safety Check………………………………… 13

11.9

Entry Permits For The Tank ………………………………………

14

11.10

Safety During Tank Cleaning…………………………………….

15

11.11

Hot Work Inside The Tank……………………………………….

16

11.12

Safety During Tank Re-Commissioning …………………………

16

11.13

Safety During Tank Construction, Erection & Maintenance....

20

A.

Safety Aspects During Tank Construction ………………

20

B.

Safety Aspect During Tank Erection ...........……………..

20

C.

Safety Aspects During Tank Maintenance ....................

21

11.14

11.15

Pipeline Safety ………………………….............................

22

A.

Safety Aspects During Pipeline Installation............

22

B.

Safety Aspects During Pipeline Operations........................

22

C.

Safety Aspects During Pipeline De-contamination..……..

23

Oil Spills & Pollution Control ….......................................

F&S Regulations Chapter 11

24

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KOC F&S Regulations

CRUDE OIL - STORAGE TANK, PIPELINES & OIL SPILL

CRUDE OIL - STORAGE TANK, PIPELINES & OIL SPILL 11.1 Storage Tank Hazards For Cleaning & De-sludging: All tanks that have contained crude oil or petroleum products may present one or more of the following hazards during some phase of preparing the tank for entry and cleaning: • Fires & Explosion • Oxygen deficiency or enrichment • Toxic substances (liquid, vapors, fumes & dust) • Physical and other hazard.

11.1.1 Fire & Explosion Hazard: The potential for a fire within or outside a tank can exist during all phases of tank work from decommissioning through recommissioning. Depending upon a number of factors, including tank design, its integrity, air/fuel ratio and the number of open vents, fire inside a tank may cause an explosion due to expanding gas. 11.1.2 Oxygen Deficiency: An oxygen deficiency can exist in tank for a number of reasons. (a) The vapors of some hydrocarbons stored in atmospheric or lowpressure tank s are heavier than air and will displace or dilute air. (b) If tank has been closed, oxidation (rust) can deplete the tank oxygen content. (c) A tank that is maintained under an inert gas will be almost devoid of oxygen

11.1.3 Oxygen Enrichment: An oxygen enrichment hazard is that where the oxygen concentration is over 23.5%. Occasionally, oxygen bottles or cylinders used during tank work may leak and provide a source of oxygen enrichment.

11.1.4 Toxic Substances: Toxic substances hazards likely to be encountered in tank entry & cleaning are listed as hereunder: (a) (b) (c) (d) (e) (f)

Hydrogen Sulfide Dusts Petroleum Substances Welding Fumes Lead - based Paints Physical & Other Hazard

(a) Hydrogen Sulfide: H2S is an extremely toxic flammable gas that is encountered in the production, processing & storage of sour crude oil.

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KOC F&S Regulations

CRUDE OIL - STORAGE TANK, PIPELINES & OIL SPILL Exposure to high enough concentration of H2S causes death by respiratory system.

paralysis of

(b) Dusts: Dust encountered in tank maintenance includes those caused by the removal rust, paint & tank insulation.

(c) Petroleum Substances: The inhalation of high concentration of hydrocarbon vapors can cause sign & symptoms of intoxication. These symptoms range from dizziness to excitement to unconsciousness; they are similar to those produced by alcohol or anesthetic gases. Appropriate personal protective equipment should be worn according to recommendation & applicable regulation. (d) Welding Fumes: Toxic fumes are generated during welding on metals coated with or containing alloys of lead, zinc, cadmium, beryllium and certain other metals. Some paints may produce toxic fumes when heated with a welding torch. The potential health effects of welding fumes vary in type & severity depending composition & concentration of fumes generated.

(e) Lead Based Paints: Significant lead exposure can occur during removal of paint from surfaces previously coated with lead-based paint. Cumulative exposure to lead may result in damage to the blood, nervous system, kidneys, bones, heart and reproductive system. Prior to commencing work on a tank, a written lead abatement program shall be developed for the safe removal & handling of lead based paint. This program shall include procedures for the use of appropriate engineering controls, work practices and personal protective equipment to keep exposure below permissible limits.

(f) Physical & Other Hazard: In addition to injury or property damage that may result from fires, explosions, asphyxiation & toxic substances; additional hazards may emerge from the following situations.

(i) Structural failure of the tank shell, roof, roof support members, swing line cables etc. (ii) Falls through corroded roofs or from scaffolds, stairs & ladders. (iii) Accidental discharge of steam, high-pressure air, water or oil either into the tank or against personnel working outside; due to inadequate isolation. (iv) Failure to disconnect or make electrical or mechanical equipment in operative. (v) Use of lighting classification.

fixtures

inappropriate

to

hazardous

area

(vi) Sharp angles, welding lugs etc. within the tank that can snag clothing or skin in addition to tangling or cutting retrieval lines.

11.2 Additional Hazard Considerations for Floating Roof Tank: The following additional hazard considerations are to be kept in view as a measure to identify, evaluate and protect entrants from potential hazard associated with entry on floating roofs:

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CRUDE OIL - STORAGE TANK, PIPELINES & OIL SPILL

11.2.1 Hydrocarbon Entrapment Hazard: A flammable atmosphere may also be present inside pontoons (Device for providing buoyancy), floats, primary & secondary seals areas or underneath floating roofs out of floatation. These areas must be considered as separate confined spaces and must be tested appropriately. These spaces may also need to be ventilated or inerted & the atmosphere retested prior to permitting entry. The floatation & sealing devices should be inspected and hydrocarbon trapped be removed to minimize the potential of fire, oxygen and toxicity hazards. The greatest vapor concentration above the floating roof may be expected when the roof has been out of floatation and is then being refloated. These vapors may persist for extended periods depending on conditions. 11.2.2`Potential Fire Hazard: Some of the potential fire hazards associated descent upon floating roofs include, but are not limited to the following: (a) A flammable vapor air mixture may exist in the atmosphere above the floating roof due to roof seal leakage. (b) A flammable liquid may be present on the floating roof due to overflow or pontoon leakage. (c) A flammable liquid or vapor may be present in the pontoon or seal area due to pontoon leak or seal rupture. (d) The leakage of liquids or vapor from pontoons, buoyant foam panels, other floatation devices, linings and seals may result in toxic or flammable vapors being present in the tank vapor space. (e) When the floating roof is out of floatation and the liquid level is below the roof support, a flammable vapor air mixture may exist in the atmosphere below the roof. (f) A build of vapors may be more likely in internal floating roof tanks because of the possibility of liquid being retained inside the envelope formed of floatation & sealing components. (g) Plastic used in internal floating roofs may be combustible, and this characteristic should be considered, particularly for activities involving hot work or source of ignition. Seals may also be made of combustible material or may be oil soaked. (h) When filling a tank whose roof has been out of floatation and the liquid level has been below the roof level, vapors may be forced through the roof seal & into the atmosphere above the floating roof. 11.2.3 Potential Physical Hazards: Entry onto floating roofs presents potential physical hazards including but not limited to: (a) Floating roofs shall be visually inspected from above for structural stability prior to descent. The height of the roof above the tank bottom may not permit personnel to walk erect. F&S Regulations Chapter 11

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KOC F&S Regulations

CRUDE OIL - STORAGE TANK, PIPELINES & OIL SPILL

(b) Many internal floating roofs are of light construction and walking on the roof surface can be hazardous unless limited to areas designated for that purpose. (c) If weak areas are found during inspection or are known to exist in the floating roof, access to these areas shall be prohibited until suitable reinforcement has been provided. (d) Defective roof areas or panels, which were not designed to support the weight of the personnel, may be difficult to detect because of the restricted visibility above the roof. (e) Entry upon internal floating roofs which do not have pontoons for increased buoyancy should be considered extremely hazardous and conducted under specific safe work procedures & practices to protect entrants from entrapment in case the roof sinks / tilts. (e) The outside roofs & covers, wind girders, ladders, stairways, walkways, rails and other roof supports shall be inspected to assure that they can hold the weight of any equipment / material which to be placed on top or attached to them.

11.3 Safety Aspects In Tank Preparation For Entry & Cleaning: The following precautions but not limited to must be taken while preparing the tank for safe entry & cleaning: (A) A review of tank configuration, piping details, site layout & determine scope of work. (B) A review of information concerning the products contained in the tank to be entered and assess potential safety & health hazard for the job (C) Preparation of a safety and work plan for the entire job mentioning - the equipment needed & its suitability for area classification, establishment of work permit & emergency response system. 11.3.1 Safety Considerations In Emptying The Tank: The tank shall be emptied of all recoverable products through the tank discharge nozzle & line or other suitable connections. The unrecoverable product that remains below the tank discharge nozzle shall be removed using procedure established by the asset owner in the safety & work plan. However the following salient points are suggested for inclusion in the tank emptying procedure: (a) The tank to emptied through existing lines until the main pump nearly loses suction. (b) If a temporary field pump is used to complete the emptying process, check the safety & integrity of the pump, hose and other accessories including conformance to hazardous area classification. (c) If the flammable & toxic gas test result is negative and the permit system is satisfied, move the temporary pump & hose to the diked area. F&S Regulations Chapter 11

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KOC F&S Regulations

CRUDE OIL - STORAGE TANK, PIPELINES & OIL SPILL

(d) Confirm that temporary equipment is electrically bonded & grounded. (e) Pump out remaining liquid with the field pump until it loses suction. (f) Alternate method for removing remaining product is by filling water into the tank and the remaining oily product will float on water and can be removed through discharge line. 11.3.2 Safety Considerations In Isolating The Tank: The tank shall be isolated from all lines connected to the tanks by using blanks / blinds or double block & bleed valves, all of which shall be as close as possible to the tank. If the tank valve or line is to be removed and the tank has cathodic protection, the following precaution to be taken: (i) (ii) (iii)

The cathodic protection shall be turned off. A bond wire shall be installed from the tank to the line. The valve or line shall be disconnected and removed alongwith the bond wire.

The following additional safety consideration to be adhered for tank isolation & preparation prior to tank entry: (a) Prepare documents required under the permit program and the lockout / tagout procedure including isolating device listing. (b) Close all suction & discharge lines at the tank and install lockout/tagout devices. (c) Lockout & tagout all energy sources such as pump, motors, mixers & instrumentation devices. (d) Use of motorized equipments, such as automobiles, trucks, forklifts, welding machines and compressors shall be limited to safe areas by posting signs & barricading access as necessary. (e) If a compressor is used for ventilation, it should be equipped with filters to remove scale, rust, oil, moisture and dust particles, which can be a source of ignition due to static electricity. (f) Precaution shall be taken to prevent Pyrophoric deposits from becoming an ignition source. (g) The metallic parts of ventilating equipment and hoses shall be electrically bonded to the tank. (h) Control ignition sources before opening any lines. 11.3.3 Safety Considerations In Vapor Freeing The Tank: The tank shall be freed of flammable & hazardous vapors by using appropriate methods that will safely ventilate the tank. In the initial stage of vapor freeing, while the tank still contains high concentrations of flammable vapor, maintenance work in the F&S Regulations Chapter 11

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KOC F&S Regulations

CRUDE OIL - STORAGE TANK, PIPELINES & OIL SPILL

immediate area surrounding the tank shall be restricted. Since some hydrocarbon vapors are heavier than air, it is advisable to discharge vapors at high elevation for quick dispersion. There are several methods of vapor freeing a tank such as: • Mechanical Ventilation • Steam Ventilation • Inert Gas Purging • Natural Ventilation (i) Mechanical Ventilation: Mechanical Ventilation equipment normally consists of air movers (such as Eductors or Blowers) that are driven by electricity, air or steam. The equipment must be suitable for classified locations and the air movers must be electrically bonded to the tank. Air movers, which have moving parts or can otherwise produce spark or ignition source should not be used in application where the tank vapors may be in the flammable range and will pass through the air mover. Eductors with no moving parts should be used in such application. (ii) Steam Ventilation: Steam ventilation may be advantageous in specific cases, but its use introduces some additional hazards. Steam ventilation should be avoided when suitable alternatives are available. (iii) Inert Gas Purging: If this method of gas freeing is used, then additional

precautions are necessary to ensure appropriate ventilation for removing the inert gas prior to tank entry & cleaning. (iv) Natural Ventilation: Natural ventilation simply entails removing the roof

& shell manway covers and allowing the tank to stand idle until natural ventilation makes the tank vapor free. Natural ventilation should be avoided if other methods are available because vapor may drift to a source of ignition. (N.B.: It is highly recommended for the asset owner to prepare a detail procedure of vapor freeing based on size & type of tank).

11.3.4 Safety Precautions For Testing The Tank Atmosphere: Prior to starting any work outside or inside the tank, testing of the tank atmosphere for the following contents shall be carried out in the order as mentioned hereunder: • • •

Oxygen Content Flammable Vapors Toxic Vapors

The following precautions to be kept in view for testing the tank atmosphere: (a) The test equipment should be intrinsically safe or suitable for hazardous area classification. (b) The atmosphere around the tank shall be tested after the completion of preparatory steps and during the ventilation process when & how much activity can take place around the tank.

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CRUDE OIL - STORAGE TANK, PIPELINES & OIL SPILL

(c) The test shall be also taken at points where vapors are being exhausted from the tank and in the area around to ensure non-existence of flammable & toxic vapors above permissible levels. (d) A qualified person shall test the internal atmosphere to establish existence of permissible entry condition through out the tank. (f) The atmosphere inside tank interior shall be tested especially in critical & suspect areas, such as leaking tank bottom, roof supports, sumps, roof seals, roof drains etc. (g) The ventilating equipment should be shutdown for 15 minutes allowing tank atmosphere to reach equilibrium conditions before testing the interior. (h) The qualified person performing the test shall wear Self Contained Breathing Apparatus (SCBA) and appropriate protective clothing when entering the tank for testing purpose. (i) The care shall be taken by the qualified person who performs the tests to ensure that results represent the true condition of the tank. (j) Atmospheric testing shall be conducted, as necessary, to protect workers while in the tank and to ensure that the desired atmospheric conditions are maintained throughout. (k) The results of atmospheric testing, the time of testing, and the signature of the person who performed the tests shall be recorded in the entry permit. as well as in the work permit. (l) If test results & tank conditions are acceptable, the entry permit for work will be issued. If test results are not acceptable, then ventilation process will continue and testing steps will be repeated. (m)

The table as hereunder indicates the permissible levels with respect to entry & work restrictions.

ENTRY WITHOUT RESPIRATORY PROTECTION PERMITTED (Refer Note 1 & 2) RESPIRATORY PROTECTION REQUIRED FOR ENTRY

F&S Regulations Chapter 11

• • • • • • • •

Oxygen concentration between 19.5 % & 23.5 % H2S concentration is less than 10 ppm Air Contaminants are below permissible exposure limits (PEL) & Hydrocarbon concentration is less than 1% of LEL An adequate flow of fresh air is maintained. Oxygen content is less than 19.5% or greater than 23.5%. H2S concentration is greater than 10 ppm. Air contaminants are above permissible exposure limit (PEL) Hydrocarbon concentration is greater than 1% LEL but less than 10%LEL

June 2004 Page 8

KOC F&S Regulations

NO ENTRY

CRUDE OIL - STORAGE TANK, PIPELINES & OIL SPILL • • • •

Note:

Hydrocarbon concentration is greater than 10% LEL. Hazardous materials such as acids or caustics are present. The toxicity of atmosphere is immediately dangerous to life or health. The facility or associated process are experiencing operational problems

1. It is to be taken care that level of gas concentrations may change due to variation in ambient temperature. 2. The entry in a tank having sludge or residue inside shall be permitted only by using BA sets all the time.

11.4 Precautions For Entry upon Floating Roof Tank: 11.4.1 Ventilation Requirements: Mechanical forced air ventilation arrangement will vary according to the type, size and configuration of the tank. Air or steam driven Eductors or Blowers are recommended in order to reduce ignition hazards. If electric motor driven blowers are used, they shall be suitable for the hazardous area classification. All air movers shall be properly bonded to the tank shell or roof to eliminate the possibility of any electrostatic accumulation. (a) The atmosphere within the work area shall be periodically tested as necessary to ensure that the continuous mechanical forced air ventilation is preventing the accumulation of any hazardous atmosphere. (b) Ventilation equipment should be shutdown for 15 minutes to allow the tank atmosphere to reach equilibrium conditions before testing the interior. (c) In addition to hydrocarbon flammability factors, tank must be evaluated with respect to with respect to potentially toxic exposure. 11.4.2 Testing the atmosphere above & below the Floating Roof: In addition to precautions & procedures described in section 6.4 for testing the tank atmosphere; the following care should be also be kept in view: (a)

In case of floating roof tanks, particularly the internal type, initial oxygen, flammable vapor and toxic substances test may be made with an instrument equipped with an extension device.

(b)

This testing can be done from the top of the tank so that preliminary readings can be obtained without descending onto the internal roof.

(c)

For descent onto the tank roof for further testing, the tester should have appropriate respiratory protection and protective clothing.

(d)

The entry supervisor shall assure that all necessary tests have been conducted and all personnel, procedures & equipment required by the entry permit are in place, before authorizing descent on floating roof.

(e)

As a minimum, atmospheric testing shall be conducted prior to descent at the beginning of each shift, prior to re-entry after any prolonged

F&S Regulations Chapter 11

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KOC F&S Regulations

CRUDE OIL - STORAGE TANK, PIPELINES & OIL SPILL periods of inactivity or work interruption, prior to starting hot work and any time conditions are suspected to have changed.

(f)

The atmospheric testing in work area above the surface of floating roof shall be either continuous or conducted as necessary to assure the continuation or maintenance of permitted safe working conditions.

(g)

The need for continuous or intermittent monitoring and the use of approved respiratory protective equipment shall depend on the results of the testing and the potential for increased atmospheric contamination or oxygen availability during entry & work operation.

(h)

If potential exists for acute toxic exposures, such as H2S, then continuous monitoring equipment shall be used even if initial monitoring indicates safe level.

(i)

The criteria for entry without respiratory protection will be based on permissible exposure limit (ppm) rather than % of LFL.

(j)

The results of testing the atmosphere above floating roof must meet the following criteria: i)

The Oxygen content of the air is at least 19.5% and not greater than 23.5% for entry on to the floating roof without air supplied respiratory protection (provided there is no flammable or toxic concentration)

ii)

The oxygen content of the atmosphere is at least 10% in order to accurately determine flammable hydrocarbon vapor levels.

iii)

Hydrocarbon vapor level in the atmosphere are below 10% LEL in order to allow entry onto the floating roof with approved respiratory protection system.

11.5 Precautions for Descent onto External (Open – Top) Floating Roofs: Before initial descent onto the floating roof is authorized, the assigned tester shall conduct atmospheric tests from outside the tank. The following precautions in this regard is to be observed: (a)

In order to defeat the possibility of a static electricity discharge, the tester, when approaching the top and before opening any gauge hatch or other opening shall touch the steel handrail or tank shell with a bare hand.

(b)

After atmospheric test have been conducted from outside the tank, the tester shall descend cautiously for the purpose of gas testing, wearing an approved air supplied respirator if the tank contains sour tank.

(c)

An attendant shall be stationed at the platform or access ladder on the roof of the tank, to observe and maintain visual and / or aural contact with the tester during the initial descent.

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KOC F&S Regulations

CRUDE OIL - STORAGE TANK, PIPELINES & OIL SPILL

(d)

The external floating roof should be in floatation and the bleeder valve closed prior to descent.

(e)

Entrants shall not be allowed to descend onto an external floating roof, which is out of floatation until atmospheric testing has been conducted both above and below the roof and the condition is acceptable.

(f)

Following the initial descent and completion of atmospheric testing and inspection by tester, the entry supervisor shall ensure that all required conditions specific to the proposed work have been met prior to issuing an entry permit.

(g)

Leg positioning pins should be located in the high roof position with retaining cotter pins. This precaution will facilitate cleaning operation by supporting the roof at as high a position as possible above the tank bottom.

(h)

Atmospheric testing shall be conducted continuously or at regular intervals during work on the external floating roof. If the work is to be performed on or near seals, vents or other openings, additional testing must be conducted to assure that the atmosphere in the immediate work area meets established safe work conditions.

(i)

Any entry into the pontoons or underneath the secondary seals of an external floating roof shall be considered as permit required confined space entry. Each individual space shall be checked to determine the atmospheric conditions prior to issuance of entry permit.

(j)

Should operating, physical or atmospheric conditions change so that the area is no longer safe for work, entrants shall leave the floating roof immediately and shall not return until the safe entry conditions are confirmed through retesting as per procedure.

(k)

At the end of each work period or upon vacating the external floating roof for any extended period of time, the floating roof shall be returned to safe conditions, as near to normal as possible.

11.6 Precautions for Descent onto Internal Floating Roofs: Descent onto internal floating roofs or covered floating roofs constitutes permit required confined space entry and all associated safety requirements must be met as summarized (but not limited to) as hereunder: (a)

The entry supervisor is responsible to ensure that all the required conditions specific to the proposed work have been met, prior to issuing the entry permit.

(b)

The potential atmospheric hazards (flammable, toxic & Oxygen deficiency) in the space between the internal floating roof and the cover on the top of the tank shall duly be considered.

(c)

The internal floating roof should be in floatation (not sitting on its legs) and bleeder valve closed prior to descent.

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CRUDE OIL - STORAGE TANK, PIPELINES & OIL SPILL

(d)

Entrants shall not be allowed to descend onto an internal floating roof, which is out of floatation (sitting on its legs) until atmospheric testing has been conducted both above & below the floating roof and conditions allow the issuance of work permit.

(e)

Prior to descent, the internal floating roofs shall be checked for potential physical hazards & stability. The potential for falling through or tilting aluminum, expanded foam, or plastic floating roof shall be evaluated.

(f)

All electrical and other power operated equipment such as tank mixers, heaters, steam coils and remote control tank valves shall be shut off at their motor controllers and locked &/or tagged as per procedure.

(g)

Continuous forced air mechanical ventilation may be necessary to maintain a safe atmosphere in the space above the internal floating roof.

(h)

Any entry into the pontoons or underneath the secondary seals of an internal floating roof shall be considered, as permit required confined space entry. Each individual space shall be checked to determine the atmospheric conditions prior to issuance of entry permit.

(i)

Should operating, physical or atmospheric conditions change so the area is no longer safe for work, entrants shall leave the internal floating roof immediately and shall not return until the safe entry conditions are confirmed through retesting as per procedure.

(j)

Product shall never be put into a tank while entrants are on an internal or covered open-top floating roof.

(k)

Entrants engaged in cleaning liquid products, sludge, rust and scales on tanks which have previously contained sour crude or toxic gas such as H2S, shall wear appropriate approve personal protective clothing and air supplied respiratory apparatus or self contained breathing apparatus

11.7 Safety & Rescue Equipment: Difficult rescue situations can develop if entrants become ill, are injured, or are otherwise incapacitated while on the floating roof or inside the tank. The appropriate rescue provision to be used will depend upon the type, service, operations of the tanks and the work being performed. The safety plan for tank work should include a means for timely rescue of workers from the tank with following considerations: (a)

Self Contained Breathing Apparatus (SCBA) should be immediately available at the tank for rescue operation by the trained personnel.

(b)

A lightweight material to spread the weight of personnel over a greater area of floating roof.

(c)

A rescue Toboggan, which will fit through the roof manway for lifting an incapacitated person out of the tank.

(d)

Safety harness and lifeline should be used when descending on the floating roof.

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CRUDE OIL - STORAGE TANK, PIPELINES & OIL SPILL

(e)

A davit, which can be attached to the fixed roof tank for lifting the Toboggan with an incapacitated person out of the tank.

(f)

An attendant shall be stationed at the top of the ladder or near the roof opening to maintain visual or aural contact with entrants on the floating roof.

(g)

The attendant shall immediately advise the entrants if an emergency occurs elsewhere in or near the facility, which requires them to exit from the floating roof.

11.8 Decommissioning Safety Check:

The Decommissioning Safety Check as

tabulated hereunder shall be carried out: S. No. 1

2

3

F&S Regulations Chapter 11

Status

Decommissioning Safety Checks Electrical – • The tank shell earthing connections are removed • The earth cables associated with floating roof cover are disconnected and intact. • The grounding seal / bonding shunts on the floating roof are removed. • The cathodic protection system on the piping is deenergized. • Electrical fittings associated with any side entry mixers are disconnected. • The temporary equipment (such as pumps & hoses etc.) used for emptying out the tank, are electrically bonded & grounded. • The metallic parts of ventilating equipment and hoses shall be electrically bonded to the tank. Operational – • Inlet V/Vs to tank are isolated, spaded & tagged. • The tank is emptied out till the field pump loses suction. The floatation & sealing devices are free from hydrocarbon. • The tank is thoroughly vapor freed. • All outlet valves from the tank are isolated, spaded & tagged after the tank is empty & vapor free. • The tank atmosphere has been tested for Oxygen content, flammable & toxic vapors and the results are acceptable from safety viewpoints. Fire Protection – • The foam lines & their associated fittings are disconnected after necessary override. • The sprinkler system is isolated & disconnected. • The fire protection system is override and isolated. • Confirm prior to opening any line that there is no ignition source in the vicinity.

June 2004 Page 13

KOC F&S Regulations 4

CRUDE OIL - STORAGE TANK, PIPELINES & OIL SPILL Mechanical – • The internal floating cover is removed. • The side entry mixers are removed. Instruments – • Tank level gauging equipment is disconnected • Any separate high or low-level alarms are override. • The tank temperature measurement instrumentation is disconnected. • Any instrumentation associated with side entry mixers is removed

5

11.9 Entry Permits for the Tank: Before entering a tank, a written entry permit shall be issued by a qualified person The qualified person who issues the permit shall be familiar with the configuration of the tank to be entered and the reason for tank entry. Conditions & precautionary measures for entry will depend upon the potential hazards associated with the entry, atmospheric test results, other physical hazards, and structural conditions & constraints. The conditions within the tank will determine the level of precautions necessary for entry; however the following considerations to be kept in view prior to authorizing entry permits: (a)

All tanks shall be considered to require entry with special precautions until the results of tank atmosphere tests demonstrates otherwise.

(b)

If tank entry is required in order to verify atmospheric tests conducted from the exterior of the tank, then the appropriate level of respiratory & protective equipment shall be worn to protect the tester from any potential hazards within the tank.

(c)

The tank conditions shall be carefully monitored throughout the entry, as necessary, to ensure conditions remain within permitted entry levels.

(d)

If conditions change during course of entry, all work shall stop and worker shall exit the tank until the conditions can be re-assessed.

(e)

Any tank that has been cleaned but closed & inactive shall be retested for entry as though it were the initial test.

(f)

Appropriate respiratory & protective equipment shall be kept ready to meet the existing and potential atmospheric conditions within the tank and to allow the performance of specific tasks or activities.

(g)

A contingency plan shall be prepared for retrieval & rescue operation.

11.10 Precaution During Tank Cleaning: The tank entry permit shall be executed provided the tests results & tank conditions are acceptable and safe for entry, ignition source have been controlled, no lightning storms are threatening and the integrity of the tank is satisfactory. The following consideration shall be kept in view during the tank cleaning operations:

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KOC F&S Regulations

CRUDE OIL - STORAGE TANK, PIPELINES & OIL SPILL

(a)

A prior arrangement shall be made for disposal of tank sludge, which must comply with company & state regulations for disposal in environmentally approved manner.

(b)

Prior to physical sludge removal, it is advisable to remove as much of the sludge as possible by re-suspending and pumping it out. This is particularly viable if the sludge level is above manways.

(c)

The workers who enter the tank for cleaning shall wear appropriate protective clothing for atmospheric conditions & for the task to be performed.

(d)

If a tank is entered while under Special Precautions (OSHA permit – required confined space), at least one attendant shall be made available as standby personnel outside the tank to monitor activities, record entrants, control potential hazards & co-ordinate for rescue operations.

(e)

Atmospheric testing shall continue periodically such as at the start of each workday, at each shift and during the shift as conditions change due to temperature increase, agitation of sludge, leaking tank bottom exposed, piping leaks, hydrocarbon absorbed in roof seal etc.

(f)

If the tank has side manholes, water hose stream can be used for cleaning from outside the tank. The hose nozzle must be electrically bonded to the tank.

(g)

The loose sludge & waste materials shall be removed and as needed the tank can be washed from inside.

(h)

Tank nozzles, columns, floating roofs and support members are capable of trapping hydrocarbons and should be cleaned. The areas above floating roof and floatation compartments should also cleaned. Continuous ventilation should be ensured throughout the cleaning process. The impact of gaseous emissions resulting from cleaning operations shall be taken into account.

(i)

(j)

The contractor engaged in the off-site transportation of the sludge must comply with EPA regulations in this regard.

(k)

The workers inside the tank should be closely monitored particularly working during warm climates.

(l)

The required control over potential ignition sources should be continuously maintained.

11.11 Precautions During Hot Work inside the Tank: If the tank repairing involve hot work – then the surface to be heated, including roofs, structural, scaffoldings & pontoons – shall be free of flammable vapor & liquid, ignitable scale deposits, waxes and other deposits that may evolve vapors. Sometimes such deposits are hidden on the upper surfaces of roof rafters and flammable vapor analyzers may not indicate the presence of these materials. Extreme care & consideration as mentioned hereunder shall be taken prior to starting hot work inside the tank:

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KOC F&S Regulations

CRUDE OIL - STORAGE TANK, PIPELINES & OIL SPILL

(a)

Flammable & toxic liquids and vapors may enter through leak in the tank bottom or may evolve from pockets that exist in spaces such as pipe column roof supports, chambers, swing lines, and sumps etc.

(b)

The application of heat may produce flammable and / or toxic vapors. The frequent test shall be made to verify that the atmosphere in the tank is not in the LEL and / or TLV range of such substances.

(c)

Tanks that contain waxy substances and heavy oils can emit flammable vapors and be ignited.

(d)

Toxic atmosphere s may originate from - welding fumes, the material being welded or the lead based paint coatings. The necessary protection shall be provided against hazardous materials such as toxic vapors generated from welding rods or coatings, dust produced by wire brushing or grinding, and exposed hot metallic surface.

(e)

(f)

The sewers & drains should be covered and oil contaminated soil should be removed if hot work is to carried out side the tank.

(g)

There is a possibility of oxygen – enriched atmosphere from leaking hoses, torches or cylinder valves when using oxy / acetylene/ propane -burning equipment.

(i)

Oxygen & other gas bottles shall not be taken inside the tank for hot work requirement and hoses & torches should be disconnected from source if not in use for longer duration.

(j)

A hot work permit shall be issued by a qualified person before starting the work and atmospheric tests must be taken in surrounding & immediate area of work. The fire extinguishers and / or pressurized firewater hose in working order shall be kept available at the work location.

(k) (l)

The area in which hot work will be performed must be thoroughly cleaned and visual inspections must be undertaken for cleanliness of wall bottoms, together with atmospheric tests.

(m)

Continuous ventilation may minimize the accumulation of flammable vapors inside the tank.

11.12 Recommissioning the Tank: The planning & procedure to re- commission the tank must consider the following safety aspects: (a)

The tank must be surveyed thoroughly to ensure cleaning & other work completion, tank internals replaced, floating roof components installed and no debris or maintenance tools left inside.

(b)

All manways shall be closed properly and all unexpired permits are revoked.

(c)

The Inspection & Corrosion Team must confirm about any required mechanical integrity tests such as hydrotest.

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KOC F&S Regulations

CRUDE OIL - STORAGE TANK, PIPELINES & OIL SPILL

(d)

All blinds & tags used for lockout or tagout must be removed and signed off..

(e)

The tank must be filled with water up to level covering pump suction connection. Subsequently the tank shall be purged with nitrogen venting the exhaust gas through the vent at top most position. The purging shall continue till 4% oxygen content is achieved in the tank.

11.12.1 Returning Floating Roof Tank to service: When a flammable product is pumped into an empty floating roof tank, some of the vapors above the liquid will remain below the floating roof and some may be expelled to the space above the floating until the roof floats. The following safety considerations must be kept in view while returning a floating tank to service: (a) Vapor above or below the roof may be in the flammable range. (b)

In case of internal floating roof tanks, vapor may be expelled from the vents and pumping to refloat the roof shall not be done during a lightning storm or with electrical or mechanical ventilating equipment in service.

(c)

Any source of ignition shall not be permitted in the vicinity of the tank during roof refloating.

(d)

The precautions concerning pumping rates and prevention of splashing to prevent static ignition & to minimize vapor generation shall be observed with external & internal floating roof tanks until the roof is floating.

(e)

Sampling or hand gauging shall not be done during filling operation of tank.

(f)

Personnel shall not go onto the top of internal floating roof tanks or on the floating roof of external floating roof tanks for a period of approximately 18 hours after refloating or until the vapor concentration above the roof is below 10% LEL and the atmosphere is safe to breath. 11.12.2 Recommissioning Safety Check: The Recommissioning Safety Check as tabulated hereunder shall be carried out: S. No.

Recommissioning Safety Checks

1

Inspection – • The tank foundation have been inspected and confirmed to be in satisfactory condition. • The bund walls have been re-instated. • The dyke drainage system is serviceable & clean • Necessary repairs to the tank have been carried out. • Tank fittings & valves have been correctly reinstalled & serviceable.

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Status

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KOC F&S Regulations

CRUDE OIL - STORAGE TANK, PIPELINES & OIL SPILL

2

Electrical – • The tank shell is grounded & earthed • The earth cables associated with floating roof cover are securely connected and intact. • The grounding seal / bonding shunts on the floating roof are correctly installed and intact. • The cathodic protection system on the piping has been re-instated. • Electrical fittings associated with any side entry mixers have been correctly installed.

3

Instruments – • Tank level gauging equipment has been reinstalled and function tested. • Any separate high or low-level alarms have been reinstalled and function tested. • The tank temperature measurement instrumentation has been correctly reinstalled. • Any instrumentation associated with side entry mixers have been correctly replaced.

4

Fire Protection – • The foam lines and their associated fittings have been correctly installed • The deluge system is correctly installed. • The fire protection system has been function tested as per applicable code & standards.

5

Operational – • The tank has been inspected internally and is acceptable for service. • The tank has been inspected externally, including the roof and any internal floating cover, and is acceptable for service. • All roof drains, water draw-off, suction & discharge V/Vs are serviceable & identified. • The tank drain valves are closed. • The bund wall drain valve is tightly closed.

6

Mechanical – • Materials & debris from all corners of the tank have been removed outside the dyke area for appropriate disposal. • The internal floating cover has been installed in accordance with manufacturer’s requirements.

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June 2004 Page 18

KOC F&S Regulations

CRUDE OIL - STORAGE TANK, PIPELINES & OIL SPILL • • • • • • • •

The side entry mixers have been correctly installed. Handrails on stairways and around the tank roof are intact and secure. The roof ladder is correctly positioned and intact. The roof legs are all in position and correctly set. The automatic vent legs are correctly installed and have been tested. The roof drain sumps are clear of debris and all check valves are operational. Any free vent on the tank shell / roof have mesh / screen fitted and free from blockage. All manways cover on roof are closed.

11.12.3 Tank Filling: Once the above-mentioned safety checks results are acceptable then the tank will be lined up for filling and the following precautions are to be taken during the operation: (a)

The initial filling is to be carried out slowly until the tank suction line is well submerged to avoid turbulence and generation of static charges.

(b)

As the open area above the liquid level may go through the flammable range, hence a strict control of ignition sources is required. The tank shall not be filled during lightning storm.

(c)

The floating roof tank shall be filled slowly to avoid canting of roof until roof lifts off its support legs.

(d)

The workers should not go on top of the floating roof tanks for a period of approximately 18 hours after refloating or until the vapor concentration above the roof is below 10% LFL and the atmosphere is safe to breath.

(e)

The tank and lines shall be checked frequently for leak during filling process, especially manholes & nozzles that were opened.

(f)

The required documentation is to be completed after tank is filled up to the operating level.

11.13 Safety During Tank Construction, Erection & Maintenance: (A)

Safety Aspects During Tank Construction: Tanks shall be constructed in accordance with internationally accepted codes & Standards - such as American Society of Mechanical Engineers (ASME), American Society for Testing & Material (ASTM), American Petroleum Institute (API), and Institute of Petroleum (IP). The following safety aspects must be kept in view during tank construction phase: (a)

F&S Regulations Chapter 11

All above ground tanks designed for the storage of low flash point or intermediate range products shall be completely surrounded by a fire wall unless the topography of the surrounding area is such that spillage due to

June 2004 Page 19

KOC F&S Regulations

CRUDE OIL - STORAGE TANK, PIPELINES & OIL SPILL overflow or a major leak from any tank are directed quickly and safely to a depression or impounding bund located within the boundary. The bund capacity should be a minimum of 115% of tank capacity.

(B)

(b)

The bund wall shall be designed to withstand the pressure, to which it would be subjected if the volume within the walled enclosure were filled with water.

(c)

Adequate drainage shall be provided for safe removal of water from the walled enclosure or depression.

(d)

The piping arrangement for above ground tank/s enclosed by a firewall shall not run through other bunded area. However, piping of tanks within a group may cross intermediate toe walls within that group. This condition does not apply to intermediate bund walls of paired tanks.

(e)

Pumps shall be located outside the bund area unless high flash point viscous stock requires the pump to be located within the bunded area. The piping, valves or flanges shall also be kept to the minimum required and buried wherever possible. Any fittings prone to failure on exposure fire shall be avoided.

Safety Aspects During Tank Erection : The following safety aspects must be kept in view during tank erection (a)

The area in which a tank is to be erected must be made safe for HOT WORK activities before mobilizing construction material at site.

(b)

As far as practicable each tank should be housed in the individual bund.

(c)

Any crude oil storage tank in the vicinity of erection site shall be adequately protected considering the fire eventuality.

(d)

When a new tank is to be constructed in close proximity to an existing tank/s forming a group within a common bund, the tank containing intermediate or low flash point products must be emptied, cleaned and made gas free before erection of the new tank commences.

(e)

Plates shall be securely held in position by temporary cleats or tack welds until finally secured by riveting or welding.

(f)

To reduce the possibility of damage by wind, all the plates in uppermost strake shall be supported properly in position and secured adequately when left unattended at the end of the working day.

(g)

During erection of fixed roof tank when a height of four strakes is reached, adequate guy ropes shall be attached to each plate of the uppermost stake preventing damage by wind pressure. The same requirement shall be observed for floating roof tanks also if roof floatation is not employed during construction phase.

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KOC F&S Regulations

C.

CRUDE OIL - STORAGE TANK, PIPELINES & OIL SPILL

(h)

After erection the tank shall be subjected to hydraulic test as per applicable code and standard. A prior arrangement shall be made to safely dispose off water from the tank on completion of hydrotest.

(i)

The pneumatic testing of the erected tank may also be carried out provided the protection against pressure exceeding the safe limit has been incorporated. The pneumatic testing shall not be carried out during high ambient temperature.

(j)

The necessary protection must also be taken for preventing formation of vacuum inside the tank.

Safety Aspects During Tank Maintenance: Any maintenance work on a tank is subject to authorization through appropriate WORK PERMITS fulfilling the safety requirement for the job. The following safety aspects must be kept in view during tank maintenance: (a)

Extra care shall be exercised in assessing the safety requirement prior to authorizing the maintenance work. All potential hazards (such as – possible presence of oil / gas pockets below bottom plates) pertinent to hot work shall be considered.

(b)

The stability of tank roof structure must be ascertained before attempting to land on it. If required firmly supported scaffolding may be erected prior to access the location.

(c)

Plates are not to be thrown from the top of tanks but lowered to the ground by ropes or lifting tackle. Steps must be taken to ensure that materials and tools do not fall to the bottom of the tanks.

(d)

Handrails around tank tops must not be used to support any form of scaffolding or in raising or lowering of roof plates.

11.14 Pipeline Safety: (A)

Safety Aspects During Pipeline Installation: The following safety aspects must be kept in view during pipeline installation: (a)

The workers deployed for installation or dismantling stacks of pipe must protect themselves from hazard and danger associated with the work.

(b)

The pipe spool shall be guided into position using tag lines attached to it.

(c)

Coated pipes shall be stacked in such a way that the coating is not damaged.

(d)

The pipes being transported through a trailers or sea bound vessel shall be secured alongwith side restraints to prevent any accidental fall. The pipe shall be lifted safely with suitable lifting gear & tackles and must not be dragged at site.

F&S Regulations Chapter 11

June 2004 Page 21

KOC F&S Regulations (e)

Dollies, rollers or any form of packing used for pipe support to facilitate its rotation while welding, shall be properly secured to prevent pipe tilt during the operation.

(f)

The submarine pipelines shall be suitably buried under the seabed and protected from accidental damage as per international standard and recommended practice in this regard.

(g)

The most suitable measures (such as pipe sleeve, thickness compensation, covering with concrete slabs or culvert) shall be used to protect the pipeline crossing near the road.

(h)

The exposed portions of pipelines shall be identified as per colour coding stipulated under company standard.

(i)

The valve pits and sump shall be kept free from water or hydrocarbon accumulation. A suitable drainage facility shall be provided for draining & venting away from the pipeline. Pipelines running trough open trenches shall be kept free from water accumulations by natural drainage or suitable pumping device shall be installed for dispose off such accumulation safely.

(j)

B.

CRUDE OIL - STORAGE TANK, PIPELINES & OIL SPILL

(k)

The hot surface pipelines shall have proper insulation preventing injury due to accidental contact.

(l)

The pipeline supports must be properly designed and installed avoiding undesirable stress in the system.

Safety Aspects During Pipeline Operation: The following safety aspects must be kept in view during pipeline operations: (a)

The valves and fittings on the pipeline shall be operated by authorized personnel only.

(b)

The necessary care shall be exercised to prevent excessive pressure buildup due to ambient temperature rise in closed sections of the pipeline.

(c)

A close monitoring shall be kept and pipeline shall be regularly inspected to assess its health and integrity. .

(d)

In case a pipeline carrying hydrocarbon, chemical or other harmful material leaks, then the surrounding area shall be considered as HAZARDOUS AREA and accordingly precautions complying with Fire & safety Regulations shall be strictly implemented.

(e)

The required warning notices shall be posted at appropriate location depending upon nature and extent of leakage. Moreover immediate measure shall be taken to arrest the leakage.

(f)

The area shall be cordoned off and corrective action mobilised with all safety considerations in hand.

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KOC F&S Regulations (g)

C.

CRUDE OIL - STORAGE TANK, PIPELINES & OIL SPILL The leakage site shall not be left unattended until necessary repairs have been made, leak arrested and the area is declared safe after through inspection.

Safety Aspects During Decontamination of Pipeline: The following safety aspects must be kept in view during de-contamination of pipeline: (a)

All de-contamination works (such as depressurising, venting, draining, flushing and purging) shall be carried out in compliance to Work Permit System in this regard.

(b)

Prior to draining the pipeline content, the arrangement must be made to dispose it off safely & environmental friendly manner.

(c)

The workers deployed for dismantling of pipelines must take necessary care against possible exposure to line residues.

(d)

It is prohibited to use compressed air for purging an oil pipeline, where subsequent welding is to take place. Air must never be used under any circumstances for purging a gas line. Prior to dismantling a pipeline or valve inside a sump pit located near a fence, it is recommended to open the fence providing safe exit and escape routes in case of eventuality.

(e)

(f)

The necessary fire extinguishers and damage control equipment as approved by Fire Team shall be kept available at site in ready to use condition.

(g)

Before any welding activity or any other work is done on a pipeline, spills of oil which might catch fire be removed or rendered safe and all work must be covered by appropriate WORK PERMITS.

(h)

The workers deployed for pipeline repair activities must be made aware of the potential hazards. Extreme care shall be taken prior to entering a sump pit for the possible presence of flammable and / or toxic vapours. The workers should remain on windward side while breaking a line.

(i)

No hot work shall be done on a hydrocarbon carrying pipeline until it has been positively isolated, depressurised, de-contaminated and purged with nitrogen.

11.15 Oil Spills & Pollution Control: Every effort shall be made to prevent spillage or escape of any hydrocarbon or other materials, which could cause pollution to ground, air or sea and create a hazard for personnel, plant or equipment. A drip tray shall be made available at the sampling points as well as at other location where minor escape may occur due to operational reasons. The liquid accumulated inside the drip tray shall be routed to the drainage system or safely disposed off in an environmental friendly manner.

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KOC F&S Regulations

CRUDE OIL - STORAGE TANK, PIPELINES & OIL SPILL

Any source of leakage must be thoroughly investigated, reason established and corrective actions taken for reoccurrence. The required preventive actions such as prohibition of any ignition source and availability of damage control equipment shall be insured at the site where the probability of leakage exists. In case of leakage, the situation shall be dealt as per contingency plan and oil spill response program. The oil spill on the ground shall be immediately cleaned and oil soaked sand shall be disposed off to the approve disposal facility. Any spillage at KOC Export Facilities must be reported immediately to the Harbour Master who will take the necessary steps to deal with it as per established procedure.

F&S Regulations Chapter 11

June 2004 Page 24

Kuwait Oil Company

Fire & Safety Regulations

(K.S.C.)

Chapter No. 12 June 2004

LABORATORY SAFETY CHAPTER - 12 LABORATORY SAFETY

Contents

Subject

Page

12.1

INTRODUCTION………………………………...................

2

12.2

LABORATORY SAFETY................................................

2

A.

House-Keeping......................................................

2

B.

Chemicals Identification & Labelling ............................

3

C.

Compressed Gas Cylinders............................................

3

D.

Electrical Equipment...............................................

3

E.

Glass Equipment & Enclosures.................................

4

12.3

PERSONNEL PROTECTION...........................................

4

12.4

FIRST AID.................................................…………..

4

12.5

FIRE PROTECTION......................................................

5

12.6

VENTILATION.............................................................

5

12.7

CHEMICAL HANDLING................................................

5

F&S Regulations Chapter 12

June 2004

Page 1

KOC F&S Regulations

LABORATORY SAFETY CHAPTER - 12 LABORATORY SAFETY

12.1

INTRODUCTION: The laboratory in the upstream oil sector has distinctive functions, testing appliances and analysis facilities for routine operational requirement as well as product quality assurance. This section deals with specific measures pertinent to Laboratory Safety. It is highly recommended to take extreme care while handling laboratory chemicals categorised under flammables, corrosives, oxidizers, reactives and compressed gases. (Refer Chapter – 7 for further detail on Storage & Handling of Chemicals.)

12.2

LABORATORY SAFETY: A.

House-Keeping: A high hygienic standard shall be maintained inside the laboratory. The laboratory flooring shall be made from a non skid & non – reactive type material, which shall be kept free from oil, grease, chemicals, water or any slippery substance splashed over it. The fire extinguishers and other safety appliance inside the laboratory shall be regularly inspected and kept in ready to use condition. The chemical reagents, test equipment, partially used samples etc. should be returned to the designated storage immediately after use. Any spills should be cleaned with a suitable solvent, covered with absorbent granules and neutralized safely prior to disposing off as per procedure. The oily soaked rags, cotton waste, paper or other materials used for cleaning up, should be placed in covered metal receptacles. These receptacles must be emptied out or removed from the laboratory at the end of each day. The waste materials must be disposed off by a safe & environmental friendly procedure to prevent any air, water or ground pollution. It is recommended to keep adequate numbers of suitable waste-skips or bins to segregate different categories of wastes and dispose accordingly. The broken glass must not be put in the same container as that for waste paper or rags. The waste skip, which has contained flammable material, must be thoroughly washed and gas freed prior to its use. It is also advisable to take special care while draining or disposing off the liquid waste. If the sink or drainage system is not purposely designed to accept spent acids or alkaline solution then arrangements must be made to keep such waste liquids into a separate receptacle for safe neutralization and careful disposal. The drain system must be regularly checked to prevent any blockage and the wash downs are properly routed. A highly flammable material must be kept in a metal storage cupboard, marked with the appropriate safety signs. The potentially dangerous substances such as corrosive, reactive and flammable materials must not be stored inside the same container. At worst they should be stored in separate compartments and at best in separate cupboards.

F&S Regulations Chapter 12

June 2004

Page 2

KOC F&S Regulations

LABORATORY SAFETY

The stock of a hazardous chemical in the laboratory shall be kept to the minimum possible quantity needed for effective operations. B.

Chemical Identification & Labelling: All sample bottles, packages and containers of chemicals & other hazardous materials must be clearly marked and labelled for easy identification. The containers, bottles or packages without labels and containing unidentified material must be disposed safely under the supervision of a Laboratory Technician or chemist. An appropriate warning notice/s shall be prominently posted near the laboratory to alert the people about the potential hazard & associated risks due to chemical handling. The first aid instruction (for any untoward incident such as electric shock, severe burn) and standard preventive measures must be displayed prominently inside the laboratory for immediate response. The Material Safety Data Sheet (MSDS) of laboratory chemicals like Xylene, Methanol, Butanol & Lotoxane etc. should be readily available for ready reference.

C.

Compressed Gas Cylinders: The cylinder of compressed gas can pose a chemical as well as physical hazard. If certain gas is being used regularly, it is recommended to install a permanent manifold and gas supply arrangement with cylinders secured outside the laboratory. However an isolation valve shall be located inside for easier control. If gas cylinders are placed inside the laboratory, it must be kept away from any source of heat and stored away from highly flammable materials. Under no circumstance attempt be made to mix gases in cylinders or transfer gas from one cylinder to other. The pressure regulator, valves, relief device, connections and hose lines should be regularly inspected for any damage. The cylinders must be secured in an upright position in purpose made rack duly chained or strapped to a wall or other fixed support. A cylinder should be transported through a purpose built trolley or handcart with safety cap on and strapped for security. The empty cylinders shall be marked and stored separately in the designated rack outside the laboratory. It is highly recommended to install a multi-gas detection and alarm system to alert in case of any gas leak. The main valve on a cylinder must be kept closed whenever the cylinder is not in use. An appropriate pressure regulator must be used and the regulator should not be modified to fit to fit a cylinder it was not designed for. Oil or grease shall never be used to lubricate valves / fittings on oxygen cylinder, because a fire or explosion can result. (Refer to Chapter – 9 for further safety detail on Gas Cylinders)

D.

Electrical Equipment: All electrical equipment inside the laboratory must be installed and serviced by a competent electrical person. The laboratory personnel should not carry out any electrical repairs or alterations to electrical equipment. An electrician should do electrical connection to a flameproof plug.

F&S Regulations Chapter 12

June 2004

Page 3

KOC F&S Regulations

LABORATORY SAFETY

The electrical connections, extension chords and cable termination joints inside crude oil laboratory shall be flameproof type suitable to the enclosure. These should be checked regularly to ensure its integrity & reliability. The equipment including plugs, sockets must be kept clean and dry. The power supply must be immediately switched off and the part is to be dried in case it becomes wet. DO NOT HANDLE ELECTRICAL EQUIPMENT WITH WET HANDS. E.

Glass Equipment & Enclosures: The protective spectacles shall be worn while working with glassware. All glassware should be checked prior to its usage specially the items that will be exposed to high pressure, vacuum, or high temperatures. The glass bottles / vessels containing liquid reagents must be kept away from direct sunlight, to prevent any "lens" effect as fire may occur in this way. The Winchesters should be handled carefully and should be transported in the special containers provided for it. A purposely made baskets and trolleys shall be used for the transporting bottles and large containers. The windows for glass enclosures should be made of laminated or wired glass to ensure maximum protection to sustain exothermic reaction or any abnormal pressure build-up.

12.3

PERSONAL PROTECTION: The personnel working inside a laboratory shall wear appropriate protective equipment required for the job. An aspirator bulb should be used to pipette any corrosive or toxic liquids. Any work involving toxic gases or vapours should be carried out in a fume cupboard and not on an open bench. The personnel working with radioactive sources or X-ray machine must be suitably protected from radiation hazard. He must wear a personal Dosimeter and must go through regular medical check up as required for such works. (Refer to Chapter – 7 for Radioactivity Hazard) The appropriate respiratory protection shall be provided whenever working in toxic atmosphere or the work nature may cause inhalation of harmful substances. Such equipment shall be kept in ready to use and hygienic conditions. The workers shall be trained to wear respiratory equipment. In case a canister type respirator is used, then the workers must be made aware of its limitation. (Refer to Chapter – 7 for further detail on Personal Protective Equipment)

12.4

FIRST AID: It is required to train the Laboratory Staff to deal with First Aid cases in case of emergency. The Emergency Fountains & eyewash solution shall be available in a ready to use condition. The first aid instruction for any untoward incidents such as electric shock, severe burns and standard preventive measures must be displayed prominently inside the laboratory for immediate response.

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KOC F&S Regulations

LABORATORY SAFETY

The rescue equipment and first aid box shall be also available to provide immediate treatment (Refer to Chapter – 4 for further detail on First Aid) 12.5

FIRE PROTECTION: The laboratory shall be equipped with suitable detectors for fire & toxic gas detection. The adequate numbers & type of fire extinguishers duly approved by Fire Team shall be made available in the laboratory for emergency use. Moreover the fire blankets of the type duly approved by Fire Team will also be kept at easily accessible range from working bench. The laboratory staff will be trained in use of Fire Extinguishers & Fire blankets.

12.6

VENTILATION: Normally the laboratory shall be provided with an efficient ventilation & fume / vapour extraction system to ensure adequate air circulation. In case the operation involves generation of flammable / toxic vapour (as in case of crude Oil laboratory) the fume cupboard or degassing hood should be utilised for disposing off such gases to the safe location. The fume hood shall have suitable in-built baffles or filters as a protection against fire due to presence of flammable gas in the exhaust flue. The fume cupboard shall be regularly checked for efficient extraction of vapours and crude oil laboratory shall be equipped with detection system to monitor flammable & toxic vapours. (Refer to Appendix –2 for threshold limit values in this regard) The air-conditioning system in the crude oil laboratory will be a one-way type without re-circulating facility. It will be designed for 100% fresh air supply to eliminate all toxic vapours

12.7

CHEMICAL HANDLING: Most of chemicals being used in Laboratory are potentially harmful and should be handled with due care. Extreme care should be taken while handling concentrated acids and alkalies. While preparing acid / alkali solutions, ALWAYS ADD ACID TO WATER BUT NEVER WATER TO ACID. The personnel protective equipment such as slash suit, gumboots, rubber gloves and face shield must be worn while handling acids & alkalies. All the relevant information for any new or unfamiliar chemical shall be obtained through Material Safety Data Sheets or from Supplier prior to its use in the laboratory. These Materials Safety Data Sheets (MSDS) must be available in the laboratory under a separate file.

F&S Regulations Chapter 12

June 2004

Page 5

Kuwait Oil Company (K.S.C.)

Fire & Safety Regulations

BUILDING & CONSTRUCTION SCAFFOLDING, PAINTING, ASBESTOS

Chapter No. 13 June 2004

CHAPTER - 13 BUILDING & CONSTRUCTION - SCAFFOLDING, PAINTING, ASBESTOS Contents

Subject

13.1

BUILDING AND CONSTRUCTION.................................

2

13.2

SCAFFOLDING...........................................................

3

A.

Definition............................................................

3

B.

General...............................................................

4

C.

Trestle Scaffolds...................................................

5

D.

Independent Scaffolds.............................................

5

E.

Cantilever Scaffolds...............................................

6

F.

Swinging Scaffolds................................................

6

G.

Rolling Scaffolds...................................................

7

H.

Ladders..............................................................

7

13.3

PAINTING..................................................................

8

13.4

ASBESTOS..................................................................

8

F&S Regulations Chapter 13

Page

June 2004 Page 1

KOC F&S Regulations

BUILDING & CONSTRUCTION SCAFFOLDING, PAINTING, ASBESTOS CHAPTER - 13

BUILDING & CONSTRUCTION - SCAFFOLDING, PAINTING, ASBESTOS 13.1

BUILDING & CONSTRUCTION: When a construction work is to be carried out on a site previously used for other services, excavations in the area required for the new work must be conducted with due care to prevent probable damage to pipes, cables and other aboveground / underground facilities. Any pipeline, cable or other underground service discovered during the excavation work must be left undisturbed and immediately reported to the concerned Team for necessary advice and assistance. The approval to isolate, de-energise or remove must be taken from the concerned Team. The respective Team must ensure that the facility is not functional and safe to handle before imparting such approval. All construction & Excavation works must be covered by appropriate WORK PERMITS. It is also to be ensured that any construction activity should cause minimum possible hindrance to other facility and plant without causing any hazard in the vicinity. The work area as required may be fenced to prevent any unauthorized ingress or tempering. Moreover the work site should be arranged to avoid any congestion, obstruction and restriction for emergency access. A mobile crane or mobile heavy plant should be place at firm ground; where it is not liable to collapse. The movement or placement of such mobile plant should not disturb or interfere with any buried pipe, cable, overhead line and other facility in the neighbourhood. The guy rope for any structure shall securely attached to a permanent support / foundation base rather than to a pipeline or any other equipment preventing undesirable movement or accidental fall due to high wind or other shock. This also applies for guy ropes on a gin pole and or other lifting device. During the construction of a plant or other facility, access to the working height / location positions must be made convenient and safe for the circumstances. It is not permitted to walk on an asbestos sheet roof or any weal roofing. Crawling boards or duck ladders shall be used in such cases. A crawling board or duck ladder should be used if the roof angle exceeds 34 degrees, to prevent any accidental slipping from roof. Slope. The elevated platforms and floors should have handrails on all sides. If such handrails are removed for access of goods or machinery, the opening must be properly secured. As far as possible, operating platforms and walkways inside the process plants should not have any dead ends. Emergency escape routes should be marked on all elevated platforms. Vertical ladders rising more than 20 feet from the ground of landing should be fitted with cages or hoop guards. The height of such hoop guards must conform to safe access and dis-embarkment from such ladders. There should not be any un-insulated hot surface piping or fitting in the vicinity of a platform or walkways to prevent accidental contact. Any monitoring gadgets or fitting

F&S Regulations Chapter 13

June 2004 Page 2

BUILDING & CONSTRUCTION SCAFFOLDING, PAINTING, ASBESTOS

KOC F&S Regulations

points should not be installed below the elevated equipment, which contain hot oil or dangerous liquids, unless adequate protection is provided against the possible leak. 13.2

SCAFFOLDING: A.

Definition: 1.

Ledger: A longitudinal tube spanning in the longer direction of the scaffold, normally parallel to the structure / building and joining the adjacent standards. It may also support a working platform.

2.

Transoms: A tube spanning across ledgers to form the support for boards or units forming the working platform or to connect the outer standards to inner standards.

3.

Scaffold Boards: A timber, whose ends are protected with metal strips.

4.

Toe-boards: A scaffold board, which is erected around the edge of a working platform. It is intended to prevent accidental fall of materials or tools.

5.

Spigot Base Plate: A plate used at the base of a standard for distributing the load of scaffolding.

6.

Sole Plate: A scaffold board upon which the scaffolding is built over.

7.

Raker: An inclined load bearing tube, which is having a bearing on the ground or on an adjacent structure to provide stability.

8.

Putlog: A horizontal tube with a flattened end to rest in or on part of the brickwork or structure.

9.

Board Bearer: Tubes spanning between transoms to support a working platform.

10.

Standard: A vertical or nearly vertical tube used as a column-transferring load to the ground via a base plate.

11.

Brace: A tube incorporated diagonally across two or more members in a scaffold and fixed to them to provide stability.

F&S Regulations Chapter 13

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BUILDING & CONSTRUCTION SCAFFOLDING, PAINTING, ASBESTOS

KOC F&S Regulations B.

General: It is always preferred to use a metallic tubular scaffold rather than that of wood. A competent person (e.g. third party certifying agency / authority) must inspect the scaffold before authorizing its use. The scaffoldings duly inspected by the inspecting authority must be tagged indicating the maximum load it can bear. The scaffolding should be re-inspected after exposure to a weather condition that is likely to affect the strength or stability of the scaffold. It will also be inspected on any addition or modification works in the scaffold. The record of inspection should be maintained in a prescribed register. The scaffolding erection, substantial alterations, additions and dismantling, should be done under the supervision of a competent person (Scaffolding Supervisor). The workforce deployed for scaffolding erection, substantial alterations or additions and dismantling activities should have experience and competency for such works. Each part of a scaffolding which is to be so fixed, secured or placed preventing accidental displacement, shall be rigidly connected to the building or other structure unless designed and constructed as an independent scaffold. The scaffolding shall be securely supported and strutted. The scaffold to be erected on a soft ground shall additionally have base plates of adequate size to provide stability. The boards shall be of sufficient thickness with regard to the distance between putlogs or other supports. Maximum distance between consecutive putlogs should be as follows: Thickness of the Boards (in mm) Maximum Distance between putlog (in mm)

30 980

38 1500

50 2500

Boards should rest evenly and securely on its supports. The board should be supported at three points unless the thickness & distance between the supports prevents undue or unequal sagging even with two-point support. No board should not be extended to make it unsafe considering its thickness, strength and the weight likely to be placed on it. The necessary precautions shall be taken against tripping hazard on a scaffold. The scaffold with overlapping boards, or uneven surface shall be adequately protected and equipped to allow the passage of a barrow in case of requirement thereof. The guardrails and toe-boards shall be fitted to the inside of standards to prevent outward movement, unless purposely designed or secured preventing such movement. Guardrails and toe boards should always remain in position, however it can be removed to allow access of equipment and material if required for the work. The guardrail should have a height between 915mm to 1143mm.

F&S Regulations Chapter 13

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KOC F&S Regulations

BUILDING & CONSTRUCTION SCAFFOLDING, PAINTING, ASBESTOS

The toe board or other barriers should be high enough to prevent accidental fall of workers, tools and materials. The minimum height of a toe - board should be 200mm and he space between toe-board and guardrail shall not exceed 762mm. The slippery platform, gangway, runs and stairs must be sand blasted and cleaned for safe access ensuring free from any obstruction, rubbish and projected nails. The scaffoldings shall never be overloaded. The materials, which need to be unloaded within a reasonable time period can be placed on scaffold provided it, do not exceed its capacity. The placement of materials on scaffold must be carried out gently without causing any violent shock. A warning notice shall be displayed on partly erected or dismantled scaffolds alerting its unsuitability for use. The access to such scaffolding should be blocked. Any opening in a landing place through which a ladder passes should be as small as practicable. The folding ladders on a scaffold should have a firm footing and must not stand on loose bricks or ground. C.

Trestle Scaffold: Trestle scaffold should not be erected in such a way that a person working on the platform may fall from a height of more than 3 meters. In case folding supports are used in such scaffold, it should not have more than one tier. It should also not be erected on a scaffold platform unless sufficient space is available for the transit of materials along the platform.

D.

Independent Scaffolds: An independent scaffold is utilised to raise a working platform to the level required for carrying out a job. It has two lines of vertical tubes, with horizontal ledgers at every 2 meters. The working platform is constructed by laying additional ledgers and transoms at the required height. The intermediate transoms are laid down across the ledgers to provide additional support to the scaffold boards. The distance between horizontal ledgers must not exceed 2 meters and the height of an independent scaffold must be limited to 3½ times the minimum base measurements. Where the base is 3 x 2 metres, the height should not be greater than 600mm. However it does not apply to scaffolds, which can be tied to a permanent structure such as a building. In case an independent scaffold is erected on made up ground or an uneven surface, a scaffold board must be used as a sole plate. The sole plate should be in contact with the ground all along the length to provide uniform distribution of weight.

E.

Cantilever Scaffolds:

F&S Regulations Chapter 13

June 2004 Page 5

KOC F&S Regulations

BUILDING & CONSTRUCTION SCAFFOLDING, PAINTING, ASBESTOS

Where it is necessary to erect a scaffold that does not start from the ground, a cantilever scaffold can be used. The construction of cantilever scaffolding consists of two scaffold tubes supported between the floors & ceiling by means of a base plate at the top and a screw jack base plate on the floor. The scaffold tubes (called Puncheon tubes) are securely adjusted to from a rigid support for the cantilever. It is important to fix sole plates at the top & bottom of the puncheon tubes for uniform distribution of load over floor and ceiling. Additional ledgers are laid under cantilevers to provide supports to the working platform. Moreover further additional support can be provided by using raker tubes. An independent scaffold should have a safety fitting, which can be fastened below any critical fitting. F.

Swinging Scaffolds: For swinging scaffolds the decking & handrails must be supported by metal hangers regardless of the type of platform. Such scaffold should be equipped with guardrail of height not less than 915mm or more than 1145mm from the platform. The guardrail should be a dressed timber not less than 50mm x 75mm in cross section. It should be supported in a loop formed in the hanger and securely fastened preventing any displacement. The toe boards should be not less than 140mm in height, which is securely fastened to the outer edge of the hanger. The ropes supporting swinging scaffolds should be made of finest grade manila fibre, not less than 20mm in diameter. It should be properly rigged into a set of standard 150mm blocks, consisting of at least one double and one single block. Swinging scaffolds should be properly hung from secured supports equipped with hooks of sufficient strength to provide a safety factor of at least 4:1. Swinging scaffold hooks should be tied off with at least 25mm diameter manila rope secured to a stable roof mounted structure. Where steel cables are used, it should be less than 15mm in diameter alongwith a hoisting mechanism provided at the end of the scaffold platform. There must be at least three turns of wire rope left on the cable drums during hoisting or lowering. It is not permissible to allow more than two persons at a time on a swinging scaffold. Each person working on a swinging scaffold should wear safety belt and lifeline extending from roof to the ground. The safety belt should be tied to the lifeline with a triple sliding hitch or with a mechanical rope grab. When load testing the scaffold for its intended maximum weight, the decking should be more than 450mm from the ground.

G.

Rolling Scaffolds: All caster brakes should be locked when the scaffold is in its working position. The height of the working platform should be never be more than 3 times the

F&S Regulations Chapter 13

June 2004 Page 6

BUILDING & CONSTRUCTION SCAFFOLDING, PAINTING, ASBESTOS

KOC F&S Regulations

smallest base dimension. The guardrails must be provided for such scaffolds and moreover leg-adjusting screws should not be in a fully extended. The workers are not allowed to ride a rolling scaffold when it is being moved. It is to be ensured prior to using such scaffold that it is completely upright, level and caster on a firm base. H.

Ladders: The ladders must have adequate strength, and capability to bear the load intended to support safely. The ladder with missing or defective rungs must not be used. The wooden stiles, sides and wooden rungs should have running grained along its length. The rungs shall be properly fixed to stiles or sides and should not be painted or treated to cover the timber defects. The rungs should have reinforcement ties in case the tenon joints are not secured by wedges. The ladder, which is not standing on a firm base, must be secured properly by uniform suspension at each stile or side to prevent undue swinging. Similarly the ladder, which is standing on a firm base, must be properly supported on each stile or side and also duly secured at the upper point of rest. If such fixing is impractical, a person must be stationed at the foot of the ladder to prevent slipping. The ladder shall have a non-skid type shoes to prevent slipping. The recommended angle to set a ladder is 14° from the perpendicular. Consequently the distance between the foot of the ladder to the point immediately below the upper support should be equal to one quarter of the height. The ladder must rise to a height of at least 1050mm above the landing place or above the highest approachable rung, except in case of adequate handholding support at the landing location. The spacing at each rung should be sufficient to provide adequate foothold. A landing place of adequate size should be provided if practicable every 9.0 meters, (30 feet) of vertical distance or more often. The landing place (from which persons are liable to fall from a height of more than 2 meters) should be provided with hand rails of height between 915mm to 1143mm alongwith toe boards to a height of at least 200 mm. The space between guardrails and toe board should not be more than 762 mm. 1.

Ladder Scaffolds: The ladder scaffolds should be used for only light work and materials permitting safe use. These ladders should have adequate strength and stability to prevent collapse & slipping.

2.

Gangways & Runs: The gangways being used for passage of materials should be wide enough for the purpose. However the gangways must be at least 430 mm wide if it is to be used for the passage of persons through it.

F&S Regulations Chapter 13

June 2004 Page 7

KOC F&S Regulations

BUILDING & CONSTRUCTION SCAFFOLDING, PAINTING, ASBESTOS The boards and planks forming part of the runway or gangway should comply with the same requirements as those of a working platform. Slopes of more than one vertical to four horizontal should have stepping ladders at suitable intervals. No slopes should exceed one vertical to one and a half horizontal (by length).

13.3

PAINTING: When preparing surfaces for painting, suitable protection must be worn to prevent the inhalation of dust, vapours, etc (Refer Chapter – 4 for Protective Equipment) Any work involving use of blowlamps, torches etc. in a restricted area to remove paints, must be covered through appropriate WORK PERMIT. The suitable fire extinguishers must be available and safety measures shall be implemented at the worksite or storage facility for painting materials. (Refer Appendix – 5 for Fire Extinguishers). The receptacles containing lead based paint must be legibly marked to alert about lead hazard. Persons handling lead base paint must use the suitable coveralls and hand gloves. Such worker must wash his hand thoroughly & change the coverall before consuming any food item. The spray painting shall be carried out only in a properly designed painting booths duly equipped with exhaust fans. The fumes extracted should be discharged to a safe location away from any source of ignition. All the equipment and fixtures inside the paint booth must be suitable as per hazardous area classification. Smoking is not permitted in spray booths or paint shops. The interior surfaces of spray booth must be regularly cleaned to prevent accumulations of paint patches. The person working with spray guns should wear suitable respiratory equipment and eye protection.

13.4

ASBESTOS: This regulation applies to every process involving asbestos or any item consisting asbestos as an ingredient, except the process, which does not release any asbestos dust during the operation. Although the company is in the process of phasing out asbestos; however there are still some buildings and shelters, which has asbestos roofs. These remaining asbestos sheets are to be removed gradually taking all precaution in this regard. (Refer to H & E Guideline No. KOC – 1130 for further detail on Asbestos Safety) The contractor shall provide suitable respiratory equipment; protective clothing and headgear to the workers involved in such activities. The necessary training shall be imparted to the workers on respiratory equipment in this regard. The respiratory equipment used by an individual must not be worn by another worker unless it has been thoroughly cleaned and disinfected. The respiratory equipment & protective clothing shall be kept in a proper place. The protective clothing should be cleaned before returning to the storage facility. The contaminated clothing shall be kept inside a dusttight container, with posted warning "ASBESTOS - CONTAMINATED CLOTHING" before it is dispatched for cleaning or disposal.

F&S Regulations Chapter 13

June 2004 Page 8

KOC F&S Regulations

BUILDING & CONSTRUCTION SCAFFOLDING, PAINTING, ASBESTOS

The worker must take extreme care, while removing the facemask or respirator to prevent falling of asbestos dust inside the mask. It is advisable to remove exterior dust with hand held vacuum cleaner before removal of mask. Similarly the care shall be taken while removing protective coverall to avoid dust cloud. The work area including machinery, apparatus, benches, ventilation equipment, flooring, walls and ceilings etc. must be kept free from any asbestos dust or waste. The person deployed for cleaning must wear suitable respiratory equipment and protective clothing. A vacuum cleaner should be used to prevent escape of asbestos dust. Any loose asbestos or asbestos waste must be kept in a dust-tight receptacle for safe disposal to the approved facility such as Shuaiba Waste Disposal Facility. A clearly visible warning such as "BLUE ASBESTOS - DO NOT INHALE DUST” must be posted on receptacle containing crocidolite. It is recommended to take approval from Medical Group prior to commencing any activity that involve use of crocidolite (blue asbestos) including removal of lagging materials containing crocidolite.

F&S Regulations Chapter 13

June 2004 Page 9

Kuwait Oil Company (K.S.C.)

Chapter No. 14 June 2004

Fire & Safety Regulations GENERAL EMERGENCY PROCEDURE CHAPTER - 14

GENERAL EMERGENCY PROCEDURE Contents 1.

Page

GENERAL EMERGENCY PROCEDURE ..............................……

3

A.

Introduction .......................................................................................………

3

B. C. D.

Classification of an Emergency ............................................................…… Definition of a Major Incident .............................................................……… Declaration of a Major Incident ..........................................................………

3 4 4

2.

5 PROCEDURE TO ENSURE READINESS ...............................… A. Maintenance of Personnel Duties Lists ................................................……… 5 B. Mobilizing Advance Control .......................................................…………… 5

3.

ORGANIZATION .......................................................................……

5

4.

COMMUNICATION AND ALARM PROCEDURES ................…

5

A. B. C. D. E.

6 6 6 6 6

5.

Fire Station Control Room Call-out list ..............................................…… Ahmadi Telephone Exchange ............................................................…… Communications Team .............................................................……… Area Team Leader. ...........................................................................…… Installation Access Control Room (IAC) ........................................……

CONTROL ORGANIZATION .................................................

7

A. B. C.

7 7 7

Advance Control ................................................................................… Headquarters Control .........................................................................… Mina Al Ahmadi (KNPC) ……………………………………………

6.

DUTIES OF PERSONNEL REPORTING TO ADVANCE CONTROL

7

6.1

ADVANCE CONTROL ...........................................................…..…

7

A. B. C. D. E. F.

7 8 8 8 8 9

Operations Team Leader of the area ………………………………… Team Leader Fire ………………………………………………………… Maintenance Team Leader of the area ………………………………… HSE Team Leader (of the area)…………………………………………… Team Leader (IAC) ……………………………………………. Operating Supervisor of the area …………………………………

F&S Regulations Chapter 14

June 2004 Page 1

KOC F&S Regulations G. H. I. J.

Medical Officer or I/C Paramedic. …………………………………… Telecommunications Technicians ……………………………………… Shift Security Officer (IAC)…………………………………………… Record Keeping Employee. …………………………………………

HEADQUARTER CONTROL

6.2

GENERAL EMERGENCY PROCEDURE

………………………………

7. 8. 9. 10.

10

A.

Area Group Manger.…………………………………………………

10

B. C. D. E. F. G. H.

Manager (IS) or Team Leader Transport Operations………………… Manager (Human Resources) or Team Leader Personnel Admin. ……… Manager (Comm. Affairs) or Team Leader Purchasing (I). ……………… Manager (Information Technology) or Team Leader Communication… Manager (Public Relations & Information) or Team Leader Information… Manager HSE or TL (HSE-System)…………………………………… Manager (Ahmadi Services) or Team Leader (Building Maint.) …………

10 10 10 10 10 11 11 11

6.3 SUPPORT SERVICES....…………. A. B. C. D. E. F. G. H. I. J. K. L. M. N. O. P. Q R. S. T.

9 9 9 9

Manager Medical or Medical Admin on Call. …………………………… Team Leader Transport Opns...……………………………….………… Team Leader Mobile Plant ……………………………………………… Team Leader Central Workshops ……………………………………… Team Leader Communications..……………………………...………… Team Leader Computer Technical Services. …………………………… Team Leader Stores. …………………………………………..………… Team Leader Purchasing (I) and (II)…………………………………… Team Leader Building Maint. …………………………….….………… Team Leader Information. …………………………………………… Team Leader Community Services …………………………………… Team Leader Local Relations. ………………………………………… Team Leader Design or Team Leader Construction……………………… Team Leader Utilities ………………………………………………… Team Leader Office Admin…………………………………………… Team Leader Contracts (I) or Team Leader Contracts (II) ……………… Team Leader Safety or his deputy………………………………………… Team Leader Health & Environment…………………………………… Team Leader Insurance ………………………………………………….. Team Leader Project Support……………………………………………

DECLARATION OF THE END OF MAJOR INCIDENT………………… REVIEW OF INCIDENT …………………………...………….…………… EXERCISE..…………………………………………………………………… DEFINITIONS.………………………………………………………………

F&S Regulations Chapter 14

11 11 11 11 12 12 12 12 12 12 12 13 13 13 13 14 14 14 14 14 14 15 15 15

June 2004 Page 2

KOC F&S Regulations

GENERAL EMERGENCY PROCEDURE CHAPTER 14 GENERAL EMERGENCY PROCEDURES

1.

GENERAL EMERGENCY PROCEDURES: A.

Introduction: Successful incident response depends on personnel performing special tasks at the start of, and during the course of, an emergency. These fixed tasks are referred to as responsibilities to distinguish them from actions, which arise from the responsibilities and which vary from incident to incident, depending on the type and scale of the emergency. This document is an update of the Chapter 14 of the company Fire & Safety Regulations

B.

Classification of an Emergency: Categories (0 & 1) are to be handled in according with the Company’s F&S Regulations. Only Categories (2 & 3) shall be considered as a Major Incident.

Category 0: Minor fires, hydrocarbon spillage, leaks and injury, which can effectively be dealt with by personnel on the spot. Example:

A small fire or a minor hydrocarbon leak that is extinguished or isolated at the same time by the facility occupant.

Category 1: An event of greater magnitude than category 0, not hazardous to human life or operations but calling for support of other Company personnel, together with trained fire fighting personnel. Example:

A small fire or a minor hydrocarbon leak that is extinguished or isolated with the help of the Fire Crew.

Category 2: An incident of major proportions calling for involvement of all emergency services in addition to those mentioned above. An incident not immediately hazardous to life or property but could do so if not controlled. Example:

F&S Regulations Chapter 14

A major fire or a hydrocarbon leak that cannot be controlled easily and might spread further or cause an explosion and possible threat to life or property.

June 2004 Page 3

KOC F&S Regulations

GENERAL EMERGENCY PROCEDURE

Category 3: An emergency of disaster proportions causing or threatening, death, injury or disruption to large number of people and calling for immediate action by all emergency services. Example:

A disaster situation causing life threat and injuries must require help and assistance from many emergency services.

In any case of the categories above (0-3), an immediate evacuation shall be declared if life might be threatened. The evacuation shall be declared by: Crude & Gas Production facilities

C.

:

Shift Controller or Operator I

Export Operations

:

Shift Supervisor

Marine Operations

:

Harbour Master

Drilling Operations

:

Rig Supervisor

Definition of a Major Incident: Any incident classified as Category 2 or Category 3 will be considered a Major Incident and will be dealt with under the Major Incident procedure.

D.

Declaration of a Major Incident: The Major Incident shall be declared by one of the following through the area Fire Station: -

Team Leader Fire or his deputy (Snr. Fire Officer or Fire Officer). Crude & Gas Production facilities : Shift Controller or higher level. Export Operations : Shift Supervisor or higher level. Marine Operations : Harbour Master or higher level. Drilling Operations & Exploration : Rig Supervisor or higher level.

However, TL Fire and Snr. Fire Officers have the authority to supersede the decision of declaring Major Incident.

Fire Stations Station

Tel

Tel

Tel

Tel

Burgan Fire Station

22222

22221

66669

3986373

23111

23100

23199

3985197

North Kuwait Fire Station West Kuwait Fire Station

F&S Regulations Chapter 14

Mobile 9764045

Radio KOC-FIRE

KOC-FIRE 6633529 Numbers shall be provided when the station becomes operational. Burgan Fire Station will cover the activities of W/K Fire Station.

June 2004 Page 4

KOC F&S Regulations

GENERAL EMERGENCY PROCEDURE

The C&MD will communicate the declaration of Major Incident to: 1. His Excellency Oil Minister. 2. Deputy Chairman & Chief Executive Officer (KPC). 3. His Excellency Ahmadi Governorate.

The Deputy Chairman will communicate the declaration of Major Incident to: 1. Managing Directors of KPC-Companies. 2. KOC Board.

2.

PROCEDURES TO ENSURE READINESS: All operating teams and teams providing services must maintain procedures to ensure quick and effective response in the event of an emergency. Persons nominated for Advance Control, Headquarters Control and support services will designate persons to alternate for them in the event of their non-availability and advise Team Leader Fire accordingly. Only nominated persons or their alternate to be at their designated posts.

A.

Maintenance of Personnel duties lists: Each team will maintain lists of personnel with call-out responsibilities and their alternates. Team Leader Fire must be advised of all changes affecting Team Leaders, Head of Team, Managers and their alternates. Team leaders are responsible for ensuring that their own call-out lists are up-to-date at all times and copied to Team Leader Fire.

B.

Mobilizing Advance Control: Transport Operations Team will maintain the Trailer Mounted Advance Control unit and will mobilize it to the incident site upon declaration of a Major Incident.

3.

ORGANIZATION: During an emergency, management has responsibility for implementing the Company Emergency Procedures to ensure:i. ii. iii.

4.

Overall direction of efforts to bring the emergency under control. Organization of effective action to ensure the safety of personnel, plant, equipment etc., making the most effective use of available resources. Co-ordination of all operations during the emergency.

COMMUNICATION AND ALARM PROCEDURES: The use of communication system should be restricted to essential calls. Initial calls should give the location and a brief description of the incident and help required if known, the location or proposed location of the advance control point. Communications links must be established between advance control and Headquarter Control.

F&S Regulations Chapter 14

June 2004 Page 5

KOC F&S Regulations

GENERAL EMERGENCY PROCEDURE

Until the arrival of the Advance Control Unit, any suitable & safe location (Such as a vehicle or a building) with any means of communication shall be utilized as a temporary Advance Control upon the approval of Team Leader Fire or his deputy. The radio-equipped ambulance will maintain communication with the Ahmadi Hospital. Record shall be kept of all communications. Minimize the use of mobile cellular telephones and calls shall be through mobile radio. In the event of Major Incident the radio channel SV-EMERG shall be used (available at Fleet 1, channel 2). The use of this channel shall be restricted only for the Major Incident. Any other communication can be done through the regular radio channels:

A.

Fire Station Control Room Call-out list: Upon declaring Major Incident, the duty Assistant Fire Officer will immediately inform all concerned as per Call Out List at page 20. The duty Assistant Fire Officer will call for additional Fire Crews as required and directed by Snr. Fire Officer or Team Leader Fire, such as but not limited to, Military Fire Dept., National Guards Fire Dept. & KPC Companies Fire Teams.

B.

Ahmadi Telephone Exchange: Upon being informed by the area Fire Station that the Major Incident Procedure is in effect, the duty operators will inform all concerned as per the telephone list at pages 25& 26.

C.

Telecommunications Team: Team Leader Telecommunications will dispatch a Technician to the Advance Control with emergency communications kits for immediate installation in the Advance Control Unit or any other location as outlined in the Telecommunications Team Emergency Handling Procedure.

D.

Operations Team Leader of the Area. Operations Team Leader of the area involved shall be responsible for informing Maint. Team Leader of the area & Area Supervisors (This may be delegated under Team procedure).

E.

Installation Access Control (Control Room): Control Room of Installation Access Control will inform Team Leader Installation Access Control and the Shift Security Officer to proceed to the site. Including informing Vital & Oil Installation Protection Department and local security as per the communication list at page 27.

F&S Regulations Chapter 14

June 2004 Page 6

KOC F&S Regulations 5.

GENERAL EMERGENCY PROCEDURE

CONTROL ORGANIZATION: A.

Advance Control: The Advance Control personnel will co-ordinate the physical activities and operations required to control the incident. Team Leader Fire or his deputy will make sure that it will be situated in a suitable and safe area as near to the incident as practicable. The Operations Team Leader of the area where the incident occurs will assume general control over the incident site and control operations. In the event of a Major Incident on the offshore facilities, the Advance Control will be established in the conference room of Marine & Export Operations Building at Mina AlAhmadi. Pending the arrival of Operations Team Leader of the area or Team Leader Fire, the duties of Advance Controller will be undertaken by the senior employee present, responsibility shall shift to Senior Line Supervisors as they arrive. The Advance Control will provide the focal point and the communication link with Headquarters Control.

B.

Headquarters Control: Headquarters Control is located at the new Main Office, Building room 214 on the second floor. It will be under the direction of the Area Operations Manager where the incident occurs or until his arrival by Manager (Industrial Services). Headquarters Control will act as general intelligence and mobilizing center. It will also concern itself with the effect of the emergency on: 1. 2.

C.

Public relations and release of information. Other company operations.

Mina Al Ahmadi (KNPC): Emergencies pertaining to KOC assets inside KNPC-MAA area, KNPC Major Incident Plan shall be implemented. The KOC General Emergency Procedure shall be effective for the Headquarters and Support Services. Team Leader Fire, Operations Team Leader & Area Maint. Team Leader shall report to KNPC-MAA Advance Control and remain in contact with KOC Headquarters.

6.

DUTIES OF PERSONNEL REPORTING TO ADVANCE CONTROL: 6.1

ADVANCE CONTROL A.

Operations Team Leader of the area: 1. 2. 3.

F&S Regulations Chapter 14

Reports to Advance Control and assumes general control over incident site operations. Inform Team Leader Maint. & Implement Team call out procedure. Immediately contacts and remains in continuous communications with Headquarters Controls.

June 2004 Page 7

KOC F&S Regulations

GENERAL EMERGENCY PROCEDURE 4.

B.

Nominates experienced company personnel to keep record at Advance Control on 24-hour basis (Grade 24 or above).

Fire Team Leader or his Alternate: 1.

Establishes location for the Advance Control Unit in a safe location convenient to the scene of the incident in liaison with Operations Team Leader of the area. 2. Assumes General Control of all Fire Fighting, rescue operations. 3. Coordinates with directors of State Fire, Military Fire, Civil Defense, National Guards Fire and Sister Oil Companies Fire Teams. 4. Establishes a Fire Command Center and locates and identifies an assembly area for incoming emergency support units. 5. Relieves the Advance Controller. C.

Maintenance Team Leader of the area: 1. 2. 3. 4. 5. 6.

D.

HSE Team Leader (of the area): 1. 2. 3. 4. 5. 6. 7.

E.

Report to “Advance Control”. Support & advise the “Advance Control” of HSE issues for the Asset. Communicate with HSE Group in the “Head Quarters” for HSE issues and reports. Liaise with external agencies and consultants on HSE activities. Ensure record keeping of personnel present. Obtains identity of casualties and statement from injured, and others when convenient to do so. Provides additional measures to prevent further damage to property and injuries to personnel in liaison with Team Leader Fire.

Installation Access Control Team Leader: 1.

2. 3.

F&S Regulations Chapter 14

Reports to Advance Control. Make arrangements to assist with maintenance of water supplies. Be prepared to maintain power supplies (including lighting facilities) and make arrangements for any major feeder switching, which may be necessary. Be prepared to carry out any emergency repair, which the situation may require. Alerts service contractor(s) to be on standby with the necessary manpower. Request catering for the personnel at the Advance Control and incident site.

Directs IAC personnel to assume control of any post controlling access to the incident area, or requests re-enforcement from Vital & Oil Installation Protection Dept. and Public Security to provide personnel for gate controlling at site as requested by Advance Control and Headquarters Control. Liaise with Advance Control for any requirements. Initiates personnel pass system (Major Incident Pass) and maintains 200 major incidents passes at Advance Control, 200 at Headquarters Control June 2004 Page 8

KOC F&S Regulations

GENERAL EMERGENCY PROCEDURE

4. 5.

F.

Operations Supervisor of the area: 1. 2. 3. 4. 5.

G.

2. 3.

Reports with radio-equipped ambulance to Advance Controller at Advance Control Unit. Assesses the situation and advises the hospital Accident & Emergency Controller of present and future requirements for medical assistance. Directs the removal of casualties and renders first aid.

Telecommunications Technicians: 1. 2.

I.

Reports to Advance Control. Will control fire-fighting activities until the arrival of a Fire Officer. Makes arrangements in consultation with Advance Controller for any necessary shutdown of equipment, re-routing of oil or gas and placing the plant in the safest condition to limit damage. Assists in the co-ordination of catering distribution at site. Evacuates the facility for the safety of personnel in case of life threat or hazards.

Medical Officer or I/C Paramedic: 1.

H.

and more at Inst. Access Control building ready for distribution to advance Control & Headquarters Control as requested. Shall maintain one supervisor of IAC to remain in the IAC building to coordinate pass issuance as directed. Ensures that Advance Control Unit is adequately signposted.

Reports to Advance Control with telecommunications emergency kit that contains Radio sets, Mobile Telephones & Fax machine. Maintains existing communications and evaluate the possibility of improving or establishing additional services.

Shift Security Officer (IAC): Reports to advance control with mobile gate barriers and established access control point as directed by Advance Control.

J.

Record Keeping Employee (Area Involved Team): Reports to Advance Control and maintains record of all personnel present, will answer and log all incoming and outgoing telephone calls. Shall log all events, material and equipment orders and movements as required by the Advance Controller or Team Leader Fire.

F&S Regulations Chapter 14

June 2004 Page 10

KOC F&S Regulations 6.2

GENERAL EMERGENCY PROCEDURE

HEADQUARTER CONTROL Entry to Headquarter Control Room shall be restricted to the followings: -

A.

Area Group Manager: 1. 2. 3. 4. 5.

B.

Manager (Industrial Services) Or TL Transport Operations: 1. 2.

C.

Reports to Headquarters Control and assumes direction of it’s activities. Keeps Chairman and Managing Director, EAMD’s & Head of Trade Union informed on the emergency situation progress. Requests and co-ordinations assistance of men, materials, equipment and information called for by Advance Control. Requests helicopter services for medical evacuation as required. Contacts another area Manager to be his relief.

Reports to Headquarters Control and assist group manager in discharge his duties as required. Co-ordinate all activities requested from his group.

Manager (Human Resources) or Team Leader Personnel Admin: Reports to Headquarters Control and co-ordinates all activities requested from his group.

D.

Manager (Commercial Affairs) or Team Leader Purchasing (I): Reports to Headquarters Control and co-ordinates all activities requested from his group.

E.

Manager (Information Communications:

Technology)

or

Team

Leader

Reports to Headquarters Control and co-ordinates all activities requested from his group.

F.

Manager (Public Relations & Information) or Team Leader Information: 1. 2. 3.

4.

F&S Regulations Chapter 14

Reports to Headquarters Control and co-ordinates all activities requested from his group. Co-ordinates liaison activities between Management and State authorities other than State Fire Department. Co-ordinates release of information and Public Relations activities. Shall act as the Company’s Official Spokesman and reactivate the Company’s Media Center as required.

June 2004 Page 10

KOC F&S Regulations G.

GENERAL EMERGENCY PROCEDURE Manager (HSE) or Team Leader (HSE- Systems): 1. 2. 3. 4.

H.

Manager (Ahmadi Services) or Team Leader (Building Maint.): 1. 2.

6.3

Reports to Headquarters Control and assist the concerned Asset Manager in implementation of “ General Emergency Procedure ”. Support the damage control measures relevant to Health, Safety & Environment issues. Guide HSE resources for bringing quick end of the emergency situation. Instruct to record incident details, prominent evidences preliminary causes, obstacle faced and loss control actions being taken.

Reports to Headquarters Control and assist group manager. Co-ordinate all activities requested from his group.

SUPPORT SERVICES A.

Manager Medical or Medical Admin on call: 1. 2. 3.

B.

Team Leader Transport Opns: 1. 2. 3. 4.

C.

Reports to Mobile Plant Workshop. Provides lubrication services and any mobile repairs required. Provide any other duties requested from his team.

Team Leader Central Workshops: 1. 2. 3.

F&S Regulations Chapter 14

Reports to Transport Heavy Section Dispatch office Provides re-fuelling, Fresh & Brackish water, via road tankers. Provides transport as requested by headquarters control. Provides 2 Jeeps 4 x 4 with drivers, one at Headquarters Control, and one at Advance Control Unit.

Team Leader Mobile Plant Maint: 1. 2. 3.

D.

Reports to Ahmadi Hospital. Implements the Medical Group Emergency Procedure. Communicate with Headquarters control and provide feed back on casualties.

Reports to Central Workshops. Provides Electrical Power Generators as requested. Provides any fabrication or other required works requested from Central W/Shops.

June 2004 Page 11

KOC F&S Regulations E.

GENERAL EMERGENCY PROCEDURE Team Leader Communications: 1. 2.

F.

Reports to his office. Provides communication facilities as requested.

Team Leader Computer Technical Services: Reports to Computer Center and provides computer support to Headquarters Control and Advance Control as requested.

G.

Team Leader Stores Opns. : Reports to his office and provides facilities for the issue of stock and materials.

H.

Team Leader Purchasing (I) and (II): Reports to his office and procures any materials needed for the incident that are not available in Company stores and ensures that stock levels are kept in order.

I.

Team Leader Building Maintenance: 1. 2. 3. 4. 5.

J.

Team Leader Information: 1. 2. 3. 4. 5.

K.

Reports to own Information Building. Prepares information for release to outside authorities through M (PR&I). Controls enquiries and requests from the press, radio and television. Provides video and photographic coverage of the incident for the management review. Sends an information officer to incident site to deal with the press and media and will establish a press gathering point.

Team Leader Community Services: 1. 2. 3.

F&S Regulations Chapter 14

Reports to Central Reception at Industrial Area Dispatches 4 mobile toilets to incident site Supply water tankers from gardening section as and when required. Provides work force for erecting the tents Provides any other required services from his team.

Reports to Ahmadi House and establish Community Services Support Center Dispatch initially drinking water and wait for Headquarters and Advance Control further requirements. Provides services requested from his team related to catering waiters and provision of tents and any other ancillary services as needed.

June 2004 Page12

KOC F&S Regulations L.

GENERAL EMERGENCY PROCEDURE Team Leader Local Relations: 1. 2.

M.

Team Leader Design or Team Leader Construction: 1. 2. 3.

N.

Reports to his office and be prepared to provide drawings and maps as requested by Headquarters or Advance Control. Arrange for draftsman to be available for any request from Advance Control or Headquarters Control for any new drawing required. Alert surveyors to be on standby for any urgent survey required by Advance Control or Headquarters Control.

Team Leader Utilities: 1. 2. 3. 4. 5.

O.

Reports to Information Building Coordinate with State Authorities as requested by Headquarters Control.

Reports to Central Reception at Industrial area and be prepared to direct Utilities Team operations as required. Provides emergency safety signs and demarcate the incident area as well as warning signs as required by area Team Leader HSE. Ensures sufficient water supply is available from South Tank farm & North Tank Farm to support Fire Fighting as applicable Provide assistant to keep all access roads to the incident location clear and accessible and any required earth moving equipments. Provides any other services requested from his team such as airconditioning refrigeration, drinking water, water tankers.

Team Leader Office Admin: 1. 2.

3.

Reports to Central Reception at Industrial area and be prepared to direct Office Admin. Staff as required. Provides Office Admin. Services such as, furniture, office equipment, office consumables, (stationary) and office cleaning services as applicable for the Headquarters Control, Advance Control, and other support services. Provides updates on company telephone numbers and keeps copies at Headquarters Control, Advance Control, Ahmadi Telephone Exchange & Team leader Fire.

P. Team Leader Contracts (I) or Team Leader Contracts (II): 1. 2.

F&S Regulations Chapter 14

Reports to his office. Provide any duties requested from his team.

June 2004 Page13

KOC F&S Regulations Q.

GENERAL EMERGENCY PROCEDURE Team Leader Safety or his deputy: 1. 2. 3. 4. 5. 6.

R.

Report to his office. Support & advise the advance control crew on safety issues. Mobilize & dispatch the safety resources under his jurisdiction for bringing quick end for the emergency situation. Assist to record incident details, prominent evidence, preliminary cause & loss control actions being taken at site of emergency in liaising with HSE of the area. Act as observer to ensure the compliance of Fire & Safety Regulations in liaising with HSE of the area during loss control activities at the site of incident. Provides EOD clearance and assistance as required.

Team Leader H&E or his deputy: 1. 2. 3.

Reports to his office. Support and advise Advance Control on damage control measure pertinent to Health and Environment issues. Provide support on gas monitoring (flammable & H2S) and detection appliance relevant to oil sector work.

S. Team Leader (Insurance): 1. 2. 3.

Reports to his office. Prepare information to Management. Take necessary insurance steps.

T. Team Leader Project Support: 1. 2.

7.

Reports to his Group Manager. Arrange to temporary suspend all activities of the Contractors /Subcontractors working in or close to the vicinity of the major incidents in coordination with the controlling Team.

DECLARATION OF THE END OF MAJOR INCIDENT: 1.

The Area Group Manager in liaison with Advance Controller and Team Leader Fire shall responsible for declaring the end of the activities controlling the incident.

2.

Area Fire Station, Ahmadi Tel. Exchange & Installation Access Control Room will call back all those informed by them to notify the end of Major Incident.

F&S Regulations Chapter 14

June 2004 Page 15

KOC F&S Regulations 8.

GENERAL EMERGENCY PROCEDURE

REVIEW OF INCIDENT: Following the end of any incident in which the General Emergency Procedures have been brought into operation, there shall be, at the earliest opportunity, a full investigation into the cause of the incident by Manager Industrial Services & Manager of the area involved. Manager Industrial Services will initiate the review of General Emergency Procedure to consider any need for change, improvements, whenever required, etc.

9.

EXERCISES: There shall be at least one Major Incident exercise per year in order to test the General Emergency Procedure, organization, communication system, support services etc. The Fire Team shall monitor and observe these exercises and provide required recommendations. Team Leaders shall have a post exercise meeting with their teams to analyze actions taken and provide internal procedure for improvements.

10.

DEFINITIONS: C&MD EAMD Area Group Manager Central Reception HQ I/C IAC KNPC IS HSE H&E MAA Team Leader of the area TL V&OIPD Advance Control Unit

Chairman & Managing Director Executive Assistant Managing Director Operational Manager of the area involved Building Maint. & Utilities Reception located at industrial area Head Quarters In charge Installation Access Control Kuwait National Petroleum Company Industrial Services Health Safety & Environment Health & Environment Mina Al Ahmadi Operations Team Leader of the area involved Team Leader Vital & Oil Installations Protection Dept. (Ministry of Interior) Trailer mounted communication and command center at the incident site.

Advance Controller

The person who takes charge of Advance Control activities.

F&S Regulations Chapter 14

June 2004 Page 15

Kuwait Oil Company

Fire & Safety Regulations

(K.S.C.)

POWER AND HAND TOOLS

Chapter No. 15 June 2004

CHAPTER - 15 POWER AND HAND TOOLS Contents

Subject

Page

15.1

POWER AND HAND TOOLS..........................................

2

15.2

SAWS.........................................................................

2

A.

Portable & Electrically Operated Hand Saws......................

2

B.

Cross Cut & Rip Saws...........................................

2

C.

Tables or Bench Mounted Saws....................................

2

D.

Circular Saw ……..............................................

3

15.3

WOOD WORKING MACHINES......................................

3

15.4

OTHER POWER TOOLS................................................

3

A.

Drills..................................................................

3

B.

Grinders..............................................................

3

C.

Sanders...............................................................

4

D.

Abrasive Wheels...................................................

4

E.

Pneumatic Tools...................................................

4

15.5

HAND TOOLS.............................................................

5

A.

Wrenches And Spanners...........................................

5

B.

Centre Punches.....................................................

5

C.

Screw Drivers......................................................

5

D.

Files...................................................................

6

E.

Saws..................................................................

6

F.

Pliers..................................................................

6

G.

Picks..................................................................

6

F&S Regulations Chapter 15

June 2004 Page 1

KOC F&S Regulations

POWER AND HAND TOOLS

CHAPTER - 15 POWER AND HAND TOOLS 15.1

POWER & HAND TOOLS: The majority of accidents involving power & hand tool are caused by improper handling and poor maintenance of equipment. Such accidents can be greatly reduced through good housekeeping, proper maintenance and training the workers. It is to note that authorized & competent person is permitted to operate power tools. All portable & electrically operated tools shall be suitable for use in the respective hazardous area classification and should be approved by the respective maintenance team. No portable and electrically operated tool shall be used in a hazardous area without authorization under appropriate WORK PERMIT. Most of electrically operated tools are provided with grounding / earthing wire, which must remain connected at all the time. All power cables and leads must be frequently checked for any damage. The electrically operated tools must be disconnected from power supply prior to carrying out any adjustment, repairing or changing attachments.

15.2

SAWS: A.

Portable & Electrically Driven Hand Saws: All electric driven handsaws shall be equipped with a fixed guard over the upper half of the blade and a moving guard under the bottom half of the blade and both guards must remain in place. Saw blades must be checked regularly and maintained in good condition. The blades must be suitable for the material to be cut. The workers exposed to harmful dusts, while cutting concrete tile, lead, stone, etc., should wear approved respiratory protection.

B.

Cross Cut & Rip Saws: Any circular cross cut saw and rip saw must be provided with a hood that covers saw at least to the depth of the teeth. The hood should adjust itself automatically to the thickness and should remain in contact with, the material being cut. A fixed guard may be used, which provides the space (not exceeding 10 mm) between bottom of the guard and the material being cut.

C.

Table or Bench Mounted Saws: The operating table and surrounding area must be kept clean and clear of all debris. The workers must wear safety goggles and kickback apron while working. A push stick should be used as and when required. A sign shall be posted near all fixed saws noting that goggles / face shield and kick back apron are required.

F&S Regulations Chapter 15

June 2004 Page 2

KOC F&S Regulations

D.

POWER AND HAND TOOLS

The saw should be switched off when not in use. The machine shall have a switch off provision readily accessible to operator for stopping in emergency.. Circular Saw: Any circular saw must be guarded below as well as above the workbench and shall be fitted with an adjustable riving knife. The riving knife shall be as close to the saw as practicable, so that the distance between knife-edge and teeth of the saw does not exceed 12 mm. The adjustable top guard must have two-side flange, which can adjusted as close as practicable to the material being cut. The minimum diameter of a circular saw blade as suitable to the materials being cut shall be posted prominently near the machine. A wooden stick should be available at a circular saw bench, to remove material cuttings & chips fallen between saw blade and fence.

15.3

WOOD WORKING MACHINES: A woodworking machine should have extractor fan and device to clear dust and chips generated during the work. The dust and chips should accumulate near the machine and must be cleared regularly removed for safe disposal as per procedure. Every precaution must be taken to prevent fire in the work area ensuring the availability of required fire fighting equipment and first aid box. Each machine shall have start & stop switches for convenient access and actuation as required. The worker must wear respiratory protection, and goggles to protect against dust and flying particles generated during the work. The worker must be fully trained to operate such machines and also aware of the potential hazard and safeguards. The cutter of a woodworking machine must be closed with a substantial guard to the maximum extent practicable, unless the cutters are safely installed and housed within the machine. The guards and wooden sticks must be properly maintained. Any machine guard or other protective device must be securely adjusted and shall remain in position. The operation of machine without a protective guard shall be approved by the workshop foreman taking all-precautionary measure needed. No guard or part of a machine should be adjusted when cutters are in motion unless it is urgent and can be carried out safely with due approval workshop supervisor.

15.4

OTHER POWER TOOLS: A.

Drills: The drill point must be correctly marked prior to starting the job. Only the correct bit for the type of materials to be drilled shall be used. The necessary care must be taken to prevent sleeves, protective clothing or a long sported hair from being entangled or wound around the drill in motion..

B.

Grinders: The persons working on grinders must wear goggles, safety glasses, eye shields and other protective device required for the job. The grinding stones must be inspected and dressed regularly. The grinder and its accessories shall be

F&S Regulations Chapter 15

June 2004 Page 3

KOC F&S Regulations

C.

POWER AND HAND TOOLS

maintained properly and any adjustment to the machine should be made while it is not running. Sanders: The persons working on sanders must wear goggles, eye shields and suitable respiratory protection as needed for the job. The necessary precaution should be taken to keep moving part away preventing any accidental contact with the body while the machine is running. A sign shall be posted near all such machinery noting that goggles / face shield are required. The dust generated during the operation may create an explosion hazard and should be safely extracted. Any naked flame or source of ignition should be properly guarded and dust collection bags shall be emptied regularly.

D.

Abrasive Wheels: The crucial information such as maximum working speed, variation in spindle speed, manufacturers detail shall be prominently posted on power driven abrasive wheels. The machine must not cross the maximum speed limit and for air driven abrasive wheel, a device should be installed to prevent over-speeding. It is highly recommended to provide protective guard for a moving abrasive wheel. For any bench mounted abrasive wheel, the wheel rest should be adjusted as close as practicable to the abrasive wheel, which shall be firmly secured. Moreover fixed machine shall be securely anchored to prevent movement or tipping The person working with abrasive wheels must wear goggles, face shield and other eye protection device. The worker should also wear suitable respiratory protection also in case abrasive wheel generates dust. A sign shall be posted near all fixed abrasive wheel machinery noting that goggles / face shield are required.

E.

Pneumatic Tools: A variety of tools such as hammer, drill, saws, and vibrators are pneumatically operated by air, supplied by a mobile or stationary air compressor unit. The necessary precaution should be taken to prevent fire or explosion while operating such compressor. The use of any mobile compressor in the hazardous area must be authorized through appropriate work permit. The air supply lines should be protected from possible damage and shall be routed through a protective channel if such hose is to be carried across the road. Supply hose as well as couplings must be inspected regularly & damaged parts replaced. The hose to be carried on a long span should be suitably supported. (Refer Chapter – 9 for further detail on Compressors & Compressed Air Equipment).

15.5

HAND TOOLS: All hand tools must be maintained properly and any defective or improper toll shall not be used for carrying out the work. The tools should be kept clean and protected against corrosion and damage. Any moving or adjustable part should be lubricated regularly to

F&S Regulations Chapter 15

June 2004 Page 4

KOC F&S Regulations

POWER AND HAND TOOLS

prevent wear, misalignment and undesirable stiffness. Any cutting edges must be kept sharp but protected from accidental damage or harm. Any damaged or worn out tools should not be used and similarly the use of temporarily repaired or makeshift tools is not permissible. The hand tools, which cannot be repaired, shall be withdrawn from service. The correct tool in respect of size, weight and duty should be used to perform a job. The tool handles must be tightly fitted and any wooden handle should be checked and tightened with wedges if required. Most of the hand tools are good conductors of electricity and extreme caution shall be taken while working around electrical circuits. The hand tools, which is properly insulated, duly rated and certified for electrical work, shall be used if working with electrical circuits. The use of any ordinary hand tool is not permitted for the atmosphere containing flammable or explosive liquid, dusts & vapours (e.g. brass hammer shall be used while tightening X-mas tree bolts and flanges at Wellhead). The hand tools suitable to the respective area classification can be used through authorization under an appropriate work permit. A.

Wrenches & Spanners: The spanners of correct size and types such as socket spanners, ringed spanners, tubular spanners; open-end spanners shall be used for carrying out the job safely. The wrenched portion should always be placed on nuts and the jaw opening faces the direction of the handle to move.

B.

Centre Punches: Points of a centre punch should be accurately grounded. The punches should be straight and strong enough for work in hand. The head of punch should never be allowed to 'mushroom' causing sharp edges.

C.

Screwdrivers: A screwdriver shall not be used as a chisel. The tip should be grounded properly and squared across along the tapered sides. The screwdriver should fit the screw, which is being driven. The handles should fit shank tightly and kept directly over the screw when being driven.

D.

Files: A File should be equipped with handles of proper size and the handle should not be driven on to the file with a hammer. The small objects being filed must be clamped properly or secured in a vice.

E.

Saws: The saw should be of the proper shape and size with correct teeth for material being sawn. The saw teeth and blades must be properly fixed protected when not in use. If long pieces are being cut, a helper or support bench should be used to prevent pinching at the cut. The hacksaw blades should be of correct type and size for the material to be cut. The blade teeth should rigid pointing forward with the frame properly aligned.

F&S Regulations Chapter 15

June 2004 Page 5

KOC F&S Regulations

F.

POWER AND HAND TOOLS

Pliers: Pliers should not be used as wrenches. The insulated pliers with proper rating must be used for electrical work.

G.

Picks: The handle for a pick should be free of splinters, splits and cracks. The head should remain firmly affixed to the handle. Prior to swinging the pick, it must be ascertained that the area at rear and to the sides is clear from any obstruction

F&S Regulations Chapter 15

June 2004 Page 6

Kuwait Oil Company (K.S.C.) Chapter No.16 June 2004

Fire & Safety Regulations WELDING

CHAPTER - 16 WELDING Contents

Subject

16.1

WELDING....................................................................

2

16.2

GAS WELDING & CUTTING.......................................

3

16.3

ELECTRICAL ARC WELDING.......................................

4

16.4

GAS CYLINDERS..........................................................

5

16.5

FIRE PROTECTION......................................................

8

16.6

PERSONNEL PROTECTION ......................................

9

16.7

VENTILATION WHILE WELDING IN CONFINED SPACE.... 9

16.8

REPAIR WORKS INVOLVING WELDING IN SMALL CONTAINERS..

F&S Regulations Chapter 16

Page

10

June 2004

Page 1

KOC F&S Regulations

WELDING CHAPTER - 16 WELDING

16.1

WELDING: A.

All welding, cutting, brazing and soldering work in restricted and hazardous area shall be conducted with due authorization under appropriate WORK PERMIT.

B.

Any equipment and its surrounding where welding, cutting, brazing and soldering work is to be carried out, must be free from flammable liquid and gases.

C.

The flexible hoses of a gas welding set shall be strong enough to withstand the gas pressure and should be suitably reinforced for pressure test requirements. The suitability of a new hose should be supported by test certificates for Flexibility, Hydrostatic, Adhesion and Tensile strength requirement.

E.

The placement of a welding set in hazardous area must be authorized by the permit issuer confirming necessary precautions against the potential hazard.

F.

The adequate ventilation must be provided to expel toxic gas / fumes generated due to welding / cutting / soldering / brazing activities being carried out inside a tank / vessel or any confined space.

G.

The necessary care must be taken against the possible presence of flammable materials in the space between double plates, or weir plates, while preparing the work site for welding, cutting, brazing or soldering activities.

H.

Before cutting the bottom of any tank, test holes must be drilled and gas tests carried out to ensure the safe condition at the tank floor.

I.

Any welder, who is engaged for carrying out welding jobs inside the company facilities or premises, must be qualified in accordance with internationally accepted standards and codes of practice. Inspection & Corrosion Team should be consulted for welder’s qualification criteria.

K.

No person other than the qualified welders, work site supervisor and associated workers will access the site where welding operation is going on.

L.

Any equipment or piping having scale depositions shall not be subjected to welding, cutting, soldering or brazing activities, without confirming the nonflammable and non-toxic nature of the deposited scale. The required protective measures must be taken in case dangerous fumes are likely to evolve during such operations.

M.

No welding, cutting or hot tapping shall be carried out on "Live" pipeline, except duly authorized under appropriate WORK PERMIT alongwith strict compliance to the stipulated precautionary measures in this regard.

N.

Prior to carrying out any welding or cutting operation, the equipment or pipeline must be positively isolated, depressurised, decontaminated, purged or flushed in compliance to work permit requirement for the job.

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WELDING

O. API Recommended Practice API -2201 on "Procedures for welding or Hot Tapping on Equipment in Service" and KOC Standard shall be adhered to. 16.2

16.3

GAS WELDING & CUTTING: A.

In a gas welding or cutting operations, the oxyacetylene or propane flames shall be ignited by the lighter specifically designed for such purpose.

B.

The equipment or pipe spool should be supported on a secure and firm base while performing gas welding or cutting operations. Any drum or such temporary support should not be used to prevent flame infringement leading to possible explosion.

C.

Special care is to be taken while using acetylene due to its wide explosive range in air (from 2% to 82% by volume)

D.

The worker deployed for welding operations must be aware with colour coding of gas cylinders such as acetylene-maroon, air- grey, oxygen - black. (Refer Appendix – 4 for IDENTIFICATION OF INDUSTRIAL GAS CONTAINERS).

E.

Oxyacetylene blowpipe or other approved ignition source to be used and authorized under appropriate WORK PERMIT must be kept at a distance of more than 5 metres (16 feet) from acetylene cylinders as well as from oxygen cylinders.

F.

The pressure regulator and pressure gauge to be fitted on oxygen and acetylene cylinders shall be suitable for pressure rating and type as per standard industrial requirement. The adjustable screw on the regulator must be released prior to opening the cylinder. The cylinder valve must be closed before the regulator is removed. The blowpipes must be compatible to pressure rating of gas cylinders.

G.

All blowpipes should be cleaned properly at regular intervals as per manufacturer’s instruction. The blowpipe tip should not be dipped into the molten metal to avoid its blockage.

H.

The blowpipe shall be connected to oxygen and acetylene cylinders through a firmly attached stout canvas & reinforced rubber hose. A check valve (flash back arrestor) must be fixed between the hose and regulator to prevent flash back. The acetylene carrying hose is usually red in colour.

I.

Prior to replacing a blowpipe, regulator or pressure gauge, the gas cylinders must be isolated.

J.

French chalk coating on a new hose should be blown with air prior to connection with cylinders & blowpipes to prevent equipment clogging.

ELECTRICAL ARC WELDING: A.

The respective area Maintenance Team or project controller (as the case may be) shall confirm the correct installation of welding transformer, generator sets including its connection with power supply.

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B.

The welding leads should be adequately protected from probable damage or interference from other source. The cable connectors should be of approve type and rating for attaching with welding lead. .

C.

The respective area Maintenance Team or project controller should confirm the proper earthing of a welding transformer & generator before welding is permitted. It is recommended that each working welder have a separate return lead to its set. The protective earth connection shall not be allowed to carry the welding current. It is also advisable to connect the lead to a point as near as possible to the planned weld location on the job ensuring the security of lead connection.

D.

E.

The Arc Welding Generator should include an automatic voltage regulator for reducing the open circuit voltage to safe limit, which is normally 15 volts.

F.

The welding circuit installation should be made in compliance with the manufacturer’s instructions.

G.

The welding equipment must be inspected and maintained regularly to ensure its safety and integrity.

H.

The insulation of cables, electrode holders, plugs and sockets must be in good condition ensuring adequate current carrying capacity for the conductor. The power supply to welding equipment shall be made through approved cables and junction boxed and should be controlled from a circuit with protection sensitive to earth fault current.

I.

For stationary transformer or generator set, a suitable switch must be mounted adjacent to the equipment for power isolation in case of requirement.

J.

Any portable transformer or generator with trailing leads shall have interlocked fused switch sockets and plugs for protection of trailing cable as well as the equipment. All welding leads and returns shall a flexible & strong cable of rubberised enforcement.

K.

All leads shall be properly terminated and lead cable couplers as well as terminations shall be of adequate current carrying capacity. To avoid long lengths of power cables, the welding machines should be placed as close as possible to the power supply point. A welding return lead shall have neutral terminal from each phase of an arcwelding transformer or from negative terminal of D.C. generator to the work piece. This lead is required in addition to the earth bonding. The connections at the work piece shall be firmly made by bolting or clamping as near as possible to the point, which is to be welded. The return connections must be securely fastened to the work in order to provide a good electrical contact. The return leads should not be attached to pipes or structures, which may not be properly grounded. In all cases the return connection must have an uninterrupted lead between work being welded and the welding machine.

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WELDING

Where more than one welder is working from the same welding machine, the polarity of each welding lead and welding return shall be the same. When two or more leads are being used in a confined space, the corresponding leads must be paired and as far as possible the crossing of pairs with one another or with any single lead, should be avoided. In case welding leads trail near tanks, or sumps containing hydrocarbons, additional lengths of cable must be added to the circuit circumventing the prevalent danger.

16.4

K.

The low voltage winding on AC welding transformers shall not be earthed rather the transformer case should be effectively bounded to an earthling system adjacent to the equipment. For AC drive DC welding generators, no earth connection shall be applied to either pole of the DC welding output. The machine frame shall be effectively bonded to earth. For engine driven DC welding generators no earth connections shall be applied to the generator output terminals.

L.

While butt-welding two loose items, which are not permanently attached to any structure, both items must be connected to the welding return. A bonding may be affected by use of mechanical clamps or securely attached clips. This requirement is necessary to prevent stray electric current causing sparks at a distance from the welding point, where flammable atmosphere may exist.

M.

The electrode holders shall have a handle made of tough insulating non-ignitable material, equipped with a guard for protection from projected line.

N.

The electrode holder should not be placed on the ground if not being used rather a wooden rests should be provided for supporting the electrode holders. In no case arc strike / test shall be conducted on the equipment or structure.

O.

Any engine driven welding machine shall not be refuelled while in operation.

P.

The welding circuit must be disconnected from power supply if welding work is suspended even for short periods, ensuring that it cannot be unintentionally operated from electrode holder. When the power source is moved to another location, the power source including the supply cable must be isolated from the main line. The provision of a convenient & quick electrical disconnection must be ensured for any eventual requirement.

Q.

The workers must take precautionary measure against radiation hazard due to arc welding. (Refer Chapter – 4 for PROTECTIVE EQUIPMENT).

GAS CYLINDERS: The gas contained in a cylinder is identified by colour code conforming to British Standard Specifications No. 349, 1319, 5340. In case of cylinder with colour code other than British Standard, repainting of the colour code shall be done with approval from stores operation. The colour code chart shall be posted at stores, filling point and at consumer end for ready reference. (Refer Appendix-4 for colour code followed by the company)

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The gas cylinders received in filled condition from supplier or stores must be identified by colour code and examined for any damage. A cylinder found defective shall not be issued and returned to the supplier through stores operations taking all precautionary measure. Every cylinder shall have stamped serial numbers and due date of inspection. Stores operations shall keep the relevant detail about the gas cylinders supplied by the vendor. The supplier shall provide valid test certificate issued by company approved quality assurance agency for each gas cylinder. A.

Handling of Gas Cylinders: •

Any cylinder containing a compressed gas shall not be subjected to a temperature exceeding 54.50C (1300F) including exposure to direct sunlight.

•

The necessary care shall be taken during transportation of gas cylinders preventing excessive shock or accidental fall. The cylinders shall be secured properly to prevent violent contact or excessive shock during transportation. Any cylinder trolley should not be towed through a vehicle. A gas cylinder shall be stacked in a trolley or inside a well-secured rack and transported safely.

•

The cylinder shall never be dropped from height rather it should be stacked inside a rack and lowered safely through proper lifting device.

•

The valve protecting cover / cap must be fitted when the cylinder is not in use. The protective collar provide around the valve shall not be damaged during handling or transportation of cylinder.

•

While joining hoses or valve fittings, it is recommended to use purposelydesigned packing or washers only. The use of a lead based washer or packing in the valve joints is strictly forbidden. Such packing (particularly lead or copper based) may cause blockage in the valve orifice, making difficult and hazardous to extract.

•

The pressure relief device on cylinder or valve shall not be tampered and moreover cylinder must not be used as rollers, supports, or any purpose other than design intention.

•

Cylinder must not be placed in a situation becoming part of an electric circuit. When gas cylinders are used in conjunction with electric welding, precautions must be taken against its accidental grounding or burning by electric arc.

•

It is to be insured that the threads on regulators or other auxiliary equipment are same as those on cylinder valve outlets.

•

The valve on a gas cylinder shall be opened slowly with the valve opening away from the user. A valve key or wrench as supplied or recommended by the manufacturer shall be used for opening the cylinder valve. It is not advisable to use a wrench on valve with hand wheel.

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WELDING

•

A compressed gas cylinder must not be used if it has the possibility of contamination due to backflow of process inventory unless protected by suitable traps or check valve.

•

It is prohibited to transfer compressed gases from large to small cylinders except with duly approved facility in agreement with manufacture’s requirement in this regard.

•

Prior to removing a regulator, the cylinder valve must be closed and pressure is released safely. While releasing a flammable content, any source of ignition must be kept away.

•

The cylinders containing flammable gas must be segregated and kept away from cylinders containing oxygen.

•

Gas cylinders shall be stored with due protection against potential fire hazard. No flammable materials shall be kept in the same storage facility. The cylinders should be kept inside the storage facility in such a manner that it can be readily removed in the event of fire thereof.

• •

The accessories or equipment (such as pressure regulator, pressure gauge, blowpipe, isolation valve etc.) not being used must be disconnected from gas cylinders and stored separately.

•

The oxygen cylinder and it fittings including hoses, should be protected from contamination with grease, lube oil, or any flammable material which can spontaneously combustible in presence of oxygen.

•

The cylinders stored outside should be protected from the direct sunrays. The cylinders shall not be laid down on the wet soil rather it should be stacked inside a purposely built rack with lifting tackles.

•

Propane & acetylene cylinders shall be always be stacked vertically whereas oxygen cylinder can be either stacked vertically or horizontally. However if stacked horizontally, it must be done in pyramid shape with not more than 15 numbers to a single tier. The largest cylinders must placed be at the bottom of stack and the stack must be securely wedged to prevent accidental collapse

•

No fittings or equipment containing more than 90% copper as ingredient, except a burner tip, shall be in gas (acetylene) welding operation. As the copper in contact with acetylene is liable to form a dangerous explosive compound, named Copper Acetylide.

•

Any defective cylinder (such as with faulty joints, stiff spindles or leaking valve) must be returned immediately to the supplier / stores alongwith convoy note stating cylinder number and defective condition. The user should not attempt to repair a defective cylinder containing flammable or explosive gas.

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KOC F&S Regulations

B.

WELDING

Maintenance: Any cylinder, which has suffered damage, shall not be refilled until tested & certified complying with Code of Inspection for Plant & Equipment.

C.

Refilling: The cylinder received for refilling must be carefully examined for any defect, valve operation, colour coding and date of inspection. The cylinder free from any defect or damage with valid inspection date shall be refilled. The cylinder must be adequately secured to avoid any movement during filling. The cylinder must not be charged above the pressure exceeding permissible limit. In the case of liquefied gases, the permissible weight of the liquid introduced into cylinders must not be exceeded. The filled cylinder must be checked for any leak and stored at proper place away from direct sunlight.

16.5

FIRE PROTECTION: A.

B. C. D.

Adequate number of suitable and approved fire extinguishers shall be kept available at the welding work location. A pressurized firewater hose shall be kept ready & surrounding location is wetted with water if welding inside a restricted area. The required preventive actions & fire protection measures as suggested through duly authorized WORK PERMITS should be strictly adhered. The workforce shall remain alert & maintain a constant vigil against the potential fire hazard. The welding booth / protective screen, plant or materials used for welding or cutting operation shall be made of fire resistant or non-ignitable materials.

E.

The necessary precaution must be taken to prevent sparks from flying outside the immediate welding area.

F.

While carrying welding or cutting operations at a height, steps must be taken to prevent falling down of welding rods, spent stubs, spark & equipment etc. The work area must also be suitably enclosed through a fire resistant screen to prevent spark or molten metal from dropping down. The area immediately below the welding work location must be kept free from any flammable material. The work area will be cordoned off and warning notice posted to alert the personnel.

G.

The ignited blowpipe attached to oxy-acetylene cylinder through hose shall not be placed on or near the cylinders, regulators or other flammable material.

H.

The blowpipes and hoses not being used shall not be left inside a vessel or confined spaces even for short break period. It is recommended to disconnect such hoses & blowpipes from oxy-acetylene cylinders kept outside the confined space.

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KOC F&S Regulations

16.6

16.7

16.8

WELDING

I.

The oxy-acetylene cylinders shall be always kept outside the vessel or confined space where welding or cutting is taking place.

J.

The fire crew along with required fire tenders shall be provided in case of welding to be carried at a remote location, where firewater supply is not available.

PERSONNEL PROTECTION: A.

The welder should wear cotton coverall alongwith suitable aprons, sleeves and leggings as required for the job.

B.

The welder should also use other personal protective equipments (such as goggles, helmet, face shield, hand gloves etc.) as appropriate to the job.

C.

In case welding is to be carried out at a location situated above shoulder level, then it is recommended to wear complete protection for head, arms and upper part of the body. The protective equipment should be made of non-ignitable materials shall provide shielding from arc radiation as well as sparks exposure.

D.

A helmet with double screens should be used when chipping away slag, which covers weld-coated electrodes. Alternatively a clear glass safety goggles may also be worn alongwith suitable hand held screen.

E.

A safety footwear having anti-static characteristic alongwith protective legging should be worn as a protection from falling molten metal if the job requires

VENTILATION WHILE WELDING IN CONFINED SPACE: A.

Adequate ventilation and suitable breathing apparatus must be provided and used while carrying out welding or cutting inside a confined space. The respiratory hazards arise when welding or cutting operation may evolve toxic fumes or gases due to presence of materials such as paints, coating, oils, grease, chemicals, galvanized metals, zinc, brass, bronze and manganese steel etc.

B.

The required ventilation should be achieved by using extraction fans or air movers rather than blowing fresh air into the confined space. The compressed oxygen shall never be used for ventilating purposes.

C.

The worker must be familiar with precautionary measures associated with breathing apparatus shall be trained for wearing of breathing apparatus (Refer Chapter- 4 for PROTECTIVE EQUIPMENT).

REPAIRS WORKS INVOLVING WELDING IN SMALL CONTAINERS: A.

Special care shall be taken in the repair works (involving activities such as welding, brazing, soldering, cutting etc.) of small containers, which have contained petroleum or chemical products. As far as possible, such work should be carried out in a safe area.

B.

If the vessel, tank, drum or container cannot be removed to a safe location for carrying out repair work, the required precautionary measures pertaining to

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WELDING

ESTRICTED AREAS and duly authorized under appropriate WORK PERMIT shall be complied with. C.

The tank, vessel, drum or container must be thoroughly cleaned to ensure a gas free (flammable as well as toxic) atmosphere inside it. The compressed oxygen shall never be used for purging.

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June 2004

Page 10

Kuwait Oil Company

Fire & Safety Regulations

(K.S.C.)

Chapter No. 17 June 2004

LIFTING EQUIPMENT

CHAPTER - 17 LIFTING EQUIPMENT Contents

Subject

Page

17.1

LIFTING EQUIPMENT .................................................

2

A.

General Introduction ..........................................

2

B.

Overloading of Lifting Equipment ..............................

2

C.

Inspection & Maintenance of Lifting Gears & Appliances..............................................

2

D.

Cranes & Lifting Operation....................................

3

E.

Goods & Passenger Hoists....................................

4

F.

Forklift, Power Truck, Tractors etc...........................

5

G.

Chains, Ropes And Slings........................................

5

H.

License to Operate a Powered Lifting Device ............

5

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June 2004 Page 1

KOC F&S Regulations

LIFTING EQUIPMENT CHAPTER - 17 LIFTING EQUIPMENT

17.1

LIFTING EQUIPMENT: A.

General Introduction: Lifting equipment including all rigging & slinging appliance, tackles, gears, and anchoring devices shall be purposely designed with strong strength, sturdy structure, reliable and quality certified for the desired work. All lifting device must be die stamped or painted with an identification number, safe working load and due date of inspection to indicate its suitability as per quality assurance criteria. A valid test certificate must be available for all equipment. Where marking is not feasible, such items are to be colour coded and the safe working load recorded in a lifting tackle register, which shall be maintained by the user. The equipment should not be issued or used without a valid test certificate. The anchoring device for such equipment must have a reliable and secured support. The lifting equipment shall never be used on a soft uneven surface or on a slope unless precautions have been taken to ensure stability. Pre-slung loads or palletised load should not be accepted unless supported with valid test certificate indicating safe working load and due date of inspection. Any contractor, who intends to use lifting equipment in KOC premises must seek approval from the controlling department submitting the quality assurance certificates issued by a reputed and company recognized agency such as Lloyds, Bureau Veritas or ABS etc. The driver / operator of a lifting equipment shall have adequate training, experience and competency to operate such devices and must be at least 21 years old. A passageway of minimum 610mm shall be maintained between slewing / moving parts of a lifting equipment and guardrails / fixtures in the vicinity.

B.

Overloading of Lifting Equipment : Lifting devices must not be loaded beyond SWL, except for the purpose of proof load test supervised by an authorised person on due approval from Inspection & Corrosion Team. No crane will be operated beyond the point where SWL (Safe Working Load) alarm operates.

C.

Inspection & Maintenance of Lifting Gear & Appliances: Inspection & Corrosion Team shall inspect the lifting equipment and maintain a record for all devices subjected to inspection / survey by internal or external agency. (Refer Chapter –19 on code of Inspection for plant & equipment).

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KOC F&S Regulations

LIFTING EQUIPMENT

It is the responsibility of the user department to carry out the routine inspection of the lifting equipment before every use. However the user can request Inspection & Corrosion Team to inspect any equipment whose reliability is doubtful. • Inspection Schedule for Cranes, Winches, Ginpole Truck, Pulley Blocks, Gin Wheels & Sheer-legs: 1. Inspection to be made at least once a week by the user. 2. Thorough examination to be made at least every 6 months. 3. Testing to be carried out once a year or after substantial repairs / alteration. 4. Ginpole trucks to be tested at each commencement of work. •

Inspection Schedule of Hoist Used for Lifting Goods & Passengers: 1. Inspection to be made at least once a week by the user. 2. Thorough examination to be made at least every 6 months. 3. Testing must be carried out before first use and after repair or alteration.

Any lifting tackle such as chain, rope, and eyebolt should be inspected at least once a week. A load test must be carried out prior to first use and after any elongation, alteration, repair or welding. D.

Cranes & Lifting Operation: A crane must be erected under the supervision of a competent authority (Inspection & Corrosion Team) and should not be erected in a weather condition likely to affect its stability. A timber support shall not be used as a structural member for framework or bearer in ac crane. A safe access to the component shall be provided for examining, repairing or lubricating a crane. The working platform in a crane shall have enough space; secure fencing and safe accessibility with all moving parts / machinery duly guarded. Any winch drum, wire and pulley shall be purposely designed & constructed in conformance to accepted engineering practice and standards. The diameter for a winch drum, wire & pulley will be correct & suitable for the desired function and all chains or ropes must be properly secured to the drum. At least two turns of chain or rope must remain on the drum in all operating condition. The wire rope must wind-on evenly and not overlap itself under any circumstances. The diameter ratio of drum and rope must conform to standard practice. All gears, sprockets and wheels of driving mechanism must be properly guarded avoiding injury to the operating personnel. All boom cranes shall have an automatic safe load indicator and alarming device to alert the operator. The alarm will actuate in case the boom extension

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KOC F&S Regulations

LIFTING EQUIPMENT

approaches its safe working limit for a given load. The safe working load should be clearly visible for all boom extensions and must be strictly adhered to. For all rail-mounted cranes, a stop or buffer must be provided on each rail at the end of tracks whereas limit switch shall stop the crane automatically. These rails shall have even running surface adequately supported on a surface firm enough to prevent undue movement. Those rails must be laid straight lines or in curves of such radii that the crane can move freely without risk of derailment. The rails, sleepers, bearers, fishplates, chairs, stops and buffers etc. must be properly maintained. The rails and sleepers must not be used as anchorage. The crane user (Operator as well as Banksman) must assure the weight of the load before it is lifted. It is also recommended to identify the center of gravities for the load especially of non-uniform shape. When the hook cannot be seen directly, the crane driver should rely on signal from banksman responsible for the lift. The crane signals conforming to international practice shall be used for such communication. (Refer Appendix – 12 for further detail). The crane driver must not lift any load unless it is properly slung and safe for lifting. Each crane shall have suitable fire extinguishers duly approved by Fire Team and kept in ready to use condition. In event of fire, the crane driver should try to dispose off the load as safely as practicable before switching off the engine and subsequently attempting to extinguish the fire. . It is strictly prohibited for anybody to ride on loads, buckets or hooks suspended from a crane boom or derrick. It is also not permitted to operate a crane within a distance of 15m from an overhead power lines unless the electrical supply has been cables have been properly isolated. A crane shall not be used for dragging the load. If required a tag link should be attached to balance the load. E.

Goods & Passengers Hoists: A hoist must have strong support sufficient to carry the maximum imposed load upon it. The hoist shall also have a safe & protected access. The hoist shall be fitted with safety device to support the load-carrying basket / cage / pallet in case hoisting gear fails. A limit switch should also be provided preventing the pallet / basket to over-run at the highest or lowest point of travel. Safe working load must be marked on cage / basket alongwith number of persons allowed to travel without exceeding the load limit. Any loose material should not be directly placed on a pallet unless the load is properly secured. Any trucks or wheelbarrow shall not be carried on pallet / platform unless duly secured. Moreover a loaded truck or wheelbarrow should not be carried on open pallet / platform unless properly secured to prevent accidental fall of the content. The hoist operator must take all necessary precautions against any potential hazard associated with the lifting operations.

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KOC F&S Regulations

F.

LIFTING EQUIPMENT

Fork Lift, Power Trucks, Tractors Etc.: These vehicles shall not be driven at a speed exceeding 8 KM per hour while operating in company premises. No person other than driver is allowed to ride or stand on a power truck. A Forklift, Power Truck or any power operated lifting device shall be operated by a trained and authorized personnel only. The authorised driver shall set the brake on and remove the ignition key if the vehicle is not being used. The driver must abide by the rules & regulations pertaining to traffic safety as laid down by the company and the state government. A forklift, or power truck shall have fixed cover guard to protect the driver from accidental fall of the load being handle. The lifting capacity of such vehicles shall be clearly marked to ensure its adherence while operating. A warning sign should also be posted in the area where such devices are being operated. A power truck should be painted yellow with black stripes as standard practice. Any power truck to be deployed in ‘HAZARDOUS AREAS’ must be duly authorized under vehicle entry permit in confirmation to stipulated safety measures in this regard.

G.

Chains, Ropes & Slings: A wire rope end should be clamped with required numbers of bulldog grips as suitable to rope size These grips should be fitted at a distance of every six times the diameter of the rope. The grip should be of proper size for the rope. Wire rope ends must never be welded together at the stranded ends. The eye of all looped wire must be fitted with a proper thimble and possibly return end secured with correct size ferrule fitted by means of a crimping tool. The rope or sling must never be shortened by tying knots or swapping around a crane hook. It should not be jointed by nuts & bolts inserted through the link or clamped with flat steel plate. A suitable packing might be used to prevent the edges of a load coming into contact with slings, ropes or chains.

H.

License to Operate a Powered Lifting Device: The company or contractor employee engaged for operating cranes, bulldozers, excavators, forklifts & powered trucks etc. must have successfully passed the competency test as stipulated under state laws and company regulations.

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June 2004 Page 5

Kuwait Oil Company (K.S.C.)

Chapter No. 18 June 2004

Fire & Safety Regulations EXCAVATIONS

CHAPTER -18 EXCAVATIONS Contents

Subject

18.1

EXCAVATIONS.............................................................

2

18.2

EXCAVATIONS IN GOOD SOIL......................................

3

18.3

EXCAVATIONS IN MEDIUM SOIL..................................

4

18.4

EXCAVATIONS IN LOOSE SAND OR SOIL CONDITIONS........................................................

4

18.5

MECHANICAL EXCAVATORS..........................................

4

18.6

PREVENTION OF DROWNING.......................................

4

18.7

PROTECTION AGAINST CAVE- INS…………………….

4

18.8

SEWERS, SEWAGE TANKS & DEEP PITS........................

5

F&S Regulations Chapter 18

Page

June 2004 Page 1

KOC F&S Regulations

EXCAVATIONS CHAPTER -18 EXCAVATIONS

18.1

EXCAVATIONS: A.

No excavation work in KOC area shall be taken without ensuring EOD clearance for that location. (Refer Chapter - 7).

B.

EXCAVATION NOTIFICATION is required for all excavations regardless of its depth. The excavation notification and other relevant WORK PERMITS shall be endorsed by the concerned Groups/Teams/Sections before execution of the work.

C.

The excavation notification must accompany a clear drawing of the proposed excavation site enabling the concerned teams to check / specify precautions / hazards prior to endorsing the document.

D.

The Work Permit is applied by the Supervisor responsible for carrying out the work and shall be countersigned and distributed in accordance with the instructions on the permit.

E.

Prior to raising an Excavation Notification, the proposed location must be thoroughly inspected to assess any underground / aboveground obstructions or facilities such as cables, cable markers, manholes, catch basins, fire mains, pipelines, foundations, bases, structures etc.

F.

Ground conditions shall also be assessed by Sponsoring Team Supervisor to confirm additional protection for shallow buried services prior to deploying any mechanical excavator at site.

G.

Excavations adjacent to buildings or other obstructions / facilities may require temporary support or strutting, and accordingly the relevant safety instruction must be stated on the EXCAVATION NOTIFICATION before taking up any excavation activity.

H

A Hot Work Permit shall be required for any excavation work involving mechanical digging or excavator. Only hand excavation is permitted near buried services.

I

Excavation Notification as well as Work Permit must be cross-referenced with the other live permits & excavation activities in the vicinity of proposed excavation site.

J.

For any excavation deeper than 1m, suitable ladder must be positioned projecting a minimum of 1 metre above the edge of the excavations. Ladders shall be provided every 25 feet of lateral travel in the trench. Ladders shall be securely supported at the bottom as well as at the top.

K.

All excavations shall have barrier (such as fixed guardrails) and warning notices clearly displayed. Flashing lights are mandatory during poor visibility.

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June 2004 Page 2

KOC F&S Regulations L. M.

N.

EXCAVATIONS

Excavated material shall be placed at a distance not less than 1m from the edge of the excavation. The workers inside a trench must be protected from possibility of being struck by a falling object or piece of machinery operating nearby. All equipment, materials and plant must be kept clear from excavations to prevent accidental fall. Any heavy equipment shall be kept clear from the excavation area by at least 3 metres away. The polling board, walling and struts shall have a minimum cross-section as mentioned hereunder: Item Minimum Cross-section Polling board = Walling = Struts =

18.2

200mm x 50mm, (8" x 2") 150mm x 50mm (6" x 2") 100mm x 50 mm (4" x 2").

O.

The timbering and shoring must be checked for any strain or slackness before commencement of daily work. Moreover timbering and shoring must also be checked carefully after heavy rains and or exposure to high temperature.

P.

The required personal protective equipment (such as safety helmet, safety shoes etc.) must be worn by the worker involved in excavation activities.

Q.

The excavations must be inspected daily before work begins to ensure that the soil underneath has not eroded. All excavations must be carefully inspected following heavy rains and / or collapse of trenches due to falling materials etc.

R.

The access to plant, equipment and emergency services must not be obstructed by the trenches. The trenches shall not be left uncovered in the plant area and must be backfilled safely on completion of work returning the area to its original condition.

S.

Where equipment, workers or public are required or permitted to cross over a trench, a close planked bridge or walkway with standard guardrails must be provided.

EXCAVATIONS IN GOOD SOIL: A.

For excavations in good soil, shoring is not usually required, provided the excavations depth does not exceed more than one metre

B.

If the surface area permits, greater depth can be made by battering the side down to an angle of 45°.

C.

However in case surface area is limited and needed excavation depth is more than one metre, the polling boards must be placed approximately two metres apart with horizontal struts, whereas horizontal struts should not be more than one metre apart.

D.

Where a long trench excavation is being made, the mechanical means of digging must be limited to approximately two metres ahead of shoring to give a protected position. Competent workmen must carry out shoring.

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KOC F&S Regulations

18.3

18.4

EXCAVATIONS

EXCAVATIONS IN MEDIUM SOIL: A.

If the depth of the excavation exceeds one metre, shoring must be used. The polling boards should be placed not more than 750mm (30") apart facing the wall at a distance of one metre from the centre across strutted timber.

B.

Pit props or extra polling boards should be inserted across if the condition of the ground deteriorates.

EXCAVATIONS IN LOOSE SAND OR SOIL CONDITIONS: If excavations are to be made in loose sand or soil, the EXCAVATION NOTIFICATION must state the actual method to be used ensuring safety & integrity of personnel as well as plant involved in the work execution.

18.5

18.6

MECHANICAL EXCAVATORS: A.

HOT WORK PERMIT in addition to an EXCAVATION NOTIFICATION is required for utilizing Mechanical Excavators in RESTRICTED AREA.

B.

The care shall be taken to prevent any damage to underground / above ground facilities while using Mechanical Excavator.

C.

A Mechanical Excavator shall not be used until all underground obstruction has been uncovered through cautious hand excavation. Once underground services are exposed, the area should be further excavated by hand for at least 3 meters (10 ft) on either side of the exposed services before resuming Mechanical Excavation.

D.

The operator shall take extra care while reversing or turning the excavator to prevent any accidental strike to the workers or equipment at location.

E.

The bucket must always be lowered to the ground if the excavator is not in operation.

F.

The operator shall take care to avoid exhaust gases entering the trenches or pit, if the personnel are working below ground level in the immediate vicinity of excavation.

PREVENTION OF DROWNING: Adequate fencing, barriers and warning notices are to be provided around any excavation (which may contain enough water) to alert the person from prevalent danger and prevent accidental drowning. These barriers or fences should be removed only for the minimum period if required for the passage of plant and materials through it. It is recommended to provide suitable rescue equipment at site if there is possibility of access to the excavation area by unauthorized persons.

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KOC F&S Regulations 18.7.

18.8

EXCAVATIONS

PROTECTION AGAINST CAVE – INS: Cave-ins occur when trench sidewalls are not supported adequately and the weight of the adjacent soil collapses them. The following techniques shall be used to prevent cave-ins: (i)

Sloping: It involves angling the sides of an excavation.

(ii)

Benching: A trench sidewalls are excavated to form one or more steps.

(iii)

Shoring: It uses engineering structure such as Cross-braces, vertical rails (Uprights), and / or horizontal rails (whalers) to support a trench’s sidewalls.

(iv)

Edge Protection: Supporting the edges of a trench with struts and braces are called “Edge Protection”. Edge Protection should only be used in addition to sloping, benching or shoring.

(v)

Trench Shield: A trench shield is box like structure built in trenches to contain workers during trench work.

PROTECTION IN SEWERS, SEWAGE TANKS & DEEP PITS: A.

The area & space below ground level as inside sewers, sewage tanks and deep pits are classified as HAZARDOUS AREAS and all safety regulations pertaining to work in such areas are to be observed.

B.

The worksite supervisor is responsible for safe execution of the work ensuring compliance to the safety regulations.

C.

Any work, which requires entry into a sewer, sewage tank or deep pit, must be authorized by an ENTRY PERMIT in addition to other appropriate WORK PERMIT needed for work execution.

D.

Sewers must be thoroughly ventilated and gas test carried out complying confined space entry procedure before an attempt is made to enter inside for inspection or maintenance work.

E.

The gas tests, for flammable, toxic (H2S), Oxygen and any asphyxiating conditions, are to be made before entry, in accordance with Company regulations (Refer Chapter – 8 for Gas Testing requirement)

F.

The workers entering a sewer or tank may do so only in compliance with the conditions laid down in CONFINE SPACE ENTRY and other relevant WORK PERMITS. (Refer Chapter - 8 & Appendix -6)

G.

The workers entering a sewer or tank must be secured with lifelines and attended by at least two persons stationed at the entry manhole. The workers wearing lifelines as well as attendant them must know the code & safety signals to be used with lifelines (Refer Chapter – 4 for Safety Harness & Lifelines).

H.

The equipment, tools, lamps and torches to be used inside trenches, sewers, tanks & pits must be suitable for relevant HAZARDOUS AREA CLASSIFICATION (Refer KOC Standard No. KOC-G-002)

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KOC F&S Regulations

EXCAVATIONS

I.

Each worker entering inside a sewer, deep trenches, tanks or pits must be equipped with essential rescue equipment such as 2 numbers of lifelines, 1 safety harness, and a breathing apparatus duly approved by Fire Team.

J.

The entrant must also wear chemical resistant suit to enter inside manhole, sewer, tank or deep pit where the possibility of contamination exists.

K.

The worksite supervisor is responsible to keep the rescue equipment and other emergency items in ready to use condition.

L.

The entrants must be made aware of the potential hazard, safety precautions, emergency procedure and rescue action before commencing the work. (Refer Appendix-6 for further detail).

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Kuwait Oil Company

Fire & Safety Regulations

(K.S.C.)

Chapter No. 19 June 2004

CODE OF INSPECTION FOR PLANT AND EQUIPMENT CHAPTER - 19

CODE OF INSPECTION FOR PLANT AND EQUIPMENT Contents

Subject

Page

19.1

INTRODUCTION...........................................................

2

19.2

GENERAL PROCEDURE................................................

2

19.3

GENERAL PREPARATION REQUIREMENTS................

4

19.4

INSPECTION PROCEDURES ..............................................

5

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KOC F&S Regulations

CODE OF INSPECTION FOR PLANT AND EQUIPMENT CHAPTER - 19

CODE OF INSPECTION FOR PLANT AND EQUIPMENT 19.1

INTRODUCTION: This code as listed under General Procedure, is to be followed for all plants and equipment covered by Inspection and Corrosion Teams.

19.2

GENERAL PROCEDURE:

19.2.1 All plants and equipment as listed hereunder shall be inspected periodically:A.

Process plant within Gathering Centres and Booster Stations.

B.

Refrigeration and water chilling plant above 10 hp in size and A/C package units in Gathering Centres and Ahmadi Hospital.

C.

Cylinders for storage and transportation of compressed or liquefied gases.

D.

The vessels and tanks used for conveyance or storage of crude oil or petroleum products.

E.

Steam boilers, super heaters, steam receivers and steam carrying pipelines of four inch or more in nominal diameter.

F.

Air receivers and air driers.

G.

Cranes hoists, lifting machines and run ways. Chains, slings, ropes and all other types of lifting tackle and associated equipment.

H.

Passenger and Material transfer lifts or basket.

I.

Offshore facilities.

J.

Dehydration and Desalting Plants, Mobile or fixed.

K.

Any other equipment or plant not, which is specifically not covered in this list, but the asset owner requests periodic inspection on safety grounds (e.g. underground pipelines).

L.

Hydrocarbon Carrying Flowlines / Pipelines.

19.2.2 The inspection cycle shall be determined by Inspection & Corrosion Team, who will take account of operational requirements from asset owner, so that safety is not compromised. 19.2.3 Inspection shall be carried out by Inspection & Corrosion Team, who will subsequently issue reports on plant condition alongwith mandatory recommendations for repair and protection within a certain time frame. 19.2.4 Inspection report will mention the next due date of inspection for each plant & equipment and subsequently asset owner will prominently paint or display a

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CODE OF INSPECTION FOR PLANT AND EQUIPMENT

notice, signboard or stamped metallic tag on or near the equipment elaborating “ Next Inspection Due: …………” In case complete unit or train is due for inspection at one time, the notice for “inspection due date” may be installed at the entry point of the unit / train. 19.2.5 Inspection reports and recommendation will be rendered invalid if: (a)

Changes are made resulting in deviation from design intention or operating condition compromising safety & integrity of the plant or equipment. These alterations include but not limited to changing maximum or minimum range of operating parameters (such as pressure, flow rate, temperature, feedstock etc.), increase in impurities (H2S, CO2 etc.) or water contents in hydrocarbon stream.

(b)

The plant or equipment is altered or modified without the prior approval of Inspection & Corrosion Team.

(c)

The plant, unit or equipment is altered or modified without a HAZOP study being conducted to ensure safe operation.

19.2.6 It is the responsibility of the asset owner to consult Inspection & Corrosion Team and arrange equipment inspection on or before the due date including first time inspection for the new plant or re-inspection due to significant change in service conditions. The asset owner will also supply details of stream hours logged between consecutive inspections and from the inception / commissioning. 19.2.7 Equipment and plant to be mothballed shall be inspected before applying mothballing process and also prior to de-mothballing. 19.2.8 Any new installation constructed by international or local contractor shall be subjected to safety audit. The Audit Team shall comprise: a.

Senior members from Operations Teams (Production & Maintenance).

b.

A senior member from Engineering Group.

c.

Inspection Engineer and Corrosion Engineer from I & C Team.

d.

Senior members from Fire Team & respective area HSE Team.

Initial inspection reports will only be issued by Inspection & Corrosion Team for projects where Inspection & Corrosion Team was responsible for inspection during construction phase. In case Engineering Consultant / Contractor has carried out inspection, the Operations Team / asset owner may take over the plant and in turn will liase with Inspection & Corrosion Team to decide the first formal inspection of the plant. In most instances the time period for first formal inspection of the plant / equipment will depend upon the guarantee period rendered by the engineering consultant / contractor but in general it should not exceed two years. .

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CODE OF INSPECTION FOR PLANT AND EQUIPMENT

19.2.9 Inspection & Corrosion Team will maintain records of basic data for all plants inspected, and also establish records for new plants, which require periodic inspection. All such plants & equipment shall be considered as on the "Inspection Schedule". 19.2.10 Transfer or write-off of a plant or equipment on the Inspection Schedule, shall be reported to Inspection & Corrosion Team by the previous asset owner with due confirmation by the Team taking over the written off plant or equipment.. 19.2.11 Alterations or modifications to a plant or equipment on the inspection schedule will require both design and test approval by Inspection & Corrosion Team. . 19.2.12 Any repair and / or alteration to pressure containments shall have prior approval from Inspection & Corrosion Team. 19.2.13 Any accident involving a plant, equipment or piping shall be reported to Inspection & Corrosion Team by the asset owner and the disposition shall be agreed upon with Inspection & Corrosion Team.. 19.2.14 All welding approvals & qualifications shall be certified by Inspection & Corrosion Team. 19.3

GENERAL PREPARATION REQUIREMENTS: 19.3.1 Any plant or equipment due for inspection shall be opened up, cleaned and adequately prepared for both external and internal inspection. The due precaution shall be made where pyrophoric scale may exist. 19.3.2 Where lining or insulation exists, selected section shall be removed according to Inspection & Corrosion Team requirements. 19.3.3 Upon formal request from Inspection & Corrosion Team defective lining or insulation shall be completely removed and the surface shall be cleaned to permit inspection of the entire surface. 19.3.4 The asset owner shall provide and install necessary access facilities such as ladders, platforms and scaffolds etc for convenient approach to the equipment & plant to be inspected. 19.3.5 As the discretion of Inspection & Corrosion Team, certain equipment and / or piping may require pressure testing before recommissioning. It is the responsibility of the asset owner to arrange such tests. 19.3.6 All relief and safety valves shall be sent to Central Workshops for testing, resetting, and overhaul after a period not exceeding two years. The testing & resetting of such valves shall be required following any overhaul, irrespective of overhaul being carried out on or before inspection due date. 19.3.7 Where it is impractical to carry out cleaning, examination and or/repair of equipment in place, Inspection & Corrosion Team may require the dismantling of equipment to carry out such works at KOC Central Workshop or other outside facility duly approved by the Company.

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June 2004 Page 4

KOC F&S Regulations 19.4

CODE OF INSPECTION FOR PLANT AND EQUIPMENT

INSPECTION PROCEDURES: All inspection work to be undertaken by Inspection & Corrosion Team shall be made in conformance with “Inspection & Corrosion Procedure Manual”.

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June 2004 Page 5

Kuwait Oil Company (K.S.C.)

Chapter No. 20 June 2004

Fire & Safety Regulations

SECURITY & INSTALLATION ACCESS CONTROL CHAPTER –20

SECURITY & INSTALLATION ACCESS CONTROL Contents

Subject

20.1

GENERAL INSTRUCTIONS ...........................................

2

20.2

TYPE OF ENTRY PASSES .......................................

2

20.3

CONTRACTORS REPRESENTATIVE .............................

4

20.4

THEFT CASES ......................................................

4

20.5

LOADING NOTE ..............................................................

5

F&S Regulations Chapter 20

Page

June 2004 Page 1

KOC F&S Regulations

SECURITY & INSTALLATION ACCESS CONTROL

SECURITY & INSTALLATION ACCESS CONTROL 20.1 General Instructions: -

All company and Non-Company Employees working or visiting company areas, premises and restricted installations must be in a possession of an entry pass issued by K.O.C. which identifies the holder and indicates that he / she is authorized to enter.

-

Entry passes must be in the possession of the holder and displayed at a clear position of the body to be ready for inspection by the Security Officers whether K.O.C. or Ministry of Interior.

-

Entry passes must be kept in a safe place at all times to safeguard it from theft, loss and weather conditions. Departmental Heads and others who are approved by Manager (Industrial Services) are authorized to request entry passes and to sign temporary entry passes.

-

In case of lost entry passes, Installation Access Control Division is to be informed in writing; in addition, a note of the Incident from the Police station is required for re-issuance.

-

Copies of Civil ID, Passport, Visa, Vehicle Registration Books, etc… are required wherever applicable when applying for entry passes.

-

The security regulations may change from time to time depending on the security needs and developments.

-

The Installation Access Control Team has the right to withdraw entry passes without presenting the reasons.

20.2 Type of Entry Passes: A.

Company Identification Cards: It can be requested by Team Leader in case of new engagements, changes in employment conditions, replacement of lost ID, etc…

B.

Entry Passes for outsiders: It can be issued on request by the Contractor or State Authorities through Controlling Team, who will verify requirement, endorse and forward to Installation Access Control Team for issuing of the entry passes. The workers for whom entry passes are to be issued must be under direct sponsorship of the contractor or its approved sub-contractors.

C.

Vehicle Entry Passes: o Issued by the Contractors or State Authorities to the Controlling Departments who shall verify the request, sign and forward to Installation Access Control Team for processing of the entry passes. o Privately owned vehicles are not approved for vehicle entry pass.

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SECURITY & INSTALLATION ACCESS CONTROL

o Vehicles must be owned by the contractor or his approved subcontractors. D.

Entry Pass for Photography Camera or Video Camera: It can be issued on request to Installation Access Control. The photography camera / video camera to be used in hazardous area must be intrinsically safe and duly approved by Fire Team to qualify for entry pass issue.

E.

Explosive Transport Passes: It can be issued on request through concerned controlling team to Team Leader- Installation Access Control.

F.

Visitor’s Companions Entry Pass: This is usually issued to staff from Public Relation & Information Group accompanying VIPs and delegation visiting company premises and facilities in restricted area.

G.

Personnel /Vehicle Entry Passes for KNPC Premises: It can be issued on request through Installation Access Control Team, who will verify the requirement, endorse and forward to KNPC officials for consideration and issuance of entry passes. The pass issued by KNPC for KOC staff or vehicle shall be collected by representative from Installation Access Control Team. In turn the individual concerned or a representative from respective Team may collect such passes from Installation Access Control.

H.

Entry Passes for Mina Al-Shuaiba: It can be issued on request through Installation Access Control Team, who will verify the requirement, endorse and return to the requesting Team for onward dealing with port authorities in this regard.

I.

Entry Pass Booklet: It available with concerned Team to issue short-term entry passes (maximum up to 6 days) for persons and vehicles in case of emergency and utmost operational requirement. Temporary entry passes can be issued to principal contractors, approved subcontractors or state authorities as per need. In case the Controlling Team wishes to issue entry passes for other than approved subcontractors then a “No objection certificate” signed by the direct sponsor is required on due approval from Legal Affairs Group. (Discussion not finalized, to be held)

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SECURITY & INSTALLATION ACCESS CONTROL

20.3 Contractors Representative (Mandoop): A contractor representative shall meet the requirement as hereunder: -

Shall be approved by Team Leader- Installation Access Control.

-

Ability to speak & write Arabic.

-

Efficiency in typing and operating PC.

-

Team Leader – Installation Access Control has the right to relieve Mandoops from their responsibility for any misconduct or non-compliance with the security regulations.

20.4 Theft Cases: In compliance to Circulars No. /2003 & 22/2003 from Manager - Human Resources, theft cases shall be dealt as per procedures hereunder: (i) EVENT - 1: Loss of employee’s personal effects within the Company’s premises and offices. •

ACTION TO BE TAKEN: The employee (on his / her discretion) may notify immediate supervisor who will recommend necessary measures and administrative action to respective Team Leader or Group Manager. Team Leader / Group Manager may constitute an in-house committee for investigation which shall be completed within 24 hours. However in case of failure to reach a result, the employee may opt, under no obligation towards the Company, to report the incident to the relevant authorities for such cases.

(ii) EVENT - 2: Loss of company’s property (allocated to employee) within or outside KOC premises. •

ACTION TO BE TAKEN: a) The employee shall promptly notify his / her immediate supervisor, who in turn informs Team Leader / Department Head for necessary action. b) The concerned Team Leader may conduct an internal investigation. However in case of failure to reach a result within 24 hours, the employee, upon approval of Team Leader shall notify the competent authority for property loss as custodian. Moreover Local Relation Team must also be informed for full cognizance of the same. c) The employee, who lost the property, shall extract an incident notification document (indicating Case No.& Date) from Ministry of Interior and submit the same to the Local Relations Team for appropriate action & further follow up with officials in this regard.

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SECURITY & INSTALLATION ACCESS CONTROL

(iii) EVENT - 3: Loss of the Company’s property, which are registered as assets under a certain Team / Group •

ACTION TO BE TAKEN:

a) The respective Team Leader shall promptly notify the Group Manager and shall simultaneously conduct the required investigation. In case of failure to reach a result within 24 hours, the Team Leader or his / her delegated person (preferably who discovered the theft) accompanied by Local Relations Team representative and due approval from Group Manager shall approach competent authorities for further action. b) Local Relations Team in co-ordination with Company’s Legal Affairs Group shall follow up the case with the officials keeping the concerned Managers informed with its progress and development. (iv) EVENT 4: Loss of equipment or assets owned by third party within the Company premises. •

ACTION TO BE TAKEN: The affected party shall notify the Controlling / Sponsoring Team, who will verifies the situation, before reporting the incident to the competent authorities through Local Relations Team.

(v) IMMEDIATE ACTION: a) In the event of flagrant or delicate case of thefts or in case of emergency situation, where immediate action can not be delayed, the competent authorities must be notified promptly by the person in charge present at the time of the occurrence with due information to respective Team Leaders. b) Installation & Access Control Team can be contacted round the clock on telephone numbers 67758, 66203 or 3987114 for any assistance for all such cases as mentioned above. 20.5

Loading note: Loading Notes / Issue Tickets are required to permit material in / out of the Oil Installations. The Company issued loading note must be signed and endorsed by authorized Supervisor with full name, designation, KOC number and Controlling Team.

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June 2004 Page 5

Kuwait Oil Company (K.S.C.)

Fire & Safety Regulations

OIL WELL DRILLING, WORKOVER, EXPLORATION & WELL SURVELLANCE

Chapter No. 21

June 2004

CHAPTER –21 OIL WELL DRILLING, WORKOVER, EXPLORATION & WELL SURVELLANCE Contents

Subject

21.1

INTRODUCTION

21.2

Page ....................................................

GENERAL INFORMATIONS....................................

2 2

21.3

DRILLING & WELL SERVICING OPERATIONS …

3

21.4

HYDROGEN SULPHIDE (H2S) …………

7

21.5

SAFETY AT OR NEAR DRILLING LOCATION………

8

21.6

FIRE PREVENTION & PROTECTION …………….

8

21.7

AIR & GAS DRILLING

9

21.8

WELL SURVEILLANCE OPERATIONS....................

10

A.

Wireline Operations ...................................................

10

B.

Coiled Tubing Operations … ...........................................

12

C.

Well Testing Operations with Mobile Separators...............

13

D.

Artificial Lift Operations ………………………………

13

E.

Well Surveillance Operations at Rig Site ………………….. 14

F&S Regulations Chapter 21

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June 2004 Page 1

OIL WELL DRILLING, WORKOVER, EXPLORATION & WELL SURVELLANCE

KOC F&S Regulations

CHAPTER –21 OIL WELL DRILLING, WORKOVER, EXPLORATION & WIRELINE ACTIVITIES 21.1

INTRODUCTION: These rules and regulations are promulgated to protect the health, safety and welfare of KOC and rig personnel during the drilling, completion, workover, and exploration of oil and gas wells. They do not supersede or replace the Drilling HSE Guidelines that are used to direct HSE requirements during exploration, drilling and work over operations. If there is any conflict between this regulation and the KOC Drilling HSE Guidelines, then the Drilling HSE Guidelines take precedence over this regulation.

21.2

GENERAL INFORMATIONS: The training and action of employees, as well as proper location and operation of equipment is an important part this safety program. While this section is general in nature, it is considered a basic part of the foundation of this safety program. Employees shall be familiarized with these rules and regulations as provided herein as they relate to their function in their respective jobs. New employees should have their job outlined, explained and demonstrated. Unsafe or potentially dangerous conditions as defined by these rules, should be reported immediately by employees to their supervisor and be remedied as soon as practical. Any accident involving injury to rig or well location personnel, or to site visitors, which requires hospitalization, or significant damage to equipment or the well site shall be reported to KOC’s Drilling Department and Drilling HSE Group as soon as practicable, but in no event later than twenty-four (24) hours after the accident/incident. Where unsafe or potentially dangerous conditions exist, the rig owner/operator shall respond as directed by KOC’s Drilling Safety Group or as the Owner/Operator’s Safety Department may direct with prior approval from KOC’s Drilling Safety Group. Vehicles of persons not involved in drilling, production, servicing, or seismic operations shall be located a minimum distance of fifty (50) meters from the wellbore, or a distance equal to the height of the derrick or mast, whichever is greater. Equivalent safety measures shall be taken where terrain, location or other conditions do not permit this minimum distance requirement. Existing wells are exempt from the provisions of this regulation as they relate to the location of the well. Existing producing facilities shall be exempt from the provisions of these regulations with respect to minimum distance requirements and setbacks unless they are found by KOC’s Drilling Safety Group to be unsafe for concurrent operations. At a minimum, self-contained sanitary facilities shall be provided during drilling operations. If exploratory drilling operations are planned for an extended period, then a

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OIL WELL DRILLING, WORKOVER, EXPLORATION & WELL SURVELLANCE

portable sewage treatment unit with suitable capacity for rig and camp personnel shall be employed at the drilling location and the drilling campsite. 21.3 DRILLING & WELL SERVICING OPERATIONS & HIGH-DENSITY AREAS:

(A) Setbacks: Subparagraph (1) below shall apply to all areas except as provided under subparagraphs b. and e. of this regulation. Subparagraph (2) below shall apply to all areas. (1)

At the time of initial drilling of the well, the wellhead shall be located as follows: •

For all workover operations, a minimum of thirty-five (35) meters shall be maintained from any occupied building, public road, or major above ground utility line.

•

For all regular drilling operations, a minimum of forty-five (45) meters shall be maintained from any occupied building, public road, or major above ground utility line.

•

For all exploratory well drilling, a minimum distance of sixty-two and one half (62½) meters; or, one and one-half (1½) times the height of the derrick, whichever is greater, from any occupied building, public road, or major above ground utility line.

(2)

A well shall be a minimum distance of fifty (50) meters from a surface property line. An exception may be granted by KOC’s Drilling Safety Group if it is not feasible for the drilling operation to meet this minimum distance requirement; and, a waiver is obtained. A memorandum requesting the Drilling HSE waiver which states the reasons for the exception must be submitted to the Drilling HSE Group; and, must be received by the Drilling HSE Group a minimum of thirty (30) days prior to the commencement of the drilling operation.

(B) High-density Areas. A high-density area shall be determined during the planning stages of a drilling operation, on a well-by-well basis, by calculating the number of occupied building units within a three hundred (300) meter radius from the wellhead. If eighteen (18) or more building units are within any semi-circle of the three hundred (300) meter radius, it shall be deemed a high-density area. (C) High-density Area Rules for Other Facilities: If an educational facility, assembly building, hospital, nursing home, or board and care facility is located within three hundred (300) meter of a wellhead, high-density area rules shall apply. (D) Designated outside Activity Area: The Drilling HSE Group shall determine the appropriate boundary and setbacks for a designated outside activity areas. The minimum setback from the boundary of the designated outside activity area shall be one hundred (100) meters.

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OIL WELL DRILLING, WORKOVER, EXPLORATION & WELL SURVELLANCE

KOC F&S Regulations

(E) The following rules shall apply to designated outside activity areas: (1)

(3)

Setbacks for Wellheads: At the time of initial drilling of the well, the wellhead location shall be not less than three hundred fifty (350) feet from any building unit, educational facility, assembly building, hospital, nursing home, or board and care facility.

Blowout Prevention ("BOP") During Drilling Operations: Blowout prevention equipment for drilling operations that is consistent with the requirements of the drilling program and the expected formation conditions shall be used as follows: •

•

•

•

Pressure rating of BOP stack is sufficient to meet the predicted or known downhole pressures BOP equipment is rated (NACE) for H2S exposure when H2S can be expected downhole. IWCF, or equivalent, certification approved training for blowout prevention shall be required for at least one (1) person at the well site during drilling operations. BOP Testing for High-density Area Drilling Operations: Upon initial rigup and at least once a week during drilling operations thereafter, pressure testing of the casing string and each component of the blowout prevention equipment including flange connections shall be performed. Pressure testing shall be conducted and the documented results shall be retained by the rig operator for inspection by KOC’s Drilling HSE Group for a period of one (1) year.

(3)

Pit Level Indicators. Pit level indicators shall be used.

(4)

Drill Stem Tests. Closed chamber drill stem tests shall be allowed in high-density areas. All other drill stem tests shall require approval by the Drilling HSE Group.

(5)

BOPE for Well Servicing Operations. Adequate blowout prevention equipment shall be used on all well servicing operations. •

Backup stabbing valves shall be required on well servicing operations during reverse circulation. Valves shall be pressure tested before each well servicing operation using both low-pressure air and high-pressure fluid.

(6)

Location Requirement Exceptions & Waivers:. Exceptions to the location requirements set out in subparagraphs (2) and (3) above shall be granted by the Drilling HSE Group if copies of waivers from each person owning an occupied building within one hundred (100) meters of the proposed location is submitted as part of the drilling plan and that the proposed location complies with all other safety requirements of the Drilling HSE Guidelines.

(7)

Fencing Requirements:. At the time of initial installation, if a well-site falls within a high-density area, all pumps, pits, wellheads and production facilities

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OIL WELL DRILLING, WORKOVER, EXPLORATION & WELL SURVELLANCE

shall be adequately fenced to restrict access by unauthorized persons. For security purposes, all such facilities and equipment used in the operation of a completed well shall be surrounded by a fence six (6) feet in height, constructed in conformance with local written standards so long as the material is non-combustible and allows for adequate ventilation, and the gate(s) shall be locked. (8)

Control of Fire Hazards. Any material not in use that might constitute a fire hazard shall be removed a minimum of ten (10) meters from the wellhead, tanks and separator. Any electrical equipment installations inside the bermed area shall comply with API RP 500 classifications; and, comply with the current UL and NFPA codes.

(9)

Load -lines. In high-density areas, all load lines shall be bull-plugged or capped.

(10) Removal of Surface Trash. All surface trash, debris, scrap or discarded

material connected with the drilling operations shall be removed from the drill site and disposed of in a legal manner. (11) Guy-line Anchors. Any guy line anchors left buried for future use shall be

identified by a marker of bright color not less than one and a half (1½) meters in height and not greater than one half (½) meter east of the guy line anchor. (12) Berm Construction. All newly installed or replaced berms in high-density

areas, in the absence of remote impounding, shall be constructed around crude oil and condensate storage tanks and shall enclose an area sufficient to contain one hundred fifty percent (150%) of the largest single tank. No more than two (2) crude oil and condensate storage tanks shall be located within a single berm. Berms shall be inspected at regular intervals and containment integrity maintained. Refer to API Recommended Practices - D16. (13) Tank Specifications. All newly installed and/or portable crude oil and

condensate storage tanks used for drilling and/or workover operations in highdensity areas shall be designed, constructed, and maintained in accordance with National Fire Protection Association's latest edition (NFPA 30). KOC Operations Division shall maintain written records verifying proper design, construction, and maintenance, and shall make these records available for inspection as may be necessary by the Drilling HSE Group. (14) Access Roads. If a well-site falls within a high-density area at the time of

construction, all roads shall be constructed to accommodate local emergency vehicle access requirements, and shall be maintained in a reasonablecondition. (15) Well Ste Cleared. Within thirty (30) days after a well is plugged and

abandoned, the well site shall be cleared of all non-essential equipment, trash, and debris. For good cause shown, an extension of time may be granted by the Drilling HSE Group.

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(16) Identification of Plugged & Abandoned Wells in High-density Areas.

KOC shall identify the location of the wellbore with a permanent monument. The monument shall have the well number and date of plugging inscribe or imbed upon the permanent monument. F. Rig Floor Safety Valve Requirements. When drilling or well servicing operations are in progress on a well where there is any indication the well will flow hydrocarbons, either through prior records or through present conditions, there shall be on the rig floor a safety valve with connections suitable for use with each size and type of tool joint or coupling being used on the job. G. Static Charge Requirements. Rig substructure, derrick, or mast shall be designed and operated to prevent accumulation of static charge. H. Well Servicing Pressure Check Requirements. Prior to initiating well servicing operations, the well shall be checked for pressure and steps taken to remove pressure or operate safely under pressure before commencing operations. I. Well Control Equipment & Other Safety Requirements. Well control equipment and other safety requirements are: (1)

When there is any indication that a well will flow, through prior records, present well conditions, or the planned well work, blowout prevention equipment shall be installed.

(2)

Blowout prevention equipment when required by Rule 317 shall be in accordance with API RP 53: Recommended Practices for Blowout Prevention Equipment Systems, or amendments thereto.

(3)

While in service, blowout prevention equipment shall be inspected daily and a preventer operating test shall be performed on each round trip, but not more than once every twenty-four (24) hour period. Notation of operating tests shall be made on the daily report.

(4)

All pipe fittings, valves and unions placed on or connected with blowout prevention equipment, well casing, casing head, drill pipe, or tubing shall have a working pressure rating suitable for the maximum anticipated surface pressure and shall be in good working condition as per generally accepted industry standards.

(5)

Blowout prevention equipment shall contain pipe rams that enable closure on the pipe being used. The choke line(s) and kill line(s) shall be anchored, tied or otherwise secured to prevent whipping resulting from pressure surges.

(6)

Pressure testing of the casing string and each component of the blowout prevention equipment, if blowout prevention equipment is required, shall be conducted prior to drilling out any string of casing except conductor pipe. The minimum test pressure shall be five hundred (500) psi, and shall hold for fifteen (15) minutes without pressure loss in order for the casing string to be considered

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serviceable. Upon demand the operator shall provide to the commissioner the pressure test evidence. Drilling operations shall not proceed until blowout prevention equipment is tested and found to be serviceable. (7)

If the blind rams are closed for any purpose except operational testing, the valves on the choke lines or relief lines below the blind rams should be opened prior to opening the rams to bleed off any pressure.

(8)

All rig employees shall have adequate understanding of and be able to operate the blowout prevention equipment system. New employees shall be trained in the operations of blowout prevention equipment system as soon as practicable to do so.

(9)

Drilling contractors shall place a sign or marker at the point of intersection of the public road and rig access road.

(10)

The number of the public road to be used in accessing the rig along with all necessary emergency numbers shall be posted in a conspicuous place on the drilling rig.

J. Equipment, waste, and trash requirements. All locations, including wells and surface production facilities, shall be kept free of the following: i. Unnecessary drilling equipment ii. Vehicles iii. Supplies not necessary for use iv. Rubbish v. Other waste materials

The burning or burial of waste materials on site is not permitted with the exception of some specific wastes that may be recycled or reused on the drilling location. I all such cases, prior written approval must be received from KOC’s Drilling HSE Group. K. Equipment anchoring requirements. All equipment at drilling and production sites in geological hazard and floodplain areas shall be anchored to the extent necessary to resist flotation, collapse, lateral movement or subsidence. 21.4

HYDROGEN SULFIDE GAS (H2S) a.

When well servicing operations take place in zones known to contain at or above seventy-five (75) ppm H2S gas, as measured in the gas stream, KOC’s Drilling HSE Group must be informed of the proposed operation and the expected concentration of H2S.

b.

When proposing to drill a well in areas where H2S gas is known to be in excess of seventy-five (75) ppm; and, can reasonably be expected to encounter, a H2S drilling operations plan must be submitted and approved by KOC’s Drilling HSE Group.

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OIL WELL DRILLING, WORKOVER, EXPLORATION & WELL SURVELLANCE

Any gas analysis equipment indicating the presence of H2S gas shall be reported to KOC’s Drilling HSE Group immediately.

21.5 SITE SAFETY AT OR NEAR DRILLING LOCATIONS: a.

b.

Signs & Fences. Under some circumstances, special equipment may be required to insure the safety of high-density or occupied areas. (1)

Pumps, pits, and other site equipment shall be adequately fenced to prevent access by unauthorized persons when the drilling location, or equipment is easily accessible to the public and poses a physical or health hazard.

(2)

Sign(s) shall be posted at the boundary of the drilling location where access exists, identifying the location and listing a phone number where KOC can be reached, at all times, in the event of an emergency.

Buried or Partially Buried Tanks, Vessels or Structures. Buried or partially buried tanks, vessels, or structures used for storage of E&P waste shall be properly designed, constructed and installed in a manner to contain materials safely. Such vessels shall be tested for leaks after installation and maintained, repaired or replaced to prevent spills or releases of E&P waste.

21.6 FIRE PREVENTION & PROTECTION: a.

Flammable liquids storage areas inside any caravan or portable shed shall: (1) Be adequately vented to the outside air; (2) Have two (2) unobstructed exits leading from the building in different directions if the building is in excess of five hundred (500) square feet. (3) Be maintained with due regard to fire potential with respect to housekeeping and materials storage; (4) Be identified as a hazard and appropriate warning signs posted.

b.

Flammable liquids shall not be stored within fifteen (15) meters of the wellbore, except for the fuel in the tanks of operating equipment or supply for injection pumps. Where terrain and location configuration do not permit maintaining this distance, equivalent safety measures should be taken.

c.

Smoking shall be prohibited at or in the vicinity of operations, which constitute a fire, hazard and such locations shall be conspicuously posted with a sign, "No Smoking" or "Open Flame". Matches and all smoking equipment may not be carried into "No Smoking" areas.

d.

No source of ignition shall be permitted in an area where smoking has been prohibited.

e.

Open fires, transformers, or other sources of ignition shall be permitted only in designated areas located at a safe distance from the wellhead or flammable liquid storage areas.

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OIL WELL DRILLING, WORKOVER, EXPLORATION & WELL SURVELLANCE

f.

Only approved heaters for Class I Division 2 areas, as designated by API RB 500B, shall be permitted on or near the rig floor. The safety features of these heaters shall not be altered.

g.

Combustible materials such as oily rags and waste shall be stored in covered metal containers.

h.

Material used for cleaning shall have a flash point of not less than one hundred degrees Fahrenheit (100°F / 38°C). For limited special purposes, a lower flashpoint cleaner may be used when it is specifically required and should be handled with extreme care.

i.

Firefighting equipment shall not be tampered with and shall not be removed for other than fire protection and firefighting purposes and services. A firefighting water system may be used for wash down and other utility purposes so long as its firefighting capability is not compromised. After use, water systems must be properly drained.

j.

An adequate amount of fire extinguishers and other firefighting equipment shall be suitably located, readily accessible, and plainly labeled as to their type and method of operation.

k.

Fire protection equipment shall be inspected monthly and maintained in good operating condition at all times.

l.

Firefighting equipment shall be readily available near all welding operations. When welding, cutting or other hot work is performed in locations where other than a minor fire might develop; a person shall be designated as a fire watch. The area surrounding the work shall be inspected at least one (1) hour after the hot work is completed.

m.

Portable fire extinguishers shall be tagged showing the date of last inspection, maintenance or recharge. Inspection and maintenance procedures shall comply with the latest edition of the National Fire Protection Association's publication NFPA 10.

n.

Personnel shall be familiarized with the location of fire control equipment such as drilling fluid guns, water hoses and fire extinguishers and trained in the use of such equipment. They shall also be familiar with the procedure for requesting emergency assistance as terrain and location configuration permit.

AIR & GAS DRILLING: a.

Drilling compressors (air or gas) shall be located at least fifty (50) meters from the wellbore and in a direction away from the air or gas discharge line.

b.

The air and gas discharge line shall be laid in as nearly as a straight line as possible from the wellbore and be a minimum of fifty (50) meters in length. The line shall be securely anchored.

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21.8

OIL WELL DRILLING, WORKOVER, EXPLORATION & WELL SURVELLANCE

c.

A pilot flame shall be maintained at the end of the air or gas discharge line at all times when air, gas, mist drilling, or well testing is in progress.

d.

All combustible material shall be kept at least fifty (50) meters away from the air and gas discharge line and burn pit.

e.

The air line from the compressors to the standpipe shall be of adequate strength to withstand at least the maximum discharge pressure of the compressors used, and shall be checked daily for any evidence of damage or weakness.

f.

Smoking shall not be allowed within twenty-five (25) meters of the air and gas discharge line and burn pit.

g.

All operations associated with the drilling, completion or production of a well shall be subject to KOC’s Drilling HSE Guidelines.

WELL SURVEILLANCE OPERATIONS: The well Surveillance operations consist of Wireline (Slickline and Electricline), Coiled Tubing, Surface Well Testing and Artificial Lift activities. Due to the potentially hazardous nature of these operations, the safety precautions highlighted as hereunder must be observed. •

Service Personnel must be thoroughly conversant and comply all the time with safety regulations and standing instructions / procedures.

•

Service Personnel must ensure that all safeguards, safety appliances / devices and personal protective equipment required for the work are available and used.

•

Service Personnel must adhere to all operating procedures issued time to time by Well Surveillance Team. Any unsafe condition / practice must be immediately reported to the respective supervisor for remedial action and also logged in the “Daily Service Record”.

•

Injuries to personnel and damage to plant / equipment must be reported as stated in Fire & Safety Regulations Chapter – 4.

•

Each job must be carried out as per approved & written work programme irrespective of complexity, ranging from removal of a down-hole safety valve to a more complex activity involving perforation of a well. • Prior to commencing any work, the Contractor's representative shall discuss the fine details of the work programme with the Company representative.

A.

WIRELINE OPERATIONS: Wireline work will be carried out with due authorization under appropriate category of work permit. Well Surveillance representative will witness all the operations (as briefed hereunder), if its carried out without Rig on location: (I) Slickline Jobs: a)

Swabbing: Swabbing is the technique normally used to attempt lifting out well fluids from a dead well. Spot-checking by well Surveillance personnel is recommended (Cold Work Permit)

b)

Static Bottom Hole Pressure Survey (SBHP): Memory Gauges are lowered into the well making station stops, while the well is shut-in. Spot-checking by Well Surveillance personnel is recommended (Cold Work Permit)

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c)

Static Bottom Hole Temperature Survey (SBHT): Memory Gauges are lowered at a speed of 30 Ft / minute into the well, while the well is shut-in. Spot-checking by Well Surveillance personnel is recommended (Cold Work Permit)

d)

Flowing Bottom Hole Pressure Survey (FBHP): Memory Gauges are lowered in the well making station stops, while the well is flowing. Spotchecking by Well Surveillance personnel is recommended (Cold Work Permit)

e)

Pressure Build-up survey (PB/UP): Memory Gauges are lowered in the well, stopped in the mid perforation. Once on depth, shut-in the well from the wing valve to record pressure build up data. Spot-checking by Well Surveillance personnel is recommended (Cold Work Permit)

f)

Through Tubing, Cement Dump (TTCD): To run cement dump bailer (a small pipe like cylinder) through tubing and dump cement in the casing to isolate a perforated zone. Spot-checking by Well Surveillance personnel is recommended (Cold Work Permit)

g)

Down Hole Change (DHC): To set a plug in the landing nipple in tubing and open the Sliding Sleeve Door. Spot-checking by Well Surveillance personnel is recommended (Cold Work Permit)

h)

Back To Normal (BTN): To close the Sliding Sleeve Door and to retrieve the plug in the landing nipple of the tubing. Spot-checking by Well Surveillance personnel is recommended (Cold Work Permit)

i)

Fluid Kick Off: To reduce the hydrostatic pressure of a fluid column in the casing by allowing the well to flow. Free the tubing through a sliding sleeve door to the casing. Spot-checking by Well Surveillance personnel is recommended (Cold Work Permit)

J)

Tubing Check: Run an impression block/ gauge cutter through the tubing. Spot-checking by Well Surveillance personnel is recommended (Cold Work Permit)

k)

Sliding Sleeve Door Check (SSD Check): Run a Shifting Tool to check Sliding Sleeve Door is closed or open. Spot-checking by Well Surveillance personnel is recommended (Cold Work Permit)

l)

Tubing End Locator: Run a Tubing End Locator through the tubing. Spotchecking by Well Surveillance personnel is recommended (Cold Work Permit) Bottom Hole Sampling (BHS): Special Type of Tool run through the tubing to collect pressurized bottom hole sample at desired depth. Spot-checking by Well Surveillance personnel is recommended (Cold Work Permit)

m)

n)

Electric Free Shut-in Tool (EFST): Lowering a hollow plug with a device that can be closed at a certain time to allow pressure build-up. Spot-checking by Well Surveillance personnel is recommended (Cold Work Permit)

o)

Fishing Job: By using different type of tool, to try grab lost goods / tools in a well. Spot-checking by Well Surveillance personnel is recommended (Cold Work Permit)

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p)

Tubing Pack Off: Sliding Internal sleeve (Patch) run through the tubing to isolate a leaking point in the Tubing (hole or crack). Spot-checking by Well Surveillance personnel is recommended (Cold Work Permit)

q)

Sand Bailer: To collect sand, cement or debris from an obstruction or the well bottom. Spot-checking by Well Surveillance personnel is recommended (Cold Work Permit)

r)

Memory Gamma-Ray & Casing Collar Locator depth determination (GR+CCL): Run through tubing Memory Gamma-Ray to correlate the radio active zone and Casing Collar Locator to locate the tubing or casing collar (pipe coupling). Spot-checking by Well Surveillance personnel is recommended (Cold Work Permit)

s)

Memory Production Logging Tools (MPLT): Downhole memory recorder connected with Tools such as Spinner, Gradiometer, Pressure Sensor, Temperature Sensor, Gamma ray, and Casing Collar Locator, run through the tubing in to the casing. Spot-checking by Well Surveillance personnel is recommended (Cold Work Permit) Note: All deep & exploratory wells should be in full time attendance.

(II) Electricline Jobs: 5

B.

a)

Thermal Decay Time Log (TDT): Thermal Decay Time Log is a tool to calculate / measure water saturation and porosity. Spot-checking by Well Surveillance personnel is recommended (Cold Work Permit).

b)

Production Logging Tool (PLT): Downhole live recorder connected with Tools such as Spinner, Gradiometer, Pressure Sensor, Temperature Sensor, Gamma ray, Casing Collar Locator. Run through the tubing in to the casing. (Cold Work Permit)

c)

Corrosion Caliper Tool (CCT): Caliper log that gives the internal geometry of the tubing (thickness of tubing). (Cold Work Permit)

d)

Through Tubing Bridge Plug (TTBP): A mechanical plug installed in the casing through tubing. (Cold Work Permit)

e)

Perforations: Making holes in the casing using explosive charges. Full time attendance by Well Surveillance personnel is required (Hot Work Permit)

COILED TUBING OPERATIONS: The coiled tubing unit (CTU) is hydraulically operated driven equipment in which we lower a small tube i.e. hollow pipe in the hole to carry out different application as shown below: The unit is basically composed of: • Control Cabin • Tubing Reel • Injector Head • Blowout Preventer (BOP) The length of the coiled tubing can be up to 20,000 ft and the size of the tubing can vary from ¾” to 3 ½” OD. Well Surveillance Petroleum Engineer must supervise any operation requiring the use of liquid (Acid, Toluene) or gaseous Nitrogen, who is overall responsible for safe

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operation. The Petroleum Engineer, Controller or Supervisor should thoroughly review the operation & identify any potential hazards, equipment and personnel safety requirements. Additionally he should be on location throughout the Rig-Up, Pressure testing and pumping operations involving Nitrogen. •

Coiled Tubing Jobs: The different CTU applications can be summarized as follows: a) Unloading of Wells (Gas Lifting with Nitrogen): Due to high hydrostatic pressure in the well (mud as killing fluid) the well will not flow by itself, then it is required to lower the hydrostatic head by pumping Nitrogen down the coiled tubing. The Nitrogen will reduce the load on the reservoir and then the well will start flowing by itself. (Hot Work Permit) b) Stimulation / Acidization: The well production will decrease when there is some formation damage, plugging the formation permeability. In order to restore the initial permeability, it is required to perform an acid stimulation. One of the best ways to stimulate is with Acid (concentration not more than 15% HCL) by pumping the acid through coiled tubing, which will ensure that the entire perforated interval is covered with acid and also getting clean treated fluids into the formation. (Hot Work Permit) c) Solids Removal (Fill Clean - out): Some un-consolidated formations produce certain amount of formation particles (sand) alongwith oil. These particles will fall down in the rat-hole and it is required to clean it (for operation purpose like logging). The solid clean out is easily achieved by pumping water & gelled water through a jetting nozzle of coiled tubing and circulate the fluids up to surface. (Cold Work Permit) d) Drilling / Milling with Coiled Tubing: Drilling with coiled tubing is getting more and more an attractive option especially for slim holes (small open hole diameters). The drilling could be performed over balanced or even under balanced, which will minimize the formation damage. (Cold Work Permit) e) Logging: The Logging operations could be achieved with coiled tubing especially for horizontal wells where logging cannot be carried out with Wireline. (Cold Work Permit) f) Fishing: Many fishing tools for coiled tubing are available and various fishing operations are carried out. Tools as jars, accelerators, over-shots, release tools etc, which are available in different sizes for different purposes. (Cold Work Permit)

C.

WELL TESTING OPERATIONS WITH MOBILE SEPARATOR: Use of mobile production equipment (choke manifold, separator) to determine flowing conditions (pressures, flow rates, oil and gas gravity, water cut) of a single well. Produced fluids are typically diverted to the GC, but due to specific requirement with due safety considerations the well can be flowed to the burn off pit. Spot-checking by Well Surveillance personnel is recommended. (Cold Work Permit)

D.

ARTIFICIAL LIFT OPERATIONS: a) Electrical Submersible Pump: The main equipment components are:

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KOC F&S Regulations • • • • • •

Electrical Generator Switch Board Junction Box Transformer Electrical Cable Down Hole Electrical Submersible Pump (ESP)

Since all the above electrical equipment is asset of Well Surveillance Team thus Artificial Lift representative should sign work permits. Mainly two types of operations relating to ESP operation are carried out in the field: i. During Work-Over Operation: • Pull Out Of Hole With ESP • Run In Hole With ESP • Function Test ESP with Mobile Production Testing unit ii. Rig-Less Operation: • Calcium Carbonate Injection: Injecting calcium carbonate to plug the perforations temporarily by pump truck in order to prevent formation damage during Work-Over Operation. (Cold Permit) •

Diesel/ Acid Circulation: Pumping diesel and 15% HCL acid to remove scale blockage around the intake of the ESP. Throughout tubing in to casing. (Hot Permit)

b) Gas Lift: The main equipment components are: • Gas Compressors • Surface Gas Meters • Pressure Recorders • Gas Lift Mandrels • Gas Lift Valves • Dummy Valves Gas Lift Operations normally involve the following activities: • • •

Replacing dummy valve with active Gas Lift valves. Re-set gas lift valve at different pressure. Pull out of hole with damaged valve and re-install new valves in Mandrels. All such operations are carried under slick-line operation, and slick-line unit. (Cold Work Permit) E.

WELL SURVEILLANCE OPERATIONS AT RIG SITE: The following general precautionary measure shall be taken care during Well Surveillance Operations at Rig site: •

The rig floor / BOP area must be free of any pools of drilling mud, etc. and the whole operational area shall be free of extraneous materials as far as reasonably practicable.

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•

All non-essential personnel will leave the rig floor prior to rigging up the wireline equipment, which will be carried out under a cold work permit unless the tools to be used warrant the issue of a hot work permit.

•

The Well Surveillance contractors will operate only the equipment supplied / hired under the contract, unless otherwise instructed by the KOC Drilling Supervisor. They will not use draw-works, catheads or winches of the drilling / workover rigs, unless otherwise instructed by the KOC Drilling Supervisor.

•

The winch truck must be located at least 25 ft way from the wellhead, unless it is operationally impossible, in which case alternative safety measures must be considered.

•

The wireline winch must be made secure to a suitable anchoring point by certified chains / slings before any wireline work begins. It will prevent the unit to move towards the wellhead when a load is taken on the wireline / tubing.

•

Personnel must not stand or work near wireline / coiled tubing whilst it is being run or pulled from a wellbore. Similarly loose clothing, rags or any other materials must be kept clear of the depth counter, hay pulleys and stuffing box sheaves whilst the line is in motion.

•

Precautions must be taken to ensure that the well being worked on can only be operated by remote control from the wireline unit, and that all other means of remote control are inhibited.

•

The hydraulically / pneumatically operated surface safety valve (SSV) and the surface controlled downhole safety valve (DHSV) must be held open, by temporary means controlled by the well service operators and disconnected from the emergency shutdown system, thus preventing, cutting of the wire / tubing whilst operations are in progress.

a) Equipment Tests: The following consideration shall be kept in view while testing the equipment for Well Surveillance operations: •

Before initial pressure test, the wireline BOP should be stroked to check operation. The correct rams must be installed and pressure tested up to rated working pressure.

•

The lubricator must be pressure tested with a suitable fluid, preferably water, for ten minutes against the closed swab valve and stuffing box. Every effort must be made to avoid using a gaseous fluid because of higher inherent risks.

•

Before each run into the hole, the lubricator is required to be leak tested to a pressure equivalent to wellhead closed in pressure plus 10%. b) Wire-line Operations: The following considerations must be kept in view for Wireline operations under Well Surveillance activities: •

During wire-line operations, there should be at least one wire-line personnel in attendance all the time wherever it is required as requested by the company man.

•

All joints on strings of tools must be checked for tightness on every trip into the hole.

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•

BOP rams must be operated in each shift. Records must be kept of the tests carried out. Seals must also be checked in each shift, and adequate spare seals are to be readily available at the well site.

•

The wire-line must be cut back regularly to move the wear points.

c) Coiled Tubing Operations: In addition to the precautions laid down for wellservice operations, the following must be observed: • All personnel at worksite will be informed prior to acid washing operations specifying no unauthorized entry to the site of operation. Special precaution must be taken for anyone working below the rig floor deck area. • Personnel engaged in such operations must wear the required protective equipment, e.g. acid suits, PVC gloves, rubber safety boots, face shields/ acid goggles, etc., when working in the vicinity of acid lines. Suitable eye wash facilities must be provided and be readily available. •

Production Development supervisor must be informed in case of acid spillage on rig floor or on the ground. The acid must be flushed away with copious amounts of water. As soon as one level is clear, the ground level must also be flushed subsequently. Special care must be provided to areas exposed to acid splashes, e.g. cable trays.

•

Nitrogen gas lifting operations using coiled tubing may be required on new wells, recompleted wells by workover or dead wells. The hazards from nitrogen are cryogenic (cold) burns, asphyxiation by nitrogen gas, and the effect of extreme cold on metals. In addition to the precautions laid down for wellservice operations, the following considerations must also be observed: I. Personnel handling piping / hoses containing liquid nitrogen must wear leather gloves to protect them from cold burns. II. In the event of a liquid nitrogen leakage, the area must be evacuated. Personnel involved in isolating the leak must wear self-contained positive pressure breathing apparatus, which will be readily available at worksite. III. Metallic surface contacted by liquid nitrogen must be inspected by QAI (Quality Assurance Inspector) personnel to assess any damage. Wooden planks or such other insulating material must be placed between nitrogen carrying cold pipes / hoses and other metallic surfaces.

d) Artificial Lift Operations: All the requirements mentioned earlier for operations without rig shall be applicable for Artificial Lifting operations at Rig site.

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Kuwait Oil Company

Fire & Safety Regulations

(K.S.C.)

Chapter No. 22 June 2004

VEHICLES & TRAFFIC SAFETY CHAPTER –22 VEHICLES & TRAFFIC SAFETY

Contents

Subject

Page

22.0

SCOPE

2

22.1

GENERAL SAFETY ASPECTS FOR ALL VEHICLES

2

22.2

SAFETY CONSIDERATION FOR HEAVY DUTY VEHICLES

3

22.3

SAFETY APPLIANCES FOR VEHICLES .................

4

22.4

ESSENTIAL DOCUMENTS ....................................

4

22.5

VEHICLE’S USAGE CRITERIA.........................................

4

22.6

DEFENSIVE DRIVING PRINCIPLE …………………….

6

22.7

STANDARD REQUIREMENT FOR ROAD WORTHY VEHICLE

7

22.8

SAFE RESPONSE IN HAZARDOUS & EMERGENCY SITUATION

22.9

POST ACCIDENT MANAGEMENT……………………………… 8

22.10

DISCIPLINARY ACTION …………………………………………

9

22.11

DESERT TOOL BOX ………………….…………………………

10

22.12

SAFETY TIPS ON DEFENSIVE DRIVING…………………….. 10

22.13

VEHICLE’S INSPECTION CHECK LIST ……………………… 12

F&S Regulations Chapter 22

8

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VEHICLES & TRAFFIC SAFETY CHAPTER-22 VEHICLES & TRAFFIC SAFETY

22.0

SCOPE: This regulation applies to all motor vehicles that are, or might be, used for KOC business. It includes all such vehicles, whether they are KOC - owned, rented, leased or Contractors’ vehicles, driven in all areas of the Company’s operations and also in any other area where the employee is required to drive as part of his / her work assignment. The document is intended to supplement but not supersede State Government Regulations on this issue.

22.1

GENERAL SAFETY ASPECTS FOR ALL VEHICLES: (i)

The vehicle shall have adequate capacity for the required duty and have been purposely designed for the service allocated as well as maintained in safe working order.

(ii)

As a minimum the vehicle shall be equipped with the following features: • Left & right side view mirrors • Rear Window Defogger • A basic radio if the vehicle is to be used off plant, to receive alert about severe weather or traffic conditions. • Dual Air Bags • Anti – lock Braking System (ABS) • Side impacts bars

(iii)

It is strongly recommended that every vehicle shall have tires of the same construction (e.g. radial or bias belted) on all the wheels. Tires of different types must not be mixed on any vehicle.

(iv)

Each vehicle shall be equipped with fire extinguishers properly rated for the particular vehicle and mounted in an accessible & protected location (i.e. not in engine compartment).

(v)

A complete first aid kit as approved by government authority shall be carried in each vehicle.

(vi)

No vehicles shall be used for conveyance of personnel unless that vehicle has been specifically designated and equipped as a passenger-carrying vehicle. The number of passengers does not exceed manufactures specification for the vehicle.

(vii)

Vehicles used for carrying passengers shall have fixed seating, convenient & safe means of boarding. The vehicle shall be equipped with diagonal and lap seat in all seating positions. The driver as well as passengers must be seated wearing seatbelt during the journey.

(viii) It is to be ensured that load being carried on a vehicle are secure and do not exceed manufactures specification as well as legal limits for the vehicle. The conveyance of personnel on the body of the vehicle or in the load carrying area is forbidden. (ix)

No vehicle will transport any flammable, toxic, corrosive, radioactive, explosives and other harmful substances except in specially designed

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(x) (xi)

22.2

VEHICLES & TRAFFIC SAFETY

containers / vehicles as authorized by the State Government as well as Company regulations. Vehicles carrying gas cylinders for welding purposes should be fitted with special cylinder fasteners to secure the cylinders. Pickups / Crewcabs shall be fitted with meshed plates on the rear view windows to ensure protection to the driver and passenger(s).

SAFETY CONSIDERATION FOR HEAVY DUTY VEHICLES: A)

B)

The heavy-duty vehicle (such as Trailers, Bulldozers, Front-end loaders, Cranes, and Scrapers etc) shall include but not necessarily be limited to the following safety equipment: (i) Overhead protection Canopy. (ii) Automatically switched back-up alarm with intermittently sounding tone. (iii) A horn, which is audible above engine noise. (iv) Convex type rear view mirror. (v) Parking Brakes (vi) Safety locks on gear changes. (vii) Hearing protection for drivers on noisy equipment. (viii) Operator & assistant to wear hardhat & safety boots. (ix) Seat belts to be fitted & worn at all times. The following requirement shall be complied by a skillful driver: (i)

Before commencing any operations, the driver & his assistant shall carry out pre-start check for the vehicles, equipment & accessories. Any deficiencies noticed must be immediately reported.

(ii)

The driver must check that no equipment or people are in the path of the machine before starting.

(iii)

Whilst the machinery is in operation, the drive must maintain good all round vision and ensure the area is clear from any obstacles.

(iv)

When leaving the machine, the operator shall ensure that the blade and all other attachments are lowered to the ground. The parking brake is engaged and the machine placed in neutral with gear lock lever applied.

(v)

The driver and operator shall be aware that power brakes only operate when the engine is running.

(vi)

The driver shall not use the Rear View Mirror to assess the situation during loading / unloading operations and must rely on hand signals from the banksman.

(vii)

The required traffic signs and safety barriers must be placed in the area where loading / unloading activity is to commence.

(viii) All Low-bed Trailers shall have beacon lights at the rear end of the trailer

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VEHICLES & TRAFFIC SAFETY

SAFETY APPLIANCES FOR VEHICLES: The passenger vehicles shall be equipped with the following safety appliances: (i)

Fire Extinguishers as per distribution hereunder: a) Saloon Car - One (5 Kg. Capacity) CO2 Extinguisher. b) Pick Up Truck or Van – One (5 Kg. Capacity) DCP Extinguisher. c) Heavy Vehicles - Two (9 Kg. Capacity) DCP Extinguishers.

(ii)

An Spare Tire – Ready for Use

(iii)

Lifting Jack

(iv)

Emergency Tool Kit containing the following appropriate equipment: • • • • • • • • •

22.4

Reflective Vest Flashlight with batteries Reflective Triangle Emergency Blanket Battery Jumper Cables with instruction (ER – 8663) Tire Inflator (non – flammable) Work Gloves First Aid Kit Hand Tools (e.g. hammer & Cutters)

ESSENTAIL DOCUMENT: All vehicles must keep the following documents: (i) Vehicle Registration Paper. (ii) Vehicle’s entry pass from KOC - Installation Access Control Team. (iii) Vehicle Information Brochure / Instruction Manual – Bilingual (English & Arabic)

(iv) (v) 22.5

Vehicle Service Card / Sticker – Showing due date / mileage of next service. A copy of Inspection / Test certificate for Lifting & Material handling vehicles.

VEHICLES USAGE CRITERIA: (i)

The vehicles must be regularly inspected & serviced as a preventive maintenance program to assure its road worthy condition. It is recommended to ensure the functional availability of safety appliance as well as safety system in the course of routine inspection & schedule maintenance of the vehicle.

(ii)

A separate logbook shall be maintained for each vehicle providing essential information such as servicing schedule, equipment replaced, kilometer run, In & Out Timing and purpose of usage.

(iii)

Vehicles shall be free from any undesirable noise & emission polluting the environment. Vehicle emitting undesirable smoke & noise shall be withdrawn from service and replacement shall be provided.

(iv)

Transport Operation Team shall inspect each vehicle (if it is more than 3 years old) at least once a year or as required prior to its deployment. The entry pass & Identity Card for a vehicle found unsuitable / defective shall be withdrawn and deposited with the Installation Access Control.

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(vi)

The Transport Operation Team shall check & certify the suitability of vehicles deployment prior to requesting Entry Pass / Identity Card issuance by Installation Access Control.

(vii)

All contractually hired professional drivers must be medically assessed with a minimum follow up every three years to assure that they have the functional capacity to operate a vehicle safely. If a change in their medical condition occurs, which affects their ability to drive, they must immediately inform their supervisor and cease operating a vehicle until medically re-assessed.

(vi)

Vehicle carrying bulk materials shall ensure to stack & secure the load properly prior to transportation. Loose tools or equipment must not be carried inside the passenger compartment. Every effort shall be made to ensure that no part(s) of the load is projected / suspended / overhung outside the carrier. Yet, if unavoidable, the load shall be marked with a red flag & red light at the rear end of the load.

(viii)

No under size or under capacity vehicle shall be used for transporting goods or towing of another vehicle or equipment. Any towed equipment, which exceeds the width of prime mover, shall be fitted with indicator and brake lights powered by prime mover.

(viii)

The driver of the vehicle - engaged for transporting hazardous material such as flammable, toxic, corrosive or other harmful substances- must be explained about the risk involved and its emergency action plan as complying with the relevant regulation in this regard.

(ix)

The driver of the vehicle carrying bulk materials shall always be accompanied with a Cleaner / Assistant.

(x)

The vehicle specifically designed & certified to carry Explosive or Radio Active Materials must not carry any passenger other than classified workers duly licensed from regulatory agency to handle such materials.

(xi)

The load being carried on a vehicle shall not exceed the weight limitations as indicated in registration papers.

(xii)

Towing of mobile equipment shall be carried out by a vehicle fitted with manufacturer’s approved towing gears.

(xiii)

Any towed equipment, which exceeds the width of the prime mover, shall be fitted with reflective type indicators & brake lights powered from prime mover.

(xiv)

The weight of equipment being towed shall not exceed the capacity of prime mover / towing vehicle.

(xv)

The employees who are passengers in Company vehicles have an obligation to advise a driver who is not complying with regulations. Such incidents should be reported via the nearmiss procedure.

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22.6 DEFENSIVE DRIVING PRINCIPLE: The following minimum requirement must be fulfilled by all as a defensive driver: (i)

(ii)

Only a competent, alert and skilled driver shall drive a motor vehicle. He must hold a valid driving license of required category as issued by State Traffic Department. The driver shall be physically fit, mentally alert and must not overexert. He should not drive when medically unfit, tired or under the influence of sedatives / medication that could impair their ability to drive.

(iii)

The vehicles must be reverse parked on a firm & leveled ground in neutral / parking position with hand brake engaged and engine switched off.

(iv)

The drivers must have thorough knowledge of local traffic rules & regulations and abide by traffic signs & regulations as stipulated by the Company or state authority. It is forbidden to smoke while driving a vehicle.

(v)

The drivers must not make or receive calls (whether mobile phone or radio) or perform any other activity (like text messaging) with communication equipment. The must stop safely before any such action is taken.

(vi)

The driver must be aware of local driving hazards and shall use his Defensive Driving skill as well as take outmost care while driving in adverse climatic conditions such as sandstorm, rain and or foggy weather.

(vii)

The driver shall display a mature attitude to driving and anticipate as well as negotiate all hazards by forward planning and using vehicle controls. He must maintain exemplary patience and restraint even while driving in an extremely adverse situation. He must drive at safe speed and always observe speed limits.

(viii) The driver must take appropriate actions with regard to road signs, markings and all orders given by law enforcement officer. He must ensure before driving the vehicle that no contraband materials, ammunitions or illegal fire arm / pyrotechnic substances are kept inside the vehicle. (ix)

The driver must maintain correct speed and distance from other vehicles under varying road and weather conditions. He shall respect the right of all road users including pedestrians. He shall also maintain lane discipline, use mirrors and indicators intelligently.

(x)

Prior to reversing a vehicle, the driver must verify that space behind the vehicle is clear enough for the purpose. In case of blocked view, he must reverse with assistance from banksman / flagman.

(xi)

The driving schedule as applicable to the type of vehicle being driven under varying climatic conditions must be specified to avoid excessive driving and fatigue caused to the driver as well as to the machine.

(xii)

The driver should reduce the speed and switch on dipped headlights if he encounters dust cloud, heavy fog or rain in the course of driving. In case of severe visibility restriction, it may be essential to pull off the road, stop & wait until the dust, heavy fog or rain subsides. On no account must any attempt be made to overtake in these conditions

(xiii)

The driver must ensure the condition & operation of the vehicle before driving it. He shall perform daily maintenance & safety check of a vehicle prior to

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starting the engine including the check for hand brake, gear, seating, mirrors, headrest & seatbelt. Any alteration, adjustment or repairing shall be made only in the stationary condition of the vehicle. 22.7 STANDARD REQUIREMENT FOR A ROAD WORTHY VEHICLE: The following standard requirement must be met for declaring a motor vehicle as road worthy: (i)

The vehicle shall have adequate capacity and design suitability for the nature of service intended for.

(ii)

The vehicle shall have valid registration and insurance coverage in compliance to State Traffic Regulations.

(iii)

The vehicle shall have all headlights, rear lights, brake light and indicators in the good working condition.

(iv)

The vehicle shall have appropriate tires of equal size, ply rating, and tread pattern / profile in excellent condition with a minimum tread depth of 2 mm.

(v)

The vehicle attached to a Trailer shall be fitted with side restraints on the Trailer for containment of long piece of materials such as tubulars, casings etc.

(vi)

The vehicle having box type carrier with drop sides, tailgate and hinges shall have securing pins.

(vii)

The vehicle shall carry reflective type “Safety Triangle” for traffic alert in case of vehicle breakdown or accident.

(viii)

All vehicles must have a spare tire, lift jack and tool kit; whereas additionally a hand shovel and wooden block may also be provided for the light duty vehicles.

(ix)

All heavy-duty vehicles shall be fitted with audio-visual alarm for reversing action.

(x)

The vehicle entering the hazardous area in the field shall have spark arresters fitted on the engine exhaust system.

(xi)

The vacuum tanker or fuel carrying tanker and its pumping units shall be electrically grounded to dissipate any static charge.

(xii)

The vehicle assigned for remote location activity, shall be provided with a “Desert Tool Box” containing items as specified in Section 22.11.

(xiii)

The vehicles belonging to contractor shall have Company Name & Contact Number printed on left as well as right side front door.

(xiv)

All the vehicles shall go through regular preventive maintenance in accordance with manufactures recommendations.

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22.8 SAFE RESPONSE IN HAZARDOUS & EMERGENCY SITUATION: In case of accident, when driver & passenger(s) both or either of them is conscious and capable to move, shall take following actions: (i)

Try to come out of the vehicle, which has met an accident. The passenger (s), who are conscious and physically able to move, shall help each other in getting out of the vehicle.

(ii) The passenger(s), who are seriously injured or unconscious must not be moved out (if there is no prevalent danger) to prevent aggravating the physical condition of the victim. (iii) The driver, passenger(s) or other road users shall immediately notify Burgan Kuwait Fire Station (on telephone number 22222 / 22221 / 66669 / 3986373 or calling by radio on KOC Fire Channel) for emergency assistance giving necessary detail such as location & time of accident, severity, reporter identity etc. as specified under Chapter – 4 of F & S Regulations) (iv) The injured persons shall be immediately taken to the nearest hospital for quick medical aid. (v) The on-duty Fire Officer at Burgan Fire Station shall immediately inform respective area Fire Station for rescue and assistance. It is also required to inform HSE Team, respective controlling / sponsoring team and transport operations for investigation and further assistance. (vi) The damaged vehicle shall not be removed from the site of accident till completion of on spot investigation by the police. (vii) The accident site must be barricaded preferably with barrier tapes and if possible Vehicle Hazard Warning light shall be kept flashing. 22.9 POST ACCIDENT MANAGEMENT: The following mandatory requirements are to be fulfilled as a post accident management: (i)

All motor vehicles (whether belonging to Company or Contractor supplied vehicles) accidents {MVA}, which takes place within or outside KOC area during working hour or on duty / off duty period must be officially reported and investigated. However for contractor’s vehicle, MVA taking place during working hour and within KOC premises must be reported officially for investigation & record.

(ii) The reporting shall be made through Company prescribed format for Accident Investigation Report and shall be investigated. (iii) The accident investigation report must be submitted by the concerned immediate supervisor within one week from the date of accident. Serious accidents must be investigated and root cause established. (iv) A copy of Police report and medical report (in case treatment provided in hospital / clinic other than Ahmadi Hospital) must be attached with Accident Investigation Report. (v) The medical report issued by attending doctor / clinic / hospital must indicate the nature of injury and number of rest days recommended.

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VEHICLES & TRAFFIC SAFETY

(vi) The employee / worker shall take a fitness certificate on complete recovery from Ahmadi Hospital prior to reporting for duty. (vii) As far as possible attempt shall be made to take photographs of damaged vehicles preferably at the site of accident. (viii) The Transport Operation Team in consultation with the party / contractor / supplier involved shall carry out an evaluation to establish the severity of vehicle damage (e.g. minor, moderate, severe or total loss) based on physical inspection. 22.10 DISCIPLINARY ACTION: Any willful violations of rules & regulations on the part of employee or contractor driving vehicle within the company premises will result in disciplinary action deemed suitable to the degree of breach, negligence or misconduct as stipulated under personnel policy and breach of contract clause. Such disciplinary action may include the following measures but not limited to: (i)

In case of contractor personnel / driver’s negligence, willful violation of Vehicles’ Driving Regulations shall lead to his immediate removal from the company activities, extradition from the site, cancellation of entry pass alongwith warning to the concerned contractor.

(ii) Officials from HSE, Fire, Installation Access Control, Transport Operations Teams and the concerned asset owner, can initiate disciplinary actions; however the representative from respective area HSE Team is authorized to issue infringement notice also. (iii) Types of Violation: The negligence, violation and misconduct as mentioned hereunder, which are not exhaustive, will be considered as those attracting disciplinary action: (a) Exceeding speed limit specified for the zone. (b) Dangerous overtaking or overtaking in prohibited location. (c) Parking the vehicle in No Parking Area. (d) Seat Belts not fastened (e) Irresponsible & reckless driving, not observing traffic signs, signals, regulations and safety of fellow road users. (f) The company vehicle being driven by unauthorized person. (g) Non – reporting of motor vehicle accident. (h) Transporting contraband or dangerous material. (i) Driving the vehicle without valid documents and safety appliances (j) Driving a damaged or unsafe vehicle. (k) Carrying excess passengers than specified seating capacity. (l) Transporting improperly stacked materials endangering the other road users / facilities on the way. (m) Driving without headlight on during night or poor visibility weather condition. (n) Leaving the vehicle stranded on the road without proper alert signs and barricade. (o) Driving with a puncture tire. .

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VEHICLES & TRAFFIC SAFETY

22.11 DESERT TOOL BOX: The basic standard tool kit issued with the vehicle is usually sufficient for normal road driving but the vehicles deployed on remote location activities (such as geological survey, facility inspection, proposed site & route surveying etc) will require additional equipment for survival in desert. This equipment should include: (i) Canvas sand belts to assist in getting out of soft sands. (ii)

Foot Pump – 1 No.

(iii)

Spare Fan Belt -1 No.

(iv)

Rubber hose (of 2 meter length) – 1 No.

(v)

Short ‘D’ handled Shovel – 1 No.

(vi)

Tow rope (6 mm soft wire rope, 15 meters long) – 1 No.

(vii)

Signal Flares – 4 Nos.

(viii)

Smoke Canisters – 2 Nos.

(ix)

Heliograph Signaling Mirror – 1 No.

(x)

Blanket – 1 No.

(xi)

Compass – 1 No.

(xii)

Tyre Pressure Gauge – 1 No.

(xiii)

Drinking Water - 1 liter per person.

22.12 SAFETY TIPS ON DEFENSIVE DRIVING: (i)

Vehicle Check: • Ensure that your Vehicle is road worthy. Complete pre-driving check • Check POWER (P-Petrol, O – Oil, W – Water, E – Electricity, R – Rubber)

(ii)

Speed: • Respect the speed limit required by the law & traffic condition. • Maintain a speed where you are able to stop safely on your own side of the road. Slow down in bad weather condition.

(iii)

Steering: • Keep both hands on steering unless necessary to signal by hand. • Do smooth change in direction. • Do not use mobile phone or radio while driving.

(iv)

Seat Belt: • Always wear seatbelt and ask the passengers to do the same. Move only if everyone’s seatbelt is fastened. • Readjust seat and arm positions to reduce fatigue from long period of driving. (Not to be done whilst the vehicle is moving)

(v)

Space: • Maintain Safe distance around your vehicle • Avoid Tailgaters & let them pass. • Consider near and far road condition to anticipate oncoming problems.

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(vi)

Vision: • Look ahead & scan the road to get a big picture. • Check mirror & blind spot whenever altering speed & direction and also to keep aware of traffic around you.. • Do not fix your vision more than 2 seconds on anything.

(vii)

Overtaking: • Do not overtake at or approaching a junction. • Do not overtake where cannot see far ahead to assure safe passage. • Do not overtake in conflict with others.

(viii) Reversing: • Scan the area & check the mirror before reversing. • Make a reverse move at a minimum speed. • Travel reverse to a distance sufficient to maneuver. (ix)

Pedestrian Crossing: • Give right of the way to pedestrian at the crossing. • Slow down to the minimum speed as you approach pedestrian crossing and be ready to stop.

(x)

Headlights: • Turn headlight on at least 30 minutes before sunset. • Use low beam when there is a car close in front or coming towards you.

(xi)

Keys of Defensive Driving: • Aim High on Steering, • Get the big picture • Keep your eyes moving • Leave yourself an out • Make sure they see you.

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VEHICLES & TRAFFIC SAFETY

22.13 VEHICLE INSPECTION CHECK LIST: S.No. 1

System Braking System

•

2

Light

•

3

Tyres

•

4

Steering

• •

5 6 7

Hydraulic Systems Rear View Mirror Windshield Wipers, washers & glasses

• • •

8 9 10 11

Horn Heater & Defroster Fuel System Exhaust System

12

Under the Vehicle

• • • • • •

13 14

Road Flares & Reflectors Mud Flaps

15

Wirings

•

16

Fire Extinguishers

•

17

First Aid Kits

•

18

•

19

Back-up Audible Signals Seat Belts

20

Speedometer

•

F&S Regulations Chapter 22

• • •

•

Check For Status Proper Adjustment, Fluid Level, Leaking Cylinders or Lines, Leaking grease retainers in wheels, Linkage & Broken Lines Headlight’s proper adjustment & dimmer switch operation, Taillights, directional & Clearance lights, reflectors for cleanliness, burned out bulbs & broken or damaged lenses. Proper inflation, tread wear, breaks or blisters, Tyres changing tools & equipment, Spare Tyre, Wheel Nuts. Assure that tie-rods ends & steering knuckles are tight and tie-rods are not bend. Uneven wear of tyres may indicate improper front wheel alignment, worn spindles or worn front wheel bearings. Replace defective hoses. Check for Clear Vision & proper adjustment Good blades & proper operation of both wipers and washers, broken glasses, proper lowering / raising of windows. Check Operation Check for proper operation Entire system is in good condition No Carbon Monoxide leak Fumes do not enter passenger compartment. No broken or weak spring, broken or leaky shock absorbers. No oil or Grease leaks on universal joints. Available in good condition for use in emergency Available in good condition on all required highway vehicles Insulation - free from grease & protected from motor heat, firm in brackets, secured joints, no visible wear & tear Properly rated for particular vehicle, marked with due date of inspection. The contents are complete & securely placed inside the vehicle. Functioning properly (if provided) Installed & fully operational (preferably self adjusting inertia type) Working properly

June 2004 Page 12

Kuwait Oil Company

Fire & Safety Regulations

(K.S.C.)

Appendix - 1 June 2004

CHEMICAL HAZARDS & MATERIAL SAFETY DATASHEETS (MSDS) APPENDIX - 1

CHEMICAL HAZARDS & MATERIAL SAFETY DATASHEETS (MSDS) Introduction: Due to varied nature of oil & gas production, a wide range of chemicals are used to optimize the field operations. Many of these chemicals can be harmful to persons and / or process if not properly or safely used.. Temporary or permanent damage to the body can result if chemicals are allowed to enter it in one or more of the ways such as - injection or swallowing, direct skin contact, absorption (through pores of skin) or inhalation of vapour, mist or dust. In general the extent of physiological damage varies with the duration of exposure and concentration of contaminant present. Before a chemical is put into use, its properties must be assessed to highlight any potential hazards. Copies of technical data for each hazardous substance must be obtained. Material Safety Data Sheets (MSDS) are primary sources of information on properties of toxic substances. Exposure Limit: The Occupational Exposure Standards and Maximum Exposure Limit are intended to assist in protecting the health of workers, who may be repeatedly exposed to hazardous chemicals. Both of these limits are concentrations of hazardous substances in air, averaged over a specified period of time, referred as Time Weighted Average (TWA). The two-time periods being used are termed as: Long Term (8 Hours) & Short Term (15 Minutes). Short Term Exposure Limit (STEL) is intended to help preventing adverse health effects, which may occur following exposure to such chemicals for a few minutes. The occupational exposure limits are set at levels that will not have any adverse effect on health of the workers repeatedly exposed to such chemicals. It also provide a guideline to determine the control actions to be taken in case of over exposure. Material Safety Datasheets (MSDS): MSDS is a document that gives essential information regarding a chemical product. It provides general informations alongwith following details * Manufactures Name, Address & Contact No. * Laboratory information in case of hazardous ingredients * Chemical & physical characteristic data. * Fire / Explosion Hazard Data. *Reactivity Details * Exposure Limit * Health Hazard & Precautionary Measures * Personal Protective Equipment * Disposal Methodology Copies of MSDS are provided by the Supplier with every consignment of chemical product. F&S Regulations Appendix 1

June 2004

Page 1

KOC F&S Regulations

CHEMICAL HAZARDS & MATERIAL SAFETY DATASHEETS (MSDS)

It is available with the user, Purchasing Team / Stores and Health & Environment Team. It can also be viewed through access to MMMS. A sample Format for MSDS is enclosed herewith specifying the details to be provided by the Supplier in consignment delivered to KOC. It is recommended for the users to maintain a file containing current MSDS of chemicals being used in their premises.

F&S Regulations Appendix 1

June 2004

Page 2

Kuwait Oil Company

Fire & Safety Regulations

(K.S.C.)

Appendix No. 2 June 2004

STANDARD EXPOSURE LIMITS APPENDIX - 2 STANDARD EXPOSURE LIMITS

LD50 (Lethal dose 50): is defined as the dose of a substance, if given all at once, that is expected to cause death to 50% of a test animal population. The measurement is given in terms of the amount measured in mg per kg weight of the subject. LC50 (Lethal Concentration 50) is defined as concentration of a substance usually as gases or vapours in air, which if administered over a specific period, is expected to cause death to 50% of the test animal population. Unlike LD50, LC50 has no relationship to the weight of the exposed and is expressed in Parts Per Million (ppm). Under the Workplace Hazardous Material Information System (WHMIS), LC50 data found in the Material Safety Data Sheet (MSDS) are based on 4-hour exposures. Threshold limit Values (TLVs) refer to airborne concentrations of substances and represent conditions under which it is believed that nearly all workers may be repeatedly exposed day after day without adverse health effects. a) Threshold Limit Value-Time-Weighted Average (TLV-TWA): Time-weighted average concentration for a conventional 8-hour workday and a 40-hour workweek, to which it is believed that nearly all workers may be repeatedly exposed, day after day, without adverse effect. b) Threshold Limit Value-Short-Term Exposure Limit (TLV-STEL): The concentration to which it is believed that workers can be exposed continuously for a short period of time without suffering from any health disorder such as: 1) Irritation 2) Chronic or irreversible tissue damage 3) Narcosis of sufficient degree to increase the likelihood of accidental injury, impairing self-rescue or materially reducing work efficiency, under the condition that daily TLV-TWA is not exceeded. It is not a separate independent exposure limit; rather, it supplements the time-weighted average (TWA) limit where there is recognized acute nature. STELs are recommended only where toxic effects have been reported from high short-term exposures on either humans or animals. A STEL is defined as a 15-minute TWA exposure, which should not be exceeded at any time during a workday even if the 8hour TWA is within the TLV-TWA. Exposures above the TLV_TWA up to the STEL should not be longer than 15 minutes and should not occur more than four times for day. There should be at least 60 minutes between successive exposures in this range. An averaging period other than 15 minutes may be recommended when observed biological effects warrant this.

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STANDARD EXPOSURE LIMITS

c) Threshold Limit Value – Ceiling (TLV- C): The concentration that should not be exceeded during any part of the working exposure. In conventional industrial hygiene practices if instantaneous monitoring is not feasible, then TLV-C can be assessed by sampling over a period that should not exceed 15 minutes, except for those substance that may cause immediate irritation even when exposures are short. • •

In American Conference for Governmental Industrial Hygienists (ACGIH) listing of TLVs, the term “skin” refers to the potential contribution to the overall exposure by absorption through the skin. For some substance, such as irritant gases, only one category, i.e. TLV- Ceiling, may be relevant. For other substances, one or two categories may be relevant, depending up on their physiological action. It is important to observe that if any one of these types of TLVs are exceeded, a potential hazard from that substance is presumed to exist.

•

The chemical substance TLV Committee holds the opinion that TLVs based on physical irritation should be considered no less binding than those based on physical impairment. There is increasing evidence that physical irritation may initiate, promote, or accelerate physical impairment through interaction with other chemical or biological agent.

•

Threshold Limit Values are intended for use in industrial hygiene practice as guidelines or recommendations to assist in control of potential health hazards related to workplace and for no other use. These values are not fine lines between safe and dangerous concentrations and should not be used by any one untrained in the discipline of industrial hygiene.

d) PEL: Permissible Exposure Limit is a time - weighted average (TWA) or absolute value (usually prescribed by regulation) setting out the maximum permitted exposure to a hazardous chemical. The standard adopted by U.S Occupational Safety & Health Administration (OSHA) e) REL (Recommended Exposure Levels): It is recommended as safe levels by U.S National Institute for Occupational Safety & Health (NIOSH) f) MAK: Maximum Allowable Concentration used in Germany g) PC: Permissible Concentrations used in England. h) IDLH: Immediate Dangerous to Life or Health; value for which 30 – minute’s single escape times allowed. i) BEIs (Biological Exposure Indices): It consists of an assessment for overall exposure to chemicals, that are present in the workplace, through the measurement of appropriate determinants in biological specimens from the worker at specified times. Kuwait Environmental Protection Authority “K-EPA” in their latest gazette No. 533 follows the TLVs laid by ACGIH, and consequently the same is adopted by Kuwait Oil Company, and respective TLVs, could be referred by consulting Health & Environment Team under HSE Group.

F&S Regulations Appendix 2

June 2004

Page 2

APPENDIX – 3

DRILLING & WORKOVER

(SKIPPED AS ALREADY COVERED IN CHAPTER – 21 OF FIRE & SAFETY REGULATIONS – ISSUE 2004)

Kuwait Oil Company

Fire & Safety Regulations

(K.S.C.) Appendix - 4 June 2004

STANDARD INDUSTRIAL SAFETY SIGNS APPENDIX - 4

STANDARD INDUSTRIAL SAFETY SIGNS (CYLINDERS COLOUR IDENTIFICATION CODE) Due to technical difficulties, the reproduction and inclusion of detailed & coloured safety signs and colour codes was not feasible in the Appendix. However it is recommended to refer British Standard 5378 for coloured safety signs and colour coding. 1.

INTRODUCTION: Safety Signs & Colour Coding is intended to alert or draw attention towards objects and situation, which effect or could affect health, safety & integrity of workers or worksite. The use of safety signs or colour coding does not replace the need for appropriate measure for accident preventions.

2.

SCOPE: The scope of Safety Signs & Colour Coding is to impart warning about potential hazard related to health & safety of workers or facilities.

3.

DEFINITIONS: The following definitions apply: 3.1

Safety Colour: A colour to which a specific health or safety meaning or purpose is assigned.

3.2

Contrasting Colour: A colour that contrast with the safety colour in order to make the latter more conspicuous.

3.3

Symbols: A pictorial representation used on a safety sign.

3.4

Safety Sign: A sign that gives a message about health or safety by a combination of geometric from, safety colour and symbol or text (i.e. words, letters, numbers) or both.

3.5

Prohibition Sign: A safety sign that indicates that certain behaviour is prohibited.

3.6

Warning Sign: A safety sign that gives warning of a prevalent hazard.

3.7

Mandatory Sign: A safety sign that indicates that a specific course of action is to be taken to prevent potential hazard.

3.8

Safe Condition Sign: A safety sign that provides information about safe conditions.

3.9

Supplementary Sign: A sign with text only that may be used in conjunction with a safety sign in order to provide additional information.

F&S Regulations Appendix 4

June 2004

Page 1

KOC F&S Regulations

STANDARD INDUSTRIAL SAFETY SIGNS Table - 1 Safety Colours & Contrasting Colours

Safety Colour

Red*

Yellow

Blue

Green

*

Meaning or Purpose

Example of use

Contrasting Colour (if required)

Symbol Colour

Stop Prohibition

Stop sign, Identification & colour of emergency shutdown devices, prohibition signs

White

Black

Caution, Risk of Danger

Indication of hazards (fire, explosion, radiation, chemical etc) Warning Sign, Identification of Thresholds, Dangerous Passages, Obstacles

Black

Black

Mandatory Caution

Obligation to wear personal safety equipment, Mandatory signs

White

White

Safe Condition

Identification of Safety Showers, First Aid Posts & Rescue Points Emergency Exits Sign.

White

White

Red is also used to identify Fire Fighting equipment and its location.

F&S Regulations Appendix 4

June 2004

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KOC F&S Regulations 4.

STANDARD INDUSTRIAL SAFETY SIGNS

Examples of Safety Signs & its Meaning: -

F&S Regulations Appendix 4

June 2004

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KOC F&S Regulations

STANDARD INDUSTRIAL SAFETY SIGNS

COLOR IDENTIFICATION FOR CONTENTS OF INDUSTRIAL GAS CONTAINERS / CYLINDERS

British Standard specifies colour identification for contents of Industrial Gas Containers or cylinders. The table included hereunder serves day-to-day requirements for KOC Operations. However for further detail British Standards 349 & 1319 may please be referred. Gas Name

Acetylene Air Ammonia Argon Carbon Dioxide for temperate use Carbon Monoxide Chlorine Chlorine with internalDip pipes Coal Gas Ethyl Chloride Flammable, Ethyl Chloride Non-flammable, Ethylene Ethylene Oxide Freon F&S Regulations Appendix 4

Ground colour of cylinder

Colour of bands

Symbol

Nominal

Colour No. to BS 381C

Nominal

British Standard colour No.

C2H2 NH3 A CO2

Maroon French Grey Black Peacock Blue Black

541 630 103 -

Signal Red Golden Yellow Golden Yellow

537 356 356

None None Red and yellow None None Yellow None Black

537 & 356 356 -

Signal Red French Grey

537 630

None Red

537

French grey

630

None

-

Dark Violet Dark Violet Bottom end-

796 796 630 (Grey)

Red Red & Yellow

537 537 & 356 -

CO Cl

C2H2Cl C2H2Cl C2H4 C2H4O CCL2F2

June 2004

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KOC F&S Regulations

STANDARD INDUSTRIAL SAFETY SIGNS

(Dichlorofloumethane) Helium Hydro-Cyanic Acid Hydrogen Methane Methyl Bromide Methyl Chloride: Flammable Non-flammable Neon Nitrogen Oxygen Phosgene Propane Sulphur Dioxide

* **

He H CH4 CH3BR CH3C1

Grey Neck end mauve Middle Brown Peacock Blue Signal Red Signal Red Peacock Blue

411 103 537 537 103 225 225 411 630 537 225

Green Green Middle Brown French Grey Black Black Signal Red Green Red or Blue band shall be placed adjacent to the valve fitting that and the ground colour of the cylinder. No formula to be added. [Source: BSI]

F&S Regulations Appendix 4

NE N O COCL2 ** SO2

None Yellow None Black

356 537 103 & 356 356

Red Black Black None Blue & Yellow None Yellow & yellow band between

June 2004

Page 5

Kuwait Oil Company

Fire & Safety Regulations

(K.S.C.)

FIRE FIGHTING EQUIPMENT

Appendix - 5 June 2004 APPENDIX -5

FIRE FIGHTING EQUIPMENT One of the most frequent sources of loss in the oil & gas industry is fire. The hazardous nature of hydrocarbons lends itself to situation that can result in fire and explosions. The theory of combustion and fire spread should be understood by all workers deployed in oil & gas industries. 1.

COMBUSTION: It is the chemical reaction or series of reactions in which heat, fire gas, flame and smoke are evolved. When rate of reaction is very slow only heat is evolved and a slow oxidation occurs such as rusting. There are three primary components necessary for combustion. All three components – fuel, oxygen (usually air) and heat – must be present for any fire or combustion to occur. The elimination of one or more of these components will result in extinguishment of fire. The three components of combustions are traditionally represented as a FIRE TRIANGLE indicating that all three must be in union or contact for combustion to occur.

2.

SPONTANEOUS COMBUSTION: It is the combustion that takes place spontaneously without addition of any external heat source in the presence of fuel and oxygen. The factors necessary for spontaneous combustion to occur are as hereunder: a)

A substance, which will readily oxidize e.g. linseed oil, hay-jute, copra, certain grades of small coal, charcoal etc.

b)

Oxygen to promote oxidation and combine with flammable vapours to form an explosive mixture.

c)

A reduction in cooling effect allowing temperature rise that leads to attainment of

F&S Regulations Appendix 5

June 2004 Page 1

KOC F&S Regulations

FIRE FIGHTING EQUIPMENT

ignition temperature for the substance involved. Heat is a form of energy released during combustion. Heat intensity is measured by degrees of temperature. This generation of heat causes the temperature of surrounding material to rise. When surrounding material reaches its point of ignition then it too will burn. Depending upon flammability of material, this spread of fire can be very rapid and consequently quite disastrous. 3.

LIMITS OF FLAMMABILITY: The vapour of a flammable liquid when mixed with air is ignitable only if its concentration falls within certain limits called Flammable Limits. Outside these limit such as if a mixture is too lean (not enough flammable vapour) or too rich (too much vapour in relation to air) then ignition cannot take place. The limits of flammability for some of the flammable materials are indicated hereunder: LOWER UPPER Acetone Aviation petrol Acetylene

2.5% 1.4% 2.5%

to to to

13% 7.6% 80%

4.

OXIDATION: Oxidation is generally a gradual reaction of a substance with oxygen accompanied by the evaluation of heat. Almost every substance oxidizes to some extent, but the rise in temperature is not apparent during normal progress as the heat generation is slow and air currents dissipates the heat. The application of heat accelerates the oxidation process. Oxygen must be present for oxidation to proceed. As oxygen comprises approx. 1/5th of the volume of atmosphere surrounding the earth, the material need only be in contact with the air to gain all the oxygen necessary. Oxidation is the same chemical process as combustion but much slower and less violent evolving mild heat only, rather than flame & fire gas.

5.

THE TRANSMISSION OF HEAT: Transfer of heat is responsible for initiation, continuation, and extinguishment of most fires. Fire can spread by one or more of the following modes of heat transfer.

6.

a)

Conduction: -Heat from one body is transferred to another by direct contact.

b)

Radiation: - Heat is transferred from one body to another by heat rays passing through intervening space.

c)

Convection: - Heat is transferred by a circulating medium either a gas or a liquid. Heated air expands and rises, its place being taken by cold air, which in turn also becomes hot and rises, so on.

FIRE EXTINGUISHING PRINCIPLE: Fire extinguishment principle involves elimination one or more of the components forming a Fire Triangle. The method of extinguishing a fire can be classified conveniently under the following headings: a)

Starving: - The removal of fuel to the point where there is nothing remaining to burn e.g. turn off valves.

b)

Smothering: - The removal of air or oxygen to the point where combustion ceases, e.g. fire blanket, foam or sand.

c)

Cooling: - Cooling of fuel to the point where combustion vapours are no longer produced, e.g. water.

d)

Inhibiting the Flame Chain Reaction: By arresting the chemical chain reaction

F&S Regulations Appendix 5

June 2004

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KOC F&S Regulations

FIRE FIGHTING EQUIPMENT

in the flame zone, combustion process is terminated, e.g. introduce a Dry Chemical Extinguisher. 7.

8.

CLASSIFICATION OF FIRE: Combustible substances are grouped into the following classes: Class A

-

Carbon based materials (wood, rubber, paper, fabric, textiles)

Class B

-

Flammable Liquid (petrol, oil, thinners)

Class C -

Flammable Gases (acetylene, propane, LPG, Butane)

Class D

-

Flammable metals (Sodium, potassium, magnesium, uranium, lithium) It requires special extinguishing agent.

Class E

-

Fire, which involves energized electrical equipment, the extinguishing agent must be electrically non – conductive.

TYPES OF EXTINGUISHERS & THEIR USE: The following are types of extinguishers considered most suitable for different category of fire: Water CO2 Exp. Maint. Pressure

Foam Chemical & Mechanical (Protein Based)

Foam Alcohol Resisting

Chemical Dry Powder.

CO2

Class "A" paper, wood, textiles etc.

Most suitable.

Could be used

Not suitable.

Not suitable ABC powder can be used.

Not suitable.

Class "B" (a) liquid with F.P. below 65.6oC and insoluble in water.

Not to be generally used: 'FOG' small quantities.

Most suitable

Suitable

Most suitable

May be used

Class "B" (b) Liquids with F.P. below 65.6oC but soluble in water.

Water spray will effectively control open container MEK fires

Not suitable

Most suitable

Most suitable

May be used

Class "B" (c) Liquids with F.P. above 65.6oC and insoluble in water

Water fog or fine spray. No solid jet.

Most suitable.

Suitable

Most suitable

May be used

Class "B" (d) Liquids with F.P. above 65.6oC and soluble in water

As above

Not suitable

Most suitable

Most suitable

May be used

Class of Fire

F&S Regulations Appendix 5

June 2004

Page 3

KOC F&S Regulations Class "E" Electrical 9.

FIRE FIGHTING EQUIPMENT Not to be used

Not to be used

Not to be used

Suitable

Most suitable

TYPES OF EXTINGUISHERS IN USE: •

Water Type Extinguishers: Contents Duration Stream Operation

•

-

8.5 liters water 0.5 AFFF 30 to 90 seconds 6 meters Check gauge Carry extinguisher to the fire by the carry handle Release safety pin Test Operation Direct stream on wall of container or over surface of fire Can be used intermittently Extinguishes by smothering & cooling on Class B fire.

Dry Chemical Type Extinguishers: Contents Duration Stream Operation

•

9 liters of water pressurized with air 1.5 to 2 minutes 8 meters Carry extinguisher to the fire by carry handle Release safety pin Test Operation Direct at base of fire Can be used intermittently Extinguishes by cooling on Class A fires

Foam Type Extinguishers: Contents Duration Stream Operation

•

-

Sodium Bicarbonate 0.9 Kg to 14 Kg 90 seconds upwards for 9 Kg. 1.8 to 4 meters Check gauge Carry extinguisher to the fire by carry handle Release safety pin Test operation Direct at vapour space in sweeping motion Can be used intermittently Extinguishes by inhibiting flame chain reaction on small B & E Class fires.

CO2 Type Extinguishers: Contents Duration Stream Operation

F&S Regulations Appendix 5

Liquid CO2 1 Kg – 5.5 Kg. 20 seconds upwards 1 to 2.5 meters Carry extinguisher to the fire by carry handle Release safety pin Test operation Direct close to fire in sweeping motion Can be used intermittently June 2004

Page 4

KOC F&S Regulations

FIRE FIGHTING EQUIPMENT -

10.

11.

Extinguishes by smothering on small B & E Class fires

FIRE FIGHTING SYSTEM: Firefighting system ca n be divided into fixed and portable systems and placed to cover risks specific to the area. Firefighting system may include: *

Fixed

-

Sprinklers, Deluge System Fixed Extinguishers – Halon or CO2 Hydrants / Hose Reels Early Detection or Suppression

*

Portable

-

Fire Extinguishers Fire Blankets Dry Extinguisher Agents

FIRE STREAMS: Fire stream is the name given to the water flow coming out of a branch. Types of fire streams are: *

Straight Stream

-

A jet or solid stream of water

*

Spray

-

V shaped spray pattern consisting of large water droplets.

*

Fog

-

A wide spray pattern consisting of small water droplets.

F&S Regulations Appendix 5

June 2004

Page 5

Kuwait Oil Company (K.S.C.)

Fire & Safety Regulations

VESSEL / TANK / CONFINED SPACE ENTRY PROCEDURE

Appendix No. 6 June 2004

APPENDIX - 6

VESSEL / TANK / CONFINED SPACE ENTRY PROCEDURE 1

OBJECTIVE: To define the required procedure for confined space entry such that working conditions prevails throughout the entire scope of work being carried out.

2

SCOPE: The procedure applies to all confined spaces such as vessels, tanks, voids or any area from which immediate escape is restricted. This procedure is applicable to all installations in the company premises.

3

DEFINITIONS: (a)

CONFINED SPACE: Any enclosure having a limited means of entry & exit and not designed for continuous occupancy. Examples include (but are not limited to) the following: i. Process vessels, tanks, bins, stacks, large pipe, ducts, pits, and vaults. ii. Any enclosure where the presence of air contaminants may be harmful to a worker and prevent his ability to escape unaided.

4

(b)

CONFINED SPACE ENTRY: The act of physically entering a confined space. Entry into a vessel covers not only complete body entry, but also when only the head is inserted.

(c)

AIR CONTAMINANT: Any potentially harmful substance or chemical, which is present or may be present in the atmosphere within a confined space.

(d)

AUTHORIZED PERSON: KOC personnel who are authorized to administer & approve WORK PERMITS for the entry of personnel into a confined space.

CONFINE SPACE ENTRY ELEMENTS: The types of confined spaces and hazard associated with each varies widely according to its configuration, nature of service, material stored and work to be executed inside the confined space. The entry procedure can be conveniently interpreted to suit each case. However a general procedure & guidelines comprising the various elements of Confined Space Entry Process is summarized as hereunder: • • • • • • •

F&S Regulations Appendix 6

Pre – entry Planning & potential hazard assessment. Preparation of Confined Space for entry Ascertaining of safe condition by testing the atmosphere Obtaining permits for entry & work. Entry & Work execution. Work Monitoring & Supervision. Final inspection & returning the vessel/tank to normal service.

June 2004

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KOC F&S Regulations 5

VESSEL / TANK / CONFINED SPACE ENTRY PROCEDURE

PRE- ENTRY PLANNING & HAZARD ASSESSMENT: All activities involving the preparation of a confined space and the entry of personnel shall be carried out in a planned & systematic manner. This includes:

6

(a)

The planned work shall be discussed with all concerned teams, trades and principal personnel who will be involved in the isolation, preparation, safeguarding of the confined space and its return to normal operation.

(b)

The arrangements / requirements for spades, blinds, gaskets etc. shall be carried out in advance to ensure sufficient material prior to commencement of work

(c)

Preparation of vessel including isolation, venting, water flushing, nitrogen purging, steam purging (where required) and purging with air.

(d)

The identification, assessment & control of hazards associated with pyrophoric iron deposits, presence of toxic or flammable vapours and oxygen deficiency inside the confined space.

(e)

Conducting toxic gas, flammable gas and oxygen content on a pre-determined schedule.

(f)

Provision for rescue of personnel from the interior of confined space.

(g)

Deployment of an Observer / Standby person at the entrance of the confined space, when the personnel are within the confined space.

(h)

Authorized personnel shall ensure that confined space preparation and entry work activities are conducted in a proper & safe manner.

(i)

The Plant supervisor is the final authority to approve the entry of personnel into a confined space.

PREPARATION FOR ENTRY IN A CONFINED SPACE: 6.1

VESSEL ISOLATION: Before any part of the manifold or lines connected to a vessel are opened up, the vessel shall be isolated from any pressure source by means of “Double Block & Bleed”. Entry of personnel into a vessel shall not be authorized until the vessel is isolated as close as possible to the vessel by physical disconnection (e.g. removal of pipe spool) or by the installation of spades / spectacles blinds which have the same pressure rating as the flange.

6.2

VENTING / DRAINING OF VESSEL CONTENT: •

Venting / draining directly to atmosphere is not permitted particularly where venting / draining of a vessel can be carried out through a purpose designed venting / disposal system.

•

Venting or blowdown of a vessel containing hydrocarbons shall initially be done through normal vent system to the flare up to the minimum attainable pressure. The atmospheric vent or any other suitable valve can be opened at final stage to blowdown carefully at a controlled rate.

•

Venting operations are potentially hazardous; all personnel shall be informed that venting is planned. The area in the vicinity of the vessel is cordoned off and warning notice (both in Arabic & English) posted

F&S Regulations Appendix 6

June 2004

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KOC F&S Regulations

VESSEL / TANK / CONFINED SPACE ENTRY PROCEDURE at the location. Only essential personnel will be allowed to the location and all Hot Work permits on the installation shall be withdrawn.

•

After the above-mentioned precautions have been taken, the vent can be opened. Start at any of the top connection.

•

Ensure that the vessel is depressurized by verification through an independent point (such as an instrument tapping)

•

During the removal of pipework or manhole covers, the personnel involved shall wear breathing apparatus sets. During atmospheric venting operations, ensure the controlled rate of venting. If H2S concentrations exceeds 10 ppm in the atmosphere, stop venting and either flush / purge or locate source of gas and eliminate prior to resuming atmospheric venting.

•

7

6.3

WATER FLUSHING: A water flush programme must be considered in order to minimize the amount of residual hydrocarbon liquids in the vessel, and to wet any pyrophoric sulphide residues. The flushing procedure will depend on the scope of work and the condition of vessel being entered.

6.4

NITROGEN PURGING: Vessel service and scope of work will determine extent of nitrogen purging required. Gas & NGL processing facilities shall always be purged with nitrogen prior to opening for inspection and proceeding with next step of this procedure.

6.5

AIR PURGING:

•

Various methods of air purging can be considered such as natural draft air purge, or purging by air driven extraction fan / blower. Electrically driven air movers shall not be used for initial air purging operations.

•

Liquids or gases in motion create static electricity, therefore always ensure that the vessel & ventilators are properly are bonded to earth.

•

During the initial stages of the air purge, product gases may be within the explosive range, the following precautions shall be taken: i. All personnel shall be informed prior to commencing purging operation. ii. The area in the vicinity of vessel shall be cordoned off and warning notice (both in English & Arabic) posted at the location. iii. Only essential personnel will be allowed at the site and all Hot Work permits shall be withdrawn.

•

Electrically driven air movers may only be used at a later stage of vessel purging operations after gas testing has confirmed that the atmosphere in the vessel does not fall within the flammability range of hydrocarbon gas being purged.

FLAMMABLE VAPOUR, TOXIC GAS & OXYGEN TESTING: •

Prior to opening the vessel manway, the vessel will be barricaded from the surrounding area and a warning notice stating “ DO NOT ENTER THE

F&S Regulations Appendix 6

June 2004

Page 3

KOC F&S Regulations

VESSEL / TANK / CONFINED SPACE ENTRY PROCEDURE

VESSEL PRIOR TO APPROVAL FROM PLANT SUPERVISOR” shall be posted at the manway entrance in Arabic & English. •

Immediately after opening of the vessel manway, the atmosphere within the vessel shall be tested for explosive vapours, toxic gases and for oxygen level by the authorized gas tester.

•

The initial gas test shall be taken from the manway entrance while wearing breathing apparatus. Once acceptable vapor concentration have been confirmed, the vessel may be entered further to determine if the vessel is safe for entry by other authorized personnel. The vessel shall be checked for sludge deposit at this time.

•

The table as hereunder indicates the permissible levels with respect to entry & work restrictions.

ENTRY WITHOUT RESPIRATORY PROTECTION PERMITTED (Refer Note 1 & 2)

RESPIRATORY PROTECTION REQUIRED FOR ENTRY

NO ENTRY

• • • • •

Oxygen concentration between 19.5 % & 23.5 % H2S concentration is less than 10 ppm Air Contaminants are below permissible exposure limits (PEL) Hydrocarbon concentration is less than 1% of LEL Adequate flow of fresh air is maintained.

• • • •

Oxygen content is less than 19.5% or greater than 23.5%. H2S concentration is greater than 10 ppm. Air contaminants are above permissible exposure limit (PEL) Hydrocarbon concentration is greater than 1%LEL but less than 10%LEL

• • •

Hydrocarbon concentration is greater than 10% LEL. Hazardous materials such as acids or caustics are present. The toxicity of atmosphere is immediately dangerous to life or health. The facility or associated process are experiencing operational problems.

•

Note: 1. It is to be taken care that level of gas concentrations may change due to variation in ambient temperature. 2. The entry in a vessel having sludge or residue inside shall be permitted only by donning BA sets all the time. •

Sludge once disturbed by entry into a vessel may cause an increase in flammable vapor concentrations. Force ventilation shall continue throughout the operation in order to prevent exceeding the allowable limits. The ventilation equipment must not block manhole escape ways.

F&S Regulations Appendix 6

June 2004

Page 4

KOC F&S Regulations

8

VESSEL / TANK / CONFINED SPACE ENTRY PROCEDURE

•

During the entry period, gas testing is to be continued at a minimum interval of 6 hours or as frequent as depending upon the prevailing work conditions.

•

When the vessel is vacated, a new gas test shall be taken before the vessel is re-entered.

ENTRY PERMIT: Vessel entry shall only be permitted after the required confined space entry permit has been duly authorized in compliance to Work Permit System. The precautions summarized hereunder will apply to all confined spaces entry even when a person head is inserted for a quick inspection. • •

8.1

The worksite supervisor shall be fully aware of confined space entry procedure and Permit to Work System. The confined space must be positively isolated from all processes & utility systems by blanking /spading / disconnection. Where disconnection is employed as a means of isolation, the lines shall be blanked.

•

Isolations must be achieved as close to the confine space as possible, preferably on the nozzles. If this is not achievable then the next nearest point of isolation will be selected.

•

If the confined space is equipped with a source of electrical power, an electrical isolation must be carried out and ensured that the confined space is adequately earthed prior to the issue of entry certificate.

•

Generally not more than two persons will be allowed to work at a time in a vessel, tank or confined space.

•

The area around the confined space must be barriered off and warning sign posted in English & Arabic.

USE OF TOOLS: •

The use of tools inside the vessel shall be carefully controlled with only specific, non-sparking tools allowed for work involving explosive vapors or flammable products. It is recommended to use a wooden shovel for removing sludge from a vessel.

•

Only pneumatic lighting appliance or intrinsically safe torches shall be used within a vessel containing flammable residual.

•

All liquids or gases in motion are capable of generating electrostatic charges. Therefore all equipment used in gas freeing, cleaning and repair work must be effectively bonded and earthed. This also applies to the lines & hoses used for removing residues, mechanical ventilators / exhaust fans, jetting equipment, grit blast tool and paint spray system.

8.2

PROTECTIVE CLOTHING: For initial vessel entry and during cleaning operations, it is recommended to use suitable protective clothing such as neoprene suits or coveralls specially allocated for vessel entry. The cleaning personnel MUST NOT SMOKE while wearing clothing contaminated by hydrocarbon.

8.3

PYROPHORIC DEPOSITS: Any hazard associated with pyrophoric iron sulphide may arise in process vessel. If Pyrophoric scale from these vessels is permitted to dry

F&S Regulations Appendix 6

June 2004

Page 5

KOC F&S Regulations

VESSEL / TANK / CONFINED SPACE ENTRY PROCEDURE

out, oxygen in the air may cause it ignite spontaneously. During cleaning activities, any sludge of pyrophoric nature shall be kept wet & taken out of vessel as soon as possible and disposed off in a safe manner. To prevent a temperature rise, the interior surface of the vessel shall be wetted with water until the atmosphere in the vessel reaches below flammable range. The wetting also tends to isolate these Pyrophoric deposits from oxygen present during ventilation.

9.0

RESCUE & RELIEF: o A standby man shall be stationed at the confine space entry point. He shall be equipped with a portable radio and must keep visual contact with personnel working inside the confined space. o The standby man will inform Control Room each time the vessel is entered or vacated & all entries / exits will be recorded in CCR log book. o In case of emergency inside the plant, the vessel entry must stop immediately. The standby man shall advise the Control Room by radio, when the personnel inside the confined space have vacated, the site shall be made safe and the personnel shall proceed to muster. o If an emergency occurs within the confined space, the standby person must not enter the vessel until a relief arrives. It is the responsibility of standby man to summon aid immediately by contacting the Control Room through radio or other available means of communication. o Personnel working inside the vessel will be given a rest period at each 30 minutes intervals, or more frequent depending upon prevailing conditions.

10.

FINAL INSPECTION: Upon completion of the work (inspection or repair of the vessel) the vessel is to be closed permanently. The on-duty Supervisor shall inspect the vessel internally and ensure that there is no tools, equipment, rags or other foreign objects left in the vessel. He will then witness the closing up operations and sign off the work & vessel entry permit.

F&S Regulations Appendix 6

June 2004

Page 6

Kuwait Oil Company

Fire & Safety Regulations

(K.S.C.)

Appendix -7 June 2004

CHARACTERISTICS OF CRUDE OIL TANK FIRE APPENDIX - 7

CHARACTERISTICS OF CRUDE OIL TANK FIRE The elements of fire triangle – i.e. fuel are available in the storage tank and so is the oxygen in the atmosphere. The only missing link is source of ignition, which needs to strictly control preventing fire. A fire or possibly an explosion may occur when the proper proportion of flammable vapours and air are exposed to an ignition source. An explosion results from the ignition of flammable vapour – air mixture that fills the tank. The resultant fire inside the tank may produce a rapid pressure increase that exceeds the design the design strength of the tank and causes it to rupture. Flammable vapour – air mixture may be ignited by ignition source, such as open flames, internal combustion engine, lightning, smoking, electrical short circuit and sparks. Spark sources include electric lamps, power tools, fixtures, switches, non – explosion proof appliances, welding and static electricity. Another source of ignition may be present in tanks that have been used for storage of sour crude. The sulphur compound in the sour crude oil reacts react with steel of storage tank to form finely divided iron polysulfide deposits, which are pyrophoric on exposure to air. When these pyrophoric deposits come in contact with air, a heat generating chemical reaction takes place. If the heat generation is not dissipated, spot temperatures high enough to ignite a flammable vapour can be reached. Elimination of ignition source sources can be more difficult and less certain ignition source may go unrecognised or be remote. Unlike vapour and gases, ignition sources cannot be practically detected by an instrument. The vapours of some petroleum products are heavier than air and settle in low places. Vapours can spill from a tank and can flow like water. They can travel considerable distances and encounter remote ignition source, e.g. a car or truck engine and be ignited. They can also flashback to and into the tank where the vapour originated and cause a fire & explosion. Potential Fire Hazard in a Floating Roof Tank: Some of the potential fire hazards associated with floating roof tank include, but are not limited to the following: (a)

A flammable vapour or mixture may exist in the atmosphere above the floating roof. (e.g. roof seal can leak)

(b)

A flammable or combustible liquid may be present on the floating roof (e.g. due to overflow or pontoon leakage)

(c)

A flammable or combustible liquid or vapour may be present in the pontoon or in the seal area. (e.g. due to pontoon leak, or a rupture in the seal)

(d)

When the floating roof is out of floatation and the liquid level is below the roof support, a flammable air vapour air mixture may exist in the atmosphere below the roof (e.g. roof seal does not seal properly and air entered the interstitial space)

F&S Regulations Appendix 7

June 2004 Page 1

KOC F&S Regulations

CHARACTERISTICS OF CRUDE OIL TANK FIRE

(e)

When filling a tank whose roof has been out of floatation and the liquid level has been below the roof level, vapour may be forced through the roof seal and into the atmosphere above the floating roof)

(f)

Absorbent buoyant materials used in the construction of some floating roof may retain flammable or combustible liquids.

TANK FIRE & ITS CONTROL: As a general rule in case of small fire in the tank can be quickly extinguished by reduction of air in the vapour – air mixture. Blanketing the oil surface with foam extinguishers by reducing the vapour in the vapour – air mixture can extinguish the fire. It also cuts off air from contact with the liquid and thus prevents the formation of flammable mixture. The contained oil fire is easier to control than the uncontained. It is not going anywhere as long as it remains contained, which in case of a tank fire, is until extinguished or until the tank contents burn to consumption. Floating roof rim fires can be easily extinguished by use of foam hose nozzles from the top platform, driving the fire away beneath the platform with the foam, fog or dry chemical and then proceeding around the tank. If a fire occurs near a tank, apply water immediately to the exposed tank to cool it and to reduce vaporization. This action not only saves stock but also makes ignition at the vents less likely. It is best to plan the fighting of these fires in advance of their occurrence and better still to prevent the fire. .

F&S Regulations Appendix 7

June 2004 Page 2

Kuwait Oil Company

Fire & Safety Regulations

(K.S.C.) Appendix -8 June 2004

SPECIMEN FORMS APPENDIX - 8 SPECIMEN FORMS

A.

Hot Work Permit

B.

Cold Work Permit

C.

Radiography Work Permit

D.

Confined Space Entry Permit

E.

Vehicle / Mobile Plant Entry Permit

F.

Excavation Notification

G.

Electrical Work Certificate

H.

Incident Report Form

I.

Hazard Observation Card

J.

Safety Checklist for Office or Non-Industrial Premises

K.

Check List for Vehicle Entry into Hazardous Area

F&S Regulations Appendix 8

June 2004 Page 1

KUWAIT OIL COMPANY (K.S.C.) - HOT WORK PERMIT ‫ﺕﺼﺮﻳﺢ ﻋﻤﻞ ﺣﺎر‬ Permit No.

H

Location of Work / ‫ ﻣﻮﻗﻊ اﻟﻌﻤﻞ‬:

Zone 0

Area Classification:

2.

Zone 1

Hazardous Unclassified

Non - Hazardous

1.

‫هﺬا اﻟﺘﺼﺮﻳﺢ ﺳﺎري ﻟﻤﺪة ﺳﺒﻌﻪ أﻳﺎم ﻣﻦ ﺕﺎرﻳﺦ اﻹﺻﺪار‬

7.

VALID FOR ONLY 7 CONSECUTIVE DAYS FROM THE DATE OF FIRST ISSUE

1)

Date / ‫ اﻟﺘﺎرﻳﺦ‬:

5.

Zone 2

2) I am aware of this work & precautions / isolations specified specified in this permit have been made as c required for the work.

ISOLATION & DE-ISOLATION RECORD SYSTEM

WORK REQUEST (To be completed by Permit Applicant )

EQUIPMENT / DEVICE No.

PERMIT ISSUER DECLARATION OF WORKSITE PREPARATION I have visited & inspected the worksite

ISOLATION / INHIBIT Date

Permit Issuer

DE-ISOLATION

Initial

Time

Date

Time

Initial

Transfer of Responsibilities

Name:

Name:

Equipment to worked on:

Electrical

Designation & KOC No.

Designation & KOC No.

Work Description:

Electrical

Team / Group:

Team / Group:

Electrical

Signature:

HAZARDS / DANGERS (By Permit Issuer ) TICK RELEVENT BOXES

Mechanical

Date:

Mechanical

8. Date

Instrumentation

Time

Instrumentation

L.E.L / PPM

Naked Flames or Arcs

Flammable Gas / Liquid

Flying Particles or Sparks

Process

Toxic Gas / Liquid

Electricity

Process

Corrosive Materials

Moving Machinery

1) I declare that the Isolation(s) as specified in Section 5 of this permit have been completed & approved

Heat

Equipment Generating Sparks

2) The equipment have been locked & tagged. - Yes / No.

Pyrophoric Deposits

Vehicle Entry

a.

Adjacent Operations

Excavation

3.

Name:

c.

ASSOCIATED PERMIT NUMBERS (By Permit Issuer)

PRECAUTIONS REQUIRED (By Permit Issuer ) TICK RELEVENT BOXES

Designation: & KOC No.:

Designation: & KOC No.

Team / Group

Team / Group

Date

Signature, Date & Time :

Time

Yes

No

Signature, Date & Time :

Process / Mech Isolation

De-pressurised

Electrical Isolation

Drained

Area Cleared of Flammables

De-contaminated

(For Mechanical Isolation):

Name: (For Process Isolation):

ESD overrides on

Water Flushed

Designation: & KOC No.:

Designation: & KOC No.:

Drain sealed within 50' radius

N2 purged

Team / Group

Team / Group

F & G Detection Overrides o

Thoroughly Ventilated

Signature, Date & Time :

b.

Name:

d.

10.

Initial

11.

HANDOVER OF EQUIPMENT BY PERMIT APPLICANT

I have visited & inspected the worksite.The work described in section 1: is complete & materails / tools / equipment have been removed & area cleaned

4. PROTECTIVE & SAFETY EQUIPMENT (By Permit Issuer) Tick relevant boxes

6. (a )

Face Shield

Addiitional Lightt

1) The work & precaution will be accried out under my

Eye / Welders Goggles

Air Line Unit

Fire Blanket

Escape B.A Set

Safety Harness

Full / Partial Chemical Suit

Hearing Protection

PVC Gauntlets

Gloves

Life Jacket

Work Vest

Dust Mask

Name & Designation:

Permit Issuer :

Radio

Air Mover

Team / Group:

Company Name:

12.

Breathing Apparatus

Fire Extinguishers

Signature, Date & Time :

Signature:

Contact No.

H2S Monitor

X 2 pressurized Fire Hoses

Date:

Time:

overall responsibility 2) All personnel under my supervision have been fully briefed & understand the Permit to Work / Site Safety rules.

Designation: & KOC No.:

Other Precautions:

6 (b) WorkSite Supervisor Declaration

de-isolation(s) as specified in Section 5 have been completed and approved

1) I have read this Permit to Work & associated permits. I understand my responsibilitis & will comply with all precautions.

is to continue on another permit Unit can be returned to service

Worksite Supervisor 2) I will remain on site as defined by the Permit Applicant & obtain necessary 12 hour shift change Permit Applicant: endorsements. 3) Fire watch has been fully briefed on his resposibilitie

Name:

Excavation Notification Vessel Entry Radiography

PERMIT ISSUER SHIFT CHANGE ENDORSEMENT

Signature, Date & Time :

Permit Applicant Declaration

Vehicle Entry

Name

Isolation Details

Purging of System

Cold Work

Hot Work

(For Instrumentation Isolation):

No

Time:

Initial

9.

(For Electrical Isolation):

Yes

Date:

GAS TEST RESULT:- ( By Authorized Gas Tester )

Instrumentation

Liquid / Gas under Pressure

Signature: Time:

Transfer of Responsibilities

Name & Designation:

Designation: & KOC No.:

Company Name:

Team / Group:

Signature: Date:

Time:

Date:

Time:

Date:

Time:

ACCEPTANCE OF EQUIPMENT BY ASSET OWNER / PERMIT ISSUER

I have visited & inspected the area /equipment and agree with the condition stated in section 11 and:

All isolations have been removed

Transfer of Responsibilities

Name:

Date:

Yes / No

The completed permit(s) / associated permit Name :

N.B: ESD - Emergency Shutdown, F & G - Fire & Gas, PVC - Polyvinyl Chloride NOTE: * Enclosures: (I)

(ii)

Signature, Date & Time :

(iii)

Designation

Team / Group:

Contract No.

KOC No.

Signature:

Time;

Date:

Time:

(iv)

** The validity period for the permits pertaining to the works (such as minor construction, or of maintenance / renovation nature) can be extended with due approval from concerned Team Leader, taking all precautionary measures for safe execution of work.

*** Permit Distribution: Original - Worksite Supervisor ; 1St Copy: Permit Applicant; 2nd Copy - Fire Team; 3rd Copy - Permit Issuer

**** For Work Permit suspension - Refer to Clause No. 5.10 Permit to Work Procedure

KUWAIT OIL COMPANY (K.S.C.) - COLD WORK PERMIT ‫ﺗﺼﺮﻳﺢ ﻋﻤﻞ ﺑﺎرد‬ Permit No.

C

‫هﺬا اﻟﺘﺼﺮﻳﺢ ﺳﺎري ﻟﻤﺪة ﺳﺒﻌﻪ أﻳﺎم ﻡﻦ ﺗﺎرﻳﺦ اﻹﺹﺪار‬

Date / ‫ اﻟﺘﺎرﻳﺦ‬:

Location of Work / ‫ ﻡﻮﻗﻊ اﻟﻌﻤﻞ‬:

Zone 0

Area Classification Non - Hazardous 1.

Hazardous

Zone 1

Unclassified Area

Zone 2

WORK REQUEST (To be completed by Permit Applicant)

7.

VALID FOR ONLY 7 CONSECUTIVE DAYS FROM THE DATE OF FIRST ISSUE 5.

ISOLATION & DE-ISOLATION RECORD SYSTEM

EQUIPMENT / DEVICE No.

ISOLATION / INHIBIT Date

Initial

Time

DE-ISOLATION Date

Time

Initial

Electrical

Designation & KOC No.

Designation & KOC No.

Electrical

Team /Group

Team / Group

Work Description:

Mechanical

Signature,:

Mechanical

Date:

8. Date Time

L.E.L / PPM

Heavy Lift Operations

Process

Moving Machinery

Process

Corrosive Materials

Adjacent Operations

(I) I declare that the Isolation(s) as specified in Section 5 of this permit have been completed, approved

Diving Operations

Restricted Access

(ii) The isolated equipment / s have been locked and tagged. - Yes / No

Flammable Gas / Liquids

Oxygen Deficiency

Pyrophoric Deposits

Excavation

a. Name: (For Electrical Isolation)

Scaffolding

Electricity

Isolation Details

Yes

No

Purging of System

Yes

No

Time:

Signature

c.

Team / Group :

Drained

Electrical Isolation

De-contaminated

ESD / F & G overrides on

Water flushed

Pipework Disconnection

N2 purged

Team / Group :

Other:

Thoroughly Ventilated

Signature, Date & Time :

10.

Designation: & KOC No.

6(a).

Addiitional Lightt

1) The work & precaution will be carried out under my overall responsibility 2) All personnel under my supervision have been fully briefed & understand the Permit to Work / Site Safety rules.

Vessel Entry Radiography

PERMIT ISSUER SHIFT CHANGE ENDORSEMENT

Time Initial

Designation & KOC No.

11. HANDOVER OF EQUIPMENT BY PERMIT APPLICANT

Team / Group :

I have visited & inspected the worksite.The work described in section 1:

Signature, Date & Time :

4. PROTECTIVE & SAFETY EQUIPMENT (By Permit Issuer) Tick relevant boxes

Excavation Notification

Date

d. Name: (For Process Isolation)

b. Name: (For Mechanical Isolation)

Face Shield

Vehicle Entry

Designation: & KOC No.

Signature, Date & Time :

De-pressurised

Cold Work

Name

Signature, Date & Time :

Instrument Isolation

ASSOCIATED PERMIT NUMBERS (By Permit Issuer)

Hot Work

Team / Group :

Process / Mech. Isolation

9.

(For Instrumentaion Isolation)

Designation: & KOC No.

PRECAUTIONS REQUIRED (By Permit Issuer ) TICK RELEVENT BOXES

Date:

GAS TEST RESULT:- Authorized Gas Tester

Instrumentation

Toxic Gas / Liquid

Signature: Time:

Instrumentation

Liquid/Gas under Pressure

3.

Transfer of Responsibilities Name:

Electrical

HAZARDS / DANGERS (By Permit Issuer ) TICK RELEVENT BOXES

Permit Issuer Name:

Equipment to be worked on:

Instrumentation

2.

PERMIT ISSUER DECLARATION OF WORKSITE PREPARATION

1) I have visited & inspected the worksite 2) I am aware of this work & precautions / isolations specified in this permit have been made a required. for the work.

is complete & materails / tools / equipment have been removed & area cleaned de-isolation(s) as specified in Section 5 have been completed and approved

Permit Applicant Declaration

6 (b). WorkSite Supervisor Declaration

is to continue on another permit

Unit can be returned to service 1) I have read this Permit to Work & associated permits. I understand my responsibilitis & will compl with all precautions. Worksite Supervisor

Eye Protection

Air Line Unit / BA Set

Safety Harness

H2S Monitor

Hearing Protection

Full / Partial Chemical Suit

Gloves

PVC Gauntlets

Name:

Work Vest

Life Jacket

Designation: & KOC No.

Name & Designation:

Radio

Dust Mask

Team / Group :

Company & Contract No..

12.

Disposable Coveralls

Air Mover

Signature, Date & Time :

Controlling Team / Group :

I have visited & inspected the area / equipment and agree with the condition stated in section 11 and:

2) I will remain on site as defined by the Permit Applicant & obtain necessary 12 hour shift change endorsements.

Other Precautions:

Time:

Date:

Time:

Permit Issuer :

Date:

Time:

ACCEPTANCE OF EQUIPMENT BY ASSET OWNER / PERMIT ISSUER

All isolations have been removed

Signature, Date & Time :

Transfer of Responsibilities

Transfer of Responsibilities

N.B: ESD - Emergency Shutdown; F & G - Fire & Gas; PVC - Polyvinyl Chloride NOTE: * Enclosures: (I)

Date:

Permit Applicant:

(ii)

Can be returned to service

-

Yes / No. - Yes / No.

Name:

Name & Designation:

Designation: & KOC No.

Company & Contract No..

Name:

Designation & KOC No.

Team / Group :

Controlling Team / Group :

Team / Group

Signature, Date & Time

Signature, Date & Time :

(iii)

The completed permit(s) / associated permit (s) is now closed

Signature, Date & Time :

(iv)

** The validity period for the permits pertaining to the works (such as minor construction, or of maintenance / renovation nature) can be extended with due approval from concerned Team Leader, taking all precautionary measures for safe execution of work.

*** Permit Distribution: Original - Worksite Supervisor ; 1st Copy - Permit Applicant; 2nd Copy - Fire Team; 3rd Copy - Permit Issuer

**** For Work Permit suspension - Refer to Clause No. 5.10 of Permit to Work Procedure

KUWAIT OIL COMPANY (K.S.C.) - RADIOGRAPHY WORK PERMIT / ‫ﺗﺼﺮﻳﺢ ﻋﻤﻞ ﻣﻮاد ﻣﺸﻌﺔ‬ Permit No.

R

‫هﺬا اﻟﺘﺼﺮﻳﺢ ﺳﺎري ﻟﻤﺪة ﺳﺒﻌﺔ أﻳﺎم ﻣﻦ ﺗﺎرﻳﺦ اﻹﺹﺪار‬

Date / ‫ اﻟﺘﺎرﻳﺦ‬:

Location of work / ‫ ﻣﻮﻗﻊ اﻟﻌﻤﻞ‬:

Zone-0

Area Classification:

Zone-1

3. Protective & Safety Equipment

Zone-2

Eye Protection

Hazardous Non - Hazardous

Unclassified

1. Work Request ( To Be completed by Permit Applicant) Equipment to be worked on: Work Description:

7. Permit Issuer Authorization

VALID FOR A MAXIMUM PERIOD OF 7 DAYS FROM THE TIME OF ISSUE

1.) I have inspected the worksite. 2.) I am aware of this work & precautions / isolations specified in this permit have been made as required for the work

Safety Harness

Hearing Protection

Breathing Apparatus

Gloves

Self Rescue Set

Work Vest Additional Light lsotope Storage Pot Lead Shieded

Permit Issuer

Dust Mask

Name

Portable Gas Detector Long Handled Tongs

Designation & KOC No.:

Designation & KOC NO.:

Bolt Croppers

Team / Group:

Team / Group:

Signature:

Signature:

Date:

Date:

Time:

Time:

4. Isolation & & De- isolation Records( By Permit Applicant) Equipment No.

De-isolation

Isolation Date & Time

Transfer of Responsibilities

Name

Initial

Date & Time

Initial

8. Gas Test : (By Authorized Gas Tester) Date

Source Type :

Strength:

(Curies)

Time

Radiographer Name & Certificate No.:

L.E.L. / PPM Signature

Assistant Radiographer Name & Certificate No.:

9. Permit Issuer - Shift Change Endorsement Date

2. Precautions Required (Permit Applicant -Tick boxes to confirm action)

Time

All other permits within the controlled area will be suspended

Signature (I) I declare that the isolation (s) as specified in Section 4 of this permit have been completed & approved. Approved Gas Detectors at Work Site for continuous monitoring. - Yes / No.

The U.V.s have been inhibited

(ii) Equipment have been locked & tagged - Yes / No

10. Handback of Equipment (By Permit Applicant) We have inspected the worksite & work described in Section 1:

Name:

Name :

Designation & KOC No.:

Designation & KOC No.:

2' Classified Radiographers ' onsite

Team/Group:

Team/Group:

All personnel involved in radiography are wearing monitoring badges

Signature, Date & Time:

Signature, Date & Time:

Worksite Supervisor:

Date:

Specified ' Radiographer' issued with portable radio

5. Permit Applicant Declaration

6. Worksite Superv. Declaration

Permit Applicant

Date:

Time:

Equipment on site for retrieval of source in an emergency

1.) The work & precautions will be carried out under my responsibility

1) I have read this Permit to work & associated permits.

Permit Issuer

Date:

Time:

P.A. announcements 30 minutes prior & immediately before commencement of radiography

Is complete, materials removed, area cleaned & radiation level checked. de-isolation (s) specified in Section 4 have been completed & approved

Barrier distance is ………………..meters at 7.5 micro S.V. / Hr

Source Container checked for radiation leaks

Presonnel brifed on relevant radiography safety procedures

2) All personnel under my supervision 2) I understand my responsibilities & will comply with all precautions . have been fully briefed & understand

All ' unclassified personnel have vacated the area

permit to work safety rules

The area has been surveyed & cordoned off.

Name:

x2 Radiation Meters are on site, calibrated and serviceable

Designation & KOC No.:

Name & Designation:

Radiographers' Competency Cerificate is approved by Kuwait MOH

Team / Group:

Company:

The operational check for remote operated camera carried out.

Signature, Date & Time:

Signature, Date & Time:

Flashing warning lights & warning sign on site

Other precautions :

is to continue on another permit.

11 . Acceptance of Equipment By Permit Issuer: I have inspected the area / equipment & agree with the condition stated in section 10 and

3) I will remain on site during work & obtain shift change endorsements

Transfer of Responsibilities

Transfer of Responsibilities

Name:

Name:

Designation & KOC No.:

Designation & KOC No.:

Team/ Group:

Team/ Group:

Signature, Date & Time:

Signature, Date & Time:

Time:

All isolations have been removed

-

Yes / No.

Can be returned to service

-

Yes / No.

The completed permit (s) / associsted permit (s) is now closed . Name: Designation & KOC No.: Team / Group: Signature: Date:

NOTE: Enclosures (I) (II) (III) PERMIT DISTRIBUTION: Original - Worksite Supervisor; 1st Copy - Permit Applicant; 2nd Copy - Fire Team; 3rd Copy - Permit Issuer

Time:

(IV)

Kuwait Oil Company (K. S. C.) CONFINED SPACE ENTRY PERMIT / ‫ﺕﺼﺮﻳﺢ ﻋﻤﻞ ودﺧﻮل أﻣﺎآﻦ ﻣﻐﻠﻘﺔ‬

Permit No: Date / ‫ اﻟﺘﺎرﻳﺦ‬:

Valid for one continuous work shift only/ ‫اﻟﺘﺼﺮﻳﺢ ﺳﺎري ﻓﻘﻂ ﻟﻮردﻳﺔ ﻋﻤﻞ واﺣﺪة‬ Work Site Location / ‫ ﻣﻮﻗﻊ اﻟﻌﻤﻞ‬:

Equipment No.

1.

REASON FOR ENTRY / DESCRIPTION OF WORK

2

PREPARATION (Completed by Permit Issuer)

Yes

No

1. All lines have been removed or spaded as per spading list attached 2. The Vessel / TanK / Confined Space has been purged with Nitrogen 3. The Vessel / Tank / Confined Space has been flushed with water 4.The Vessel / Tank / Confined Space has been force ventilated with air 5. Electrical / hydraulic / pneumatic powered equipment have been isolated & made safe. 6. Precautions for Pyrophoric Deposits are in place 7. Specified Breathing Apparatus is on site and checked serviceable 8. Required Rescue Equipment is on site and checked serviceable. (If the answer to any above questions is ' No", give explanation:) N.B :The equipment (Electrical/Mechanical/Instrument) iIsolation detail shall be recorded in the relevant permit & copy attached alongwith this for ready reference

3.

DECLARATION OF CONFINED SPACE ENTRY (Completed by Permit Issuer) Enrty without Respiratory Protection Permitted

Oxygen content is between 19.5% and 23.5%,H2S concentration is less than 10 ppm, Air contaminants are below permissible exposure limits & hydrocarbon concentration is less than 10% LEL, A method of maintaining sufficient flow of fresh air is provided.

Respiratory protection such as positive Oxygen content is less than 19.5% or greater than 23.5%, or H2S concentration is greater than pressure BA set of capacity 1200 litres 10 ppm or permissible exposure limits to air contaiminates have been exceeded, or hydrocarbon (minimum), pressure 182 bar minimum, & concentration between 10% or 20% of the LEL. duration not less than 30 minutes. % Flammable Gas …………………………. %Hydrogen Sulphide ………………….. PPM Oxygen Content …………... Other Gas

…………...

%

(I) The Vessel preparations have been completed

(ii) Continuous gas monitoring is required.

(iii) Gas test to be carried out at ------ Hrs. interval(s) & recorded in Section -5 I confirm that it is now safe for personnel to enter the above vessel & carry out the work as described provided that all prescribed requirements (in Section -2 ) remain in effect & the gas monitoring levels remain below the acceptable safe limits. Name :

Signature:

Designation & KOC No.

Date & Time: Team / Group:

4. RECORD OF GAS TESTS (To be used to record any additional Gas Test required during validity of Permit) Date Time Oxgyen H2S Flammable Gas

Other Intial

6. WORKSITE SUPERVISOR DECLARATION I understand my responsibilities & will ensure that personnel under my supervision are fully briefed. I will ensure that all preparations are complete & that all protective & rescue equipment are in place at all times while personnel are in the confiened space.The nominated Stanby man has been fully briefed on his duties & responsibilities. Name:

Signatur :

Designantion.

Company & Contract No.

6.

Date:

Time:

COMPLETION AND PERMIT CLOSE OUT

(I) The Vessel is ready to Close (ii) Barriered off & Left Open for re-entry (iii) The Vessel has been left in a safe condition with all tools & equipment removed (iii) The prsons have been withdrawn & equipment / plant / electrical apparatus have been restored for normal operation Work Supervisor:

Date & Time:

Permit Issuer:

Date & Time:

Asset Owner :

Date & Time:

Permit Distribution: Original - W/Site Suprv; 1st Copy - Permit Applicant; 2nd Copy - Fire Team; 3rd Copy - Permit Issuer Remarks: (I) This Permit becomes invalid in case of any emergency at the work site or at its adjacent facilities

KUWAIT OIL COMPANY (K. S. C.)

Entry Permit No :

VEHICLE / MOBILE PLANT ENTRY PERMIT / ‫ﺗﺼﺮﻳﺢ دﺧﻮل اﻟﺴﻴﺎرات واﻟﻤﻌﺪات ااﻟﻤﺘﺤﺮآﺔ‬

[Validity: (I) one continuous Workshift for vehicle (ii) 7 consecutive days for mobile plant.] ‫ اﻟﺘﺼﺮﻳﺢ ﺱﺎري ﻟﻤﺪة أﺱﺒﻮع ﻟﻤﻌﺪات اﻟﻌﻤﻞ اﻟﻤﺘﺤﺮآﺔ‬/ ‫اﻟﺘﺼﺮﻳﺢ ﺱﺎري ﻟﻠﻤﺮآﺒﺔ ﻟﻮردﻳﺔ ﻋﻤﻞ واﺡﺪة‬. Worksite Location / ‫ ﻡﻮﻗﻊ اﻟﻌﻤﻞ‬: 1.

REASON FOR ENTRY

2

VEHICLE / MOBILE PLANT DETAIL:

Vehicle / Plant No.

Type

Date of Approval from KOC Transport

Date / ‫ اﻟﺘﺎرﻳﺦ‬:

Vehicle / Mobile Plant Condition (Tick mark or cross on Tyres Exhaust Fire Extiguisher Spark Arrester Horn & Light Good Safe Available Available Working

as per actual condition ) Earthing Brake Good Provided

Name of the Company / Contractor - owning Vehicle / Mobile Plant: Contract No:

Controlling Team:

3. VEHICLE DRIVER / MOBILE PLANT's OPERATOR DECLARATION I understand my responsibilities and will take extreme care while entering the premises through the specified route and location. I am also aware that this permit is only for the entry and a separate permit is required for carrying out any work Driving Licence No. & Validity: Name: Signature

Time:

Date:

4. RECORD OF GAS TESTS & SHIFT ENDORSEMENT Date Time Flammable Gas (%LEL) H2S (PPM) Initial 5.

AUTHORIZATION BY PERMIT ISSUER

(I) I confirm that every precaution measure has been taken against the potential hazards associated with the vehicle's entry (ii) The vehicle / mobile plant is permitted to enter the premises through the specified routes & location explained to the driver. (ii) The specified route is clear from any obstruction. (iv) The route & location has been marked in the enclosed drawing (if any)

Name:

Designation & KOC No. :

Team / Group 6.

Signature:

Date & Time:

COMPLETION AND PERMIT CLOSE OUT

(i) The vehicle / mobile plant has left the premises and all materials / tools / equipment have been removed. (ii) The work is completed and the area is safe, clean and tidy. Vehicle Driver / Mobile Plant Operartor :______________________________Date & Time: Permit Issuer;____________________________________________________Date & Time: (Name & Designation: ……………………………………………………...

KOC No:

………………………………... )

Note: (i) This permit is valid for entry only, however for carrying out any work, a separate & appropriate permit is to be authorized.. (ii) Permit Distribution:Original - W/Site Supervisor; Ist Copy - Permit Applicant; 2nd Copy - Fire Team; 3rd Copy - Permit Issuer

(‫ك‬.‫م‬.‫ﺷﺮآﺔ ﻧﻔﻂ اﻟﻜﻮﻳﺖ )ش‬

Serial No:

KUWAIT OIL COMPANY (K.S.C.)

! THIS NOTIFICATION IS NOT A PERMIT TO WORK BUT ADVANCE INTIMATION BY THE JOB EXECUTOR. A WORK PERMIT MUST BE OBTAINED PRIOR TO EXCAVATION !

‫إﺧﻄﺎر ﺣﻔﺮ‬

EXCAVATION NOTIFICATION (Valid for 90 days from the date of issue)

! PLEASE PRINT/ WRITE ALL THE PARTICULARS CLEARLY, STRIKE OUT APPROPRIATE BOXES. THIS FORM IS SELF-CARBONIZED PLEASE USE BALLPOINT PEN !

A. SITE OF EXCAVATION:…………………………………………………………………………………….

B. DATE OF ISSUE:……………………….

REFERENCE DRAWING NO. ……………………………………………………………………………….

VALID TILL. ……………………………

C. NOTIFICATION TO EXCAVATE APPROXIMARELY……………….M/FT. DEEP MANUAL IN OPEN GROUND 7) GATCH PIT

□

□

3) ACROSS ROADWAY

8) DISPOSAL PIT

□

□

9) FTC

4) ACROSS FOOTPATH

□

10) OIL LAKE

□

□ 5)

□

MECHANICAL

□

ACROSS DRAIN/FLUME

□ RESIDENTIAL □

1) IN-PLANT AREA

□

11) CUTTING TANK BUND WALL

6)

□

D. PURPOSE ………………………………………………………………………………………………………………………………………………………… E. NAME OF ORIGINATOR . ………………………………….

. ……..CONTROLLING TEAM / COMPANY / AGENCY ……………………….….…

Designation & KOC / ID No…………………………………. Signature…………………………. Date …………………… Phone ………………….… F. □ Name ………………………………………….KOC No. ……………Signature……………………Date …………………… Phone…………………….. Prod. Supvr. (N / E / W / S) Remarks …………………………………………………………………………………………………………………………………………………………… □ Name ………………………………………… KOC No …………….Signature…………………… Date ……………………Phone…………………….. Gas Opns. Supvr. Remarks …………………………………………………………………………………………………………………………………………………………… □ Name ………………………………………… KOC No …………….Signature…………………… Date ………………… Phone…………………….. Marine Opns / Marine Svcs. Remarks …………………………………………………………………………………………………………………………………………………………… □ Name ………………………………………… KOC No …………….Signature………………………Date ………………… Phone…………………….. Export Opns. / Export Svcs. Remarks …………………………………………………………………………………………………………………………………………………………… □ Name ………………………………………… KOC No …………….Signature…………………….. Date ………………… Phone……………………… Water Handlg. Team (N / W) Remarks …………………………………………………………………………………………………………………………………………………………… □ Name ………………………………………… KOC No ….………….Signature……………………. Date ………………… Phone……………….…….. Zone Maint.Engr. (N / E / W / S) Remarks …………………………………………………………………………………………………………………………………………………………… □ Name ………………………………………… KOC / ID No …………Signature……………………. Date ………………… Phone…………………….. Zone Electrical Engr. (N / E / W / S / Ahmadi / MEW) Remarks …………………………………………………………………………………………………………………………………………………………… □ Name ………………………………………….KOC / ID No … .……..Signature……………………. Date ………………… Phone…………………….. Zone Instrument Engr. (N / E / W / S / Ahmadi / MEW) Remarks …………………………………………………………………………………………………………………………………………………………… □ Name …………………………………………. KOC No …………...Signature…………………… Date ………………… Phone…….…………………. Inspection & Corrosion Engr. (N / E / W / S) Remarks …………………………………………………………………………………………………………………………………………………………… □ Name ………………………………………… KOC No …………….Signature…………………... Date …………………… Phone…………………….. Gas & Water Engr. (Ahmadi / MEW) Remarks …………………………………………………………………………………………………………………………………………………………… □ Name ………………………………………… KOC No …………….Signature……………….…. Date …………………… Phone…………………….. A/C & R Engr. Remarks …………………………………………………………………………………………………………………………………………………………… □ Name ………………………………………… KOC No ….………….Signature…………………. Date ………………….… Phone…………………….. Local Relation Team Remarks …………………………………………………………………………………………………………………………………………………………… □ Name ………………………………………… KOC No ……………..Signature………………….. Date …………………… Phone…………………….. * Road Engineer Remarks …………………………………………………………………………………………………………………………………………………………… □ Name ………………………………………… KOC No ……………..Signature…………………… Date ………………….. Phone…………………….. ** Fire Team Remarks …………………………………………………………………………………………………………………………………………………………… □ Name ………………………………………… KOC No ….………….Signature…………………… Date ……………….… Phone…………………….. *** Health & Environment Team. (Corporate) Remarks …………………………………………………………………………………………………………………………………………………………… □ Name ………………………………………… KOC No ……………..Signature…………………. Date …………………… Phone…………………….. HSE Team (N / SEK / W / E&MO) Remarks ……………………………………………………………………………………………………………………………………………………………

2)

: ‫ﻤﻼﺤﻅﺎﺕ ﻫﺎﻤﺔ‬ . ( ‫ﺇﺨﻁﺎﺭ ﺍﻟﺤﻔﺭ ﺼﺎﻟﺢ ﻟﻤﺩﺓ ﺜﻼﺜﺔ ﺃﺸﻬﺭ ﻤﻥ ﺘﺎﺭﻴﺦ ﺍﻹﺼﺩﺍﺭ) ﻤﻥ ﺘﺎﺭﻴﺦ ﺘﻭﻗﻴﻊ ﻤﺎﻟﻙ ﺍﻟﻤﻨﻁﻘﺔ‬

(1

.‫ﻻ ﻴﺴﻤﺢ ﺍﻟﺘﺼﺤﻴﺢ ﺃﻭ ﺍﺴﺘﻌﻤﺎل ﺍﻟﺤﺒﺭ ﺍﻷﺒﻴﺽ ﻋﻠﻰ ﻭﺭﻗﺔ ﺍﻷﺨﻁﺎﺭ‬

(2

‫ﻗﺒل ﻗﻁﻊ ﺍﻟﻁﺭﻕ ﻷﻏﺭﺍﺽ ﺍﻟﺤﻔﺭ ﻴﺠﺏ ﺃﺨﺫ ﺇﺫﻥ ﻤﺴﺒﻕ ﻗﺒل ﺒﺩﺀ ﺍﻟﻌﻤل ﺒﺜﻼﺜﺔ ﺃﻴﺎﻡ ﻭﺫﻟﻙ ﻤﻥ ﻓﺭﻴﻕ ﺍﻟﻌﻤل ﺍﻟﻤﺴﺅﻭل ﻭﻓﺭﻴﻕ ﻋﻤل ﺍﻟﺼﺤﺔ ﻭﺍﻟﺴﻼﻤﺔ‬

(3

. ‫ﻭﺍﻟﺒﻴﺌﺔ ﻓﻲ ﺍﻟﻤﻨﻁﻘﺔ‬ .‫ ﺤﻴﺙ ﻴﻭﻀﺢ ﻋﻠﻴﻬﺎ ﺍﻟﻤﻨﻁﻘﺔ ﻭﺍﻟﻤﻭﻗﻊ ﺍﻟﺫﻱ ﺴﻴﺘﻡ ﺍﻟﺤﻔﺭ ﻓﻴﻪ‬،‫ﻴﺠﺏ ﺃﻥ ﻴﺼﺎﺤﺏ ﻫﺫﺍ ﺍﻹﺨﻁﺎﺭ ﺍﻟﻤﺨﻁﻁﺎﺕ ﺍﻟﺴﺎﺭﻴﺔ ﻭﺍﻟﻤﻌﺘﻤﺩﺓ ﻤﻥ ﻗﺒل ﺸﺭﻜﺔ ﻨﻔﻁ ﺍﻟﻜﻭﻴﺕ‬

(4

.‫ﻋﻨﺩ ﺍﻜﺘﺸﺎﻑ ﺨﺩﻤﺎﺕ ﺃﺜﻨﺎﺀ ﺍﻟﺤﻔﺭ ﻏﻴﺭ ﻤﻌﺭﻭﻓﺔ ﻤﺴﺒﻘﹰﺎ ﻴﺠﺏ ﺇﺒﻼﻍ ﻓﺭﻴﻕ ﺍﻟﻌﻤل ﺍﻟﻤﺴﺅﻭل‬

(5

.‫ﻴﺠﺏ ﻋﻠﻰ ﻤﻤﺜل ﺍﻟﻤﻘﺎﻭل ﺍﻟﺘﻨﺴﻴﻕ ﻤﻊ ﻓﺭﻕ ﺍﻟﻌﻤل ﺍﻟﻤﻌﻨﻴﺔ ﻓﻲ ﺍﻟﺸﺭﻜﺔ ﻟﻠﺤﺼﻭل ﻋﻠﻰ ﺘﺼﺭﻴﺢ ﻭﺘﺨﻭﻴل ﺒﺎﻟﺤﻔﺭ‬

(6

‫ ﻜﻤﺎ ﻴﺤﻀﺭ ﺇﺠﺭﺍﺀ ﺃﻱ‬، ‫ﻴﺠﺏ ﺍﻹﺒﻼﻍ ﻋﻥ ﺃﻱ ﻀﺭﺭ ﻓﻲ ﺍﻟﺨﺩﻤﺎﺕ ﻟﻔﺭﻴﻕ ﺍﻟﻌﻤل ﺍﻟﻤﺴﺅﻭل ﻭﻟﻤﺤﻁﺔ ﺇﻁﻔﺎﺀ ﺒﺭﻗﺎﻥ‬

(7

‫ﻴﻜﻭﻥ ﻓﺭﻴﻕ ﺍﻟﻌﻤل ﺍﻟﻤﺴﺅﻭل ﻋﻥ ﺍﻟﻤﻨﻁﻘﺔ ) ﺍﻟﻤﺼﺩﺭ ﻟﻠﺘﺼﺭﻴﺢ ( ﺃﻭل ﻤﻥ ﻴﻘﻭﻡ ﺒﺘﻭﻗﻴﻊ ﺍﻟﺘﺼﺭﻴﺢ ﻭﻴﺤﺩﺩ ﻓﺭﻕ ﺍﻟﻌﻤل ﺍﻟﻤﻌﻨﻴﺔ ﺍﻷﺨﺭﻯ ﺍﻟﺘﻲ ﻴﻨﺒﻐﻲ ﺃﻥ ﺘﻭﻗﻊ‬

(8

‫ﺇﺼﻼﺡ ﻟﻸﻀﺭﺍﺭ ﺇﻻ ﺒﻌﺩ ﺃﺨﺫ‬

. ‫ﺍﻟﻤﻭﺍﻓﻘﺔ ﻤﻥ ﻓﺭﻴﻕ ﺍﻟﻌﻤل ﺍﻟﻤﺴﺅﻭل ﺫﺍﺕ ﺍﻟﻌﻼﻗﺔ ﺒﺎﻟﺨﺩﻤﺎﺕ ﺍﻟﻤﻌﻨﻴﺔ‬

.‫ ﻋﻠﻰ ﺃﻥ ﻴﻜﻭﻥ ﺁﺨﺭ ﺘﻭﻗﻴﻊ ﻤﻥ ﻓﺭﻴﻕ ﻋﻤل ﺍﻟﺼﺤﺔ ﻭﺍﻟﺴﻼﻤﺔ ﻭﺍﻟﺒﻴﺌﺔ ﻟﻠﻤﻨﻁﻘﺔ‬،. ‫ﻋﻠﻰ ﺍﻟﺘﺼﺭﻴﺢ‬

. ‫ ﻭﻴﺠﺏ ﺃﻥ ﻴﻜﻭﻥ ﺍﻹﺨﻁﺎﺭ ﻓﻲ ﻤﻭﻗﻊ ﺍﻟﺤﻔﺭ ﻁﻭﺍل ﺍﻟﻭﻗﺕ‬،‫ﻴﻌﺘﺒﺭ ﺇﺨﻁﺎﺭ ﺍﻟﺤﻔﺭ ﺍﻟﺼﺎﺩﺭ ﺼﺎﻟﺢ ﻓﻘﻁ ﻟﻌﻤﻠﻴﺔ ﺤﻔﺭ ﻭﺍﺤﺩﺓ‬

(9

. ‫ ﻭﺇﺫﺍ ﻜﺎﻨﺕ ﺍﻟﻤﻌﻠﻭﻤﺎﺕ ﻏﻴﺭ ﻭﺍﻀﺤﺔ ﻴﺠﺏ ﺍﻟﺤﺼﻭل ﻋﻠﻰ ﺇﺨﻁﺎﺭ ﺤﻔﺭ ﺠﺩﻴﺩ‬،‫( ﻴﺠﺏ ﺃﻥ ﻴﻜﻭﻥ ﺇﺨﻁﺎﺭ ﺍﻟﺤﻔﺭ ﻭﺍﻀﺢ ﺍﻟﻤﻌﻠﻭﻤﺎﺕ‬10 .‫( * ﺒﺎﻟﻨﺴﺒﺔ ﻟﻘﻁﻊ ﺍﻟﻁﺭﻕ ﻭﺍﻟﻤﻤﺭﺍﺕ ﻭﺍﻟﻘﻨﻭﺍﺕ ﺍﻹﺴﻔﻠﺘﻴﺔ ﻴﺠﺏ ﺇﺒﻼﻍ ﻤﻬﻨﺩﺱ ﺍﻟﻁﺭﻕ ﺒﻌﺩ ﺇﺘﻤﺎﻡ ﺍﻟﻌﻤل‬11

. ‫ ﻭﺨﺼﻭﺼﹰﺎ ﺍﻟﺒﺎﺏ ﺍﻟﺜﺎﻤﻥ ﻋﺸﺭ‬،‫( ﻴﺠﺏ ﺍﻻﻟﺘﺯﺍﻡ ﺩﺍﺌﻤﺎ ﺒﻨﻅﻡ ﺍﻹﻁﻔﺎﺀ ﻭﺍﻟﺴﻼﻤﺔ ﺍﻟﻤﻌﻤﻭل ﺒﻬﺎ ﻓﻲ ﺍﻟﺸﺭﻜﺔ ﺃﺜﻨﺎﺀ ﺍﻟﺤﻔﺭ ﻭﺒﻌﺩ ﺍﻻﻨﺘﻬﺎﺀ‬12 .‫ ﻋﻠﻤﺎ ﺒﺄﻥ ﺘﺼﺭﻴﺢ ﺍﻟﻌﻤل ﻟﻴﺱ ﻀﺭﻭﺭﻴﹰﺎ‬، ‫( ﻴﻌﺘﺒﺭ ﻫﺫﺍ ﺍﻹﺨﻁﺎﺭ ﺴﺎﺭﻯ ﺍﻟﻤﻔﻌﻭل ﻤﻊ ﻭﺠﻭﺩ ﺃﻤﺭ ﺍﻟﻌﻤل ﺒﺎﻟﻨﺴﺒﺔ ﻟﻤﺩﻴﻨﺔ ﺍﻷﺤﻤﺩﻱ‬13 . ‫( ﻴﻤﻜﻥ ﻟﻔﺭﻴﻕ ﺍﻟﻌﻤل ﺍﻟﻤﻌﻨﻲ ﺇﻀﺎﻓﺔ ﺃﻱ ﺘﻌﻠﻴﻤﺎﺕ ﺨﺎﺼﺔ ﺒﺎﻟﺴﻼﻤﺔ ﻭﺃﻤﻥ ﺍﻟﻌﻤل ﺇﻟﻰ ﺇﺨﻁﺎﺭ ﺍﻟﺤﻔﺭ ﻋﻠﻰ ﺸﻜل ﺃﻭﺭﺍﻕ ﻤﺭﻓﻘﺔ ﺇﻥ ﻟﺯﻡ ﺍﻷﻤﺭ‬14

‫( **ﻴﺠﺏ ﺍﻟﺤﺼﻭل ﻋﻠﻰ ﺘﻭﻗﻴﻊ ﻜل ﻤﻥ ﺭﺌﻴﺱ ﻓﺭﻴﻕ ﻋﻤل ﺍﻹﻁﻔﺎﺀ ﻭﺭﺌﻴﺱ ﻓﺭﻴﻕ ﻋﻤل ﺍﻟﺼﺤﺔ ﻭﺍﻟﺴﻼﻤﺔ ﻭﺍﻟﺒﻴﺌﺔ ﻟﻠﻤﻨﻁﻘﺔ ﻓﻲ ﺤﺎل ﻗﻁﻊ ﺠﺩﺍﺭ ﺍﻟﺴﺎﺘﺭ‬15 .‫ﺍﻟﺘﺭﺍﺒﻲ ﻟﻠﺨﺯﺍﻥ‬ . ‫ ﻭﺤﺩﺓ ﻤﻌﺎﻟﺠﺔ ﺍﻟﺤﻘل ﺃﻭ ﺤﻔﺭ ﺍﻟﺘﺼﺭﻴﻑ‬/ ‫*** ﻴﺠﺏ ﺍﺨﺫ ﺍﻟﻤﻭﺍﻓﻘﺔ ﻤﻥ ﻓﺭﻴﻕ ﻋﻤل ﺍﻟﺼﺤﺔ ﻭﺍﻟﺒﻴﺌﺔ ﻟﺤﻔﺭﺓ ﺍﻟﺠﺘﺵ‬ IMPORTANT INSTRUCTIONS

(16

1) This notification is valid for maximum period of 90 days from date of issuance (i.e. the date Asset Opns /owner has signed). 2) No over-writing or white ink application is allowed on the Excavation Permit. 3) Permission for excavation across roads must be obtained from Controlling Team & respective area HSE Team at least three days prior to commencement of work. 4) This notification shall always be accompanied with a valid & KOC approved drawing (s), the proposed excavation area / part for excavations should be highlighted clearly on the enclosed drawing. 5) Exposed unidentified services must be reported immediately to the Controlling Team. 6) The contractor personnel (competent & duly authorized) shall coordinate with various KOC Teams for authorization & / or endorsement of Excavation Notification. 7) Damaged services must be reported immediately to the Controlling Team and Burgan Fire Station. No repair work should start without consultation with concerned Team. 8) The Controlling Team (Permit Issuer) shall be the first to sign the notification followed by the Asset Owners and then rest of the teams whose signatures are to be obtained. The last signatory will be respective area HSE Team. In case of excavation work by external agencies (such as MPW / MEW etc.) the authorization / endorsement on the excavation notification shall be obtained through KOC Local Relation Team. 9) This excavation notification is valid for a single point excavation only. The original copy of notification shall be available on the worksite all the times. 10) The Excavation Notification must be clear and legible. If the information is not clear then a new excavation Notification is to be obtained. 11) * For road crossings, diversion - detour, paths and flumes, the concerned Road Engineer is to be informed after completion of work. 12) Relevant guidelines, procedures and KOC Fire & Safety Regulations (especially Chapter -18) must be adhered all times. 13) For Ahmadi Township, the excavation notification is valid in conjunction with proper work order. In such case Work Permit is not required. 14) If required the Concerned Team should attach separate sheet(s) for additional instructions (if any) to be given for safety & integrity of work. 15) ** In case of tank bund wall cutting, Fire Team signature shall also be obtained together with respective area HSE Team. 16) *** For gatch pit / FTC or disposal pits, Health & Environment Team signature shall be obtained. WHITE: Worksite Copy BLUE:

Permit Issuer

YELLOW : TL - HSE (Asset)

‫ ﻣﻮﻗﻊ اﻟﻌﻤﻞ‬: ‫اﻟﻨﺴﺨﺔ اﻟﺒﻴﻀﺎء‬ ‫ﻓﺮیﻖ اﻟﻌﻤﻞ اﻟﻤﺼﺮح ﻟﻠﻌﻤﻞ‬: ‫اﻟﻨﺴﺨﺔ اﻟﺰرﻗﺎء‬ ‫ رﺋﻴﺲ ﻓﺮیﻖ ﻋﻤﻞ اﻟﺼﺤﺔ واﻟﺴﻼﻣﺔ واﻟﺒﻴﺌﺔ ﻟﻠﻤﻨﻄﻘﺔ‬: ‫اﻟﻨﺴﺨﺔ اﻟﺼﻔﺮاء‬

KUWAIT OIL COMPANY (K.S.C.)

Certifiacte No.:

Electrical Work Certificate (Valid for the duration of Work Permit)

Permit No:

Location of Work: 1. Details of Electrical Isolation: The electrical equipment as detailed in this certificate as well as mentioned in respective Permit No. has been made safe for the work to proceed Equipment :___________________________________________ Volatage: ___________ AC / DC Work to be done:

Isolations(State where isolated): Earths applied at: Caution Notice posted at: Danger Notice posted at: Control Fuses removed &placed at: Safety Lock Keys Nos: Other Precautions: Name : _____________________________ Designation & Employee No. _______________________ Company / Contractor: Team / Group:__________________ Signature: _______________ Date & Time: _________________ 2. Declaration from Authorized Electrical Person

I have satisfied myself that the equipment as specified in Part 1 of this Certificate is isolated & safe to work on.No attempt will be made by me or by personnel under my control to work on any other equipment.I am personally responsible for asking the necessary safety precautions to avoid danger during work. Name : _____________________________ Designation & KOC No. _______________________ Team / Group:__________________ Signature: _______________ Date & Time: _________________ 3. Declaration for Clearance:

I hereby declare that the workspecified in Part 1 is now Complete Suspended and that all personnel under my control have been warned that it is no longer safe to work on theequipment. All tools, equipment and additional temporary Earth's have been removed. Name : _____________________________ Designation & KOC No. _______________________ Team / Group:__________________ Signature: _______________ Date & Time: _________________

4. Cancellation (I) I delclare that all Earth's listed have been removed & this Electrical Work Certificate cancelled. (ii) The equipment is ISOLATED / DE-ISOLATED (Strike which is not applicable) (iii) Reason for equipment to remain isolated: Name : _____________________________ Designation & KOC No. _______________________ Team / Group:__________________ Signature: _______________ Date & Time: _________________ NOTE:

Electrical Work Certificate is issued by Authrized Electrical Personnel, in conjuction with a primary Work Permit, specifying that the electrical equipment is safe to work on.

INCIDENT REPORT

REF. NO. ALLOCATED BY HSE DEPT.:

Help Box

Mark with an X ALL appropriate box(es) on the form LOCATION REF. No. TO BE FILLED OUT BY ORIGINATOR AND SUPERVISOR 1. TYPE OF INCIDENT Consequences, tick appropriate box Tick appropriate box(es) Incident

Actual Severity

Actual

Injury/Damage etc. Near Miss/ Hazardous Condition

Personal injury Asset damage

Help

Damage to environment Hydrocarbon release Fire/explosion

Help Box

Loss of production Investigation

Damage to reputation Help

Level

Motor Vehicle Accident Other

2. TIME AND PLACE OF INCIDENT Responsible Directorate

Name of installation/site

Module/Area

Date

Time

3. DESCRIPTION OF INCIDENT (Continue on separate sheet if necessary)

References Attached

Sketch

Photo

Additional description

Witness Interview Notes

Help Box

Other, specify

4. WORK OPERATION (tick one box only)

Catering/administration

Maintenance

Transport

Construction/Scaffolding

Offices

Warehousing

Diving

Drilling Operations

Painting/sandblasting

Wireline/well service

Exercises/drills

Pipelaying activities

Offshore Works

Inspection

Production/process

Marine Vessels

Lifting/crane operations

Seismic/survey ops.

Marine Operations

Other, specify

Sub-Activity (description)

Help Box

5. INVOLVED FACTORS

Company Involved System/Facilities Hazardous Substance

6. CONSEQUENCES IN CONNECTION WITH INCIDENT (Not to be filled in for Near Misses or Hazardous Conditions) A. Injury

Injury Class - Tick one box Fatality Permanent Total Disability

Help Box

Permanent Partial Disability

Restricted Work Case

Lost Workday Case

Medical Treatment Case

Nature of Injury - tick appropriate box(es) amputation cuts/lacerations

First Aid Case

fracture

multiple injuries

asphyxia

dislocation

hypothermia

scratches/abrasions

burn (Chemical)

drowning

inflammation

sprains and strains

burn (heat/cold)

effects of chemicals

internal injury

other injury, specify

concussion/brain injury

electric shock

loss of consciousness

crushing/bruises

foreign body

loss of sight

Page 1 of 3

REF. NO. ALLOCATED BY HSE DEPT.

A.

Help Box

Injury (Continued)

Source of Injury - tick one box (explain for "Other") Caught in, under, between

Immersion in sea/wate

Overstrain/exertion

Contact with chemicals

Ionising radiation

Slips/Trips/Fall from Height

Contact with heat

Loss of integrity

Struck by/against

Electricity

Manual handling of materials

Welding flash

Fire, explosion

Mechanical lifting

Other

Hand tools

Motor vehicle

Description of injury

Body Part Injured

Injured party name and initials Employer Days into tour

Occupation/discipline

Hours into shift

Est. No. of Lost/Restricted Workdays

Shift

Sex Male

Day shift

Employment Category Night shift

Contractor

Female

B.

Yes

No

Fire/

In hazardous area

Yes

No

Explosion

Explosion

Yes

No

Help

Detection Manual

Hydrocarbon Release

Ignition Source

Quantity (bbl)

Detection Auto

D. Help Damage to

Type of spill / leak

Extinguishing system activated

less than 1 bbl

31-1000 bbl

1-30 bbl

greater than 1000 bbl

Quantity

Duration bbl

environment

Help Box

Visitor

KOC Employee

Help Hydrocarbon fire

C.

spill to:

Min

Air Sea Ground

7. SIGNATURES Installation/Site Safety Team Leade

Originator Date

Help Box

Age (years)

Date

8. NOTIFYING AND REPORTING Yes No

Line Manager review and approval (if required

Authorities notified Line management notified Incident forms completed Incident investigation completed Report entered in database Experience will be transferred Review panel required

Signature

Date

Page 2 of 3

KOC REF. NO. ALLOCATED BY HSE DEPT.

INCIDENT REPORT ANALYSIS Location: Help Box

Help Box

9. IMMEDIATE CAUSES

Unsafe Practices (Acts and behaviour leading to the incident) Tick appropriate box(es)

Unsafe Conditions (Conditions leading to the incident) Tick appropriate box(es)

1

3rd party action

1

Corrosion/erosion

2

Disconnecting or defeating safety device/equipmen

2

Defective tools and equipmen

3

Horseplay / deliberate violations / infringement

3

Excessive noise/vibration

4

Improper loading, positioning or storing of materia

4

Extreme weathe

5

Improper manual handling practice

5

Falling/incorrectly placed objects

6

Inadequate pre-task checking

6

Fire and explosion hazards

7

Influence of alcohol/drugs

7

Hazardous atmosphere

8

Information error or omission

8

Hazardous substance exposure

9

Lack of attention/forgetfulness

9

Inadequate PPE

10

Leaving, or working in, untidy are

10

Inadequate lighting/illuminatio

11

Misuse/wrong use of equipment/tools

11

Inadequate ventilation/temperature/humidi

12

Not following rules/procedures/permits et

12

Inadequate physical guards or barrier

13

Not observing or using warning/safety devices/equipme

13

Inadequate warning systems/signs

14

Not positioning self properly for tas

14

Ionising radiation exposure

15

Not using PPE or using PPE incorrectly

15

Plant/equipment status not as expecte

16

Operating or working at unsafe speed/short cuttin

16

Poor access, layout congestion

17

Operating or working without authority/permissio

17

Slippery or uneven surface

18

Using defective tools/equipmen

18

Unavailable/missing/lapsed work procedures/instruction

19

Working on equipment in operation

19

Unclear or inadequate work procedures/instruction

20

Other unsafe practices, specify (below

20

Untidy site

21

Other unsafe conditions, specify (below

Help Box

10. ROOT CAUSES (Preliminary assessment)

Personal factors (Weaknesses associated with people) Tick appropriate box(es)

Job-factors (Insufficiently organised work procedures o weaknesses associated with the workplace) - tick approp. Box(es) 1

conflicting/excessive job demands

1

Job Safety Assessment (JSA) not properly execute

2

Excessive physical/mental stress

2

Inadequacies in Permit to Work

3

Improper motivation/inattentio

3

Inadequacies in shift handove

4

Inadequate physical/mental capabilit

4

Inadequate leadership/supervision/plannin

5

Lack of knowledge/skill experienc

5

Inadequate maintenance/inspectio

6

Lack of knowledge of/respect for procedure

6

Inadequate purchasing/procuremen

7

Lack of training

7

Inadequate tools and equipmen

8

Misperception of risk

8

Inappropriate design/layout/constructio

9 10

Poor team dynamics/tensions Other human factors, specify (below

Help Box

9

Poor housekeeping standards

10

Unclear or inadequate work procedures/instruction

11

Unclear organisation or responsibilitie

12

Wear and Tear

13

Other job factors, specify (below

11. CORRECTIVE/REMEDIAL ACTIONS (continue on separate sheet if necessary) Description of Action

Priority

Help Box

Help Box

12. OTHER COMMENTS

Page 3 of 3

Name of action

Estimated

Party

Completion date

Kuwait Oil Company (K.S.C) HAZARD OBSERVATION CARD

Location:

Date:

No. …………

Time:

Project Title : Issued To:

Issued By: A- HAZARD TYPE Unsafe Act/Condition

Nearmiss Condition

Immediate/Potential Danger

B- Work Permit Procedure Not Followed

Not Available

Not Aware

C- WORK HAZARD Energised Equipment/Lines

Improper PPE

No Safe Access /Exit

Improper Isolation & Ventilation

Safety Equipment / Sign Missing

Safety System Bypassed

(Personal Protective Equipment)

D- ENVIRONMENTAL & HEALTH HAZARD Noise

Hydrocarbon Leakage

Chemical Spillage.

Dust

Inadequate illumination

Toxic Gas (H2S) Leakage Poor House Keeping

Thunder Storm & Lightning E- TOOLS & EQUIPMENT Defective Tool / Incorrect Use

Lack of Lifting Appliance Certification

Left in Unsafe Condition

Unsuitable for Hazardous Area

Hazard Description & Recommended Corrective Action

(

) Signature

(

) Date

(

) Name & Designation

N.B : This card is to be handed over to Asset Owner / Sponsoring Team for urgent action Disribution: Original Copy - Asset Owner /Sponsor; 2nd Copy - Area HSE Team; 3rd Copy -File Page - 1/2 Pl. Turn Over

Corrective Action Taken By Asset Owner/Sponsor

)

(

(

)

(

Date

Signature

) Name & Designation

Area HSE Team's Comments on Corrective Action

)

( Signature

(

) Date

(

) Name & Designation

Page - 2/2

Document Title : Hazard Observation Card

Document No . S / CL - 7 / 03 Prepared & Issued By: Safety Team - HSE Group; Kuwait Oil Company (K.S.C.) Rev. 2, Dated: Rev. 0 , Dated: 20th Sep 2003 Rev. 1, Dated:

Kuwait Oil Company (K.S.C)

No. …………

SAFETY CHECK LIST - FOR OFFICE / NON-INDUSTRIAL ACTIVITY Location:

Date:

Time:

Team & Group: Issued By:

Issued To:

A- HAZARD TYPE Unsafe Act

Unsafe Condition

Immediate/Potential Danger

B- FIRE HAZARD Combustible Material

Flammable Material

Source of Ignition

C- NATURE OF HAZARD Slipping / Tripping / Falling

Horseplay

Unsafe Access /Exit /Obstruction

Falling Objects

Safety Equipment / Sign Missing

Safety System Bypassed

Poor Sitting Facility

Improper Access to Racks & Cabinets

D- TOOLS, EQUIPMENT & STATIONERY ITEMS Defective Tool / Incorrect Use

Equipment / Elertical outlet Overload

Left in Unsafe Condition

Defective Furnitures

Exposed Sharp Edge / Pointed Object

Electrical Equipment Ungrounded

Loose Power Cable on the ground

Filing Cabinets - Improperly Supported

E- OTHER HAZARD Noise

Water Leakage /Ingress

Blocked Drainage

Dust

Inadequate illumination

Inadeqaute Ventilation

No Container for Recycle Material

Poor House Keeping

Excessive Heat

Insects & Reptiles

Odour

Hazard Description & Recommended Corrective Action

(

Signature

)

(

) Date

Page - 1/2

(

) Name, Designation & KOC No.

Pl. Turn Over

Corrective Action Taken By Asset Owner/Sponsor

Name: Designation & KOC No.: Team / Group: Signature:

Date: Area HSE Team's Comments on Corrective Action

Name: Designation & KOC No.: Team / Group: Signature:

Distribution

Date:

Page 2/2 (I) 1st Copy - Asset Owner (………………………………… ..…) Team (II) 2nd Copy - Area HSE Team (……………………….) (III)3rd Copy - File

Document Title : Safety Checklist for Office / Document No . S / CL - 5 / 03 Non-Industrial Activity Prepared & Issued By: Safety Team - HSE Group; Kuwait Oil Company (K.S.C.) Rev. 0 , Dated: 20th Sep 2003 Rev. 1, Dated: Rev. 2, Dated:

KUWAIT OIL COMPANY (K.S.C.) Safety Team SAFETY CHECK LIST FOR VEHICLE/EQUIPMENTENTERING INTO HAZARDOUS ZONE/ OPERATION AREAS/ KOC FIELD AREAS

Vehicle KT No.: --------------------Main Contractor:-------------------------------Sr. No.

1

2

CHECK LIST ITEMS REQUIREMENTS

Driver License/Registration book/Area Pass Engine/Vehicle/Smoke& Fire

3

Puncture/ Skidding and break down

4

Rear View Mirrors

5

Lighting & illumination

6 7 8 9 10 11 12 13 14 15

KOC Fleet No.--------------------Type of Vehicle: --------------------Sub-Contractor: --------------------------------- Contract No: --------------------------

Head lights (high-low beam) Signal Lights (left, right and blinking) Break Lights Emergency Lights Reverse Lights Parking light Windscreen Wipers Seat Belt Exhaust Tail Pipe DC Current Battery

Valid and Renewed -Have Fire Extinguisher of approved type & size and quantity. Obtain certificate from Burgan Fire Station. Use std. clean filter and leak proof fuel system Good Condition of Tyre, min. tread depth 1/8”, a set of standard tool kit including a Jack and wheel spanner Good condition. Working condition and fitted with standard glasses, not cracked or broken. Working condition. Working condition. Working condition. Working condition. Working condition. Working condition Working condition Good condition UL/FM/LPC Approved make Spark Arrestor properly fitted Terminals of Battery Leads are clamped/bolted firmly with cap

COMPLIANCE YES NO

Initial Declaration of 1st Party

Remarks from KOC Inspector (1) (after verification with documentary evidences)

Remarks from KOC Inspector (2) (after verification with documentary evidences)

Sr. No.

CHECK LIST ITEM REQUIRMENTS

Entrapment 16 Electrical Wiring 17 18 19 20 21

22

23 24 25 26 27 28 29 30

Static charge development Medical Aid Tyre pressure Record Keeping – of Servicing System Failure (break, hydraulic, alarm horn and light, wire rope drum ratchet, tip hook, wire rope etc. Foot and Hand break Safety Chains & Airlines 5th wheel and pin Air Compressor Pressure Gauge Load Binder chain Boomer Spanner Noise Pollution Seating and Cushioning

31 General Information 32

Should have unfettered emergency Access door(s) /window(s) – Passenger bus only. Terminals of all wirings are tightened properly using terminal lugs and no hot joints are present Vehicle seats are provided with antistatic materials An approved type of first aid box should be kept Standard –front & rear A log Book to be kept indicating by authorized person that routine maintenance/service and electrical checks are carried out A copy of Inspection certificate issued by an authorized competent third party shall be kept at all time in the equipment Good condition (minimum 80%) Standard and Secured Standard and Secured Working condition Working condition, duly calibrated Standard and Good condition Standard and Good condition Engine sound level shall not be more than 85 dBa at 1m. Distance Seats and cushions shall be in good condition, no metal part of seats shall be exposed. Seat frames shall be firm and rigid All vehicle/equipment shall be provided with high visible signs of emergency telephone numbers

COMPLIANCE Yes No

Initial Declaration of 1st Party

Remarks from KOC Inspector (1) (after verification with documentary evidences)

Remarks from KOC Inspector (2) (after verification with documentary evidences)

(fire, ambulance, Police etc)

NO

CHECK LIST ITEM REQUIRMENTS

33

34

Regulatory Information

Special Information

Rupture/Release

35

36

General Condition

COMPLIANCE Yes No

Initial Declaration of 1st Party

Remarks from KOC Inspector (1) (after verification with documentary evidences)

Remarks from KOC Inspector (2) (after verification with documentary evidences)

Vehicle/equipment is available with a valid registration certificate 1) Vehicle carrying radioactive substance shall be provided with (inside and outside of the vehicle) radiation caution sign & symbol 2) All emergency tel. Numbers together with emergency telephone number of MOH – radiology section and Contractor’s contact person telephone number shall be provided on the outer surface of the vehicle 1) Vehicle mounted tanks/ vessels shall be pressure/hydraulic tested at least once a year 2) Safety valves, Isolation valves and the condition of associate piping, instruments shall be checked, tested and calibrated at least once a year The vehicle shall be clean & tidy, free from rust/greasy/oily floor

Team. ………………………Checked by: ------------------------- Degn.. ----------------------------- Tel. No. ------------------- Date: ------------------- Signature -----------------------Team. ………………………Checked by: ------------------------- Degn.. ----------------------------- Tel. No. ------------------- Date: ------------------- Signature -----------------------Note: 1) Pickup truck shall not be provided with seats in the back unless included in the exception list. 2) Driver must not carry non-intrinsically safe Portable Electronic Devices (PED’s) inside the Hazardous area 3) Crane of all types, Material Handlimg Equipments/Earth Moving Equipments etc. must have a valid test certificate issued by an authorized, competent third party/ agency

Kuwait Oil Company

Fire & Safety Regulations

(K.S.C.)

Appendix No. 9 June 2004

SAFETY FACTORS FOR PRODUCT TRANSFER PUMPS APPENDIX - 9

SAFETY FACTORS FOR PRODUCT TRANSFER PUMPS Product Transfer Pump shall be suitable for continuous operation at a desert location under high ambient temperature and humidity. The atmosphere at the facility is generally dusty, corrosive and may contain traces of Hydrogen Sulphide. The pumpset shall be designed and constructed as a baseplate mounted package consisting of all parts and accessories associated with the system. Pumps handling "low flash" stocks or stock at a temperature above their "flash point" and which are located in an enclosed pump house, shall be housed separately from the prime movers and be driven by jack shafts passing through gas tight glands set in gas tight walls, unless the driving units are electric motors of flameproof or explosion proof construction. In such a situation the pump housing must be kept well ventilated and no source of ignition shall be brought inside it. Any maintenance or maintenance work to be carried out inside the Pumphouse must be duly authorized under appropriate work permits. BASIC SAFETY REQUIREMENT FOR PUMPS: Equipment noise levels shall not exceed the limits stated on the equipment datasheets. Where excessive noise cannot be eliminated by low noise design, corrective measures shall the form of acoustic insulation of pipes, gearboxes and other ancillaries. Suitable fire detection and fire protection system shall be provided for pumps handling hydrocarbon products. Fire Team should be consulted for approval of fire protection system concerning hydrocarbon-handling pumps. All pumps shall be provided with valved drain and vent (where necessary) connection. Such valves shall have tight shutoff characteristics. The use of any threaded connections shall be subject to KOC approval. Pumps fitted with anti-friction bearings not equipped with dedicated vibration detection sensors shall have facility at the bearing housings to enable periodic vibration measurements to e recorded using portable monitoring equipment. When a pressure lubrication system is specified, all logic function related to the later required for the start up and shutdown of the pumpset shall be provided. All necessary pipework, orifices, flow indicators, coolers, strainers, gauges, valves and instruments shall be provide when required or specified on the equipment data sheets. Pumps operating at a pressure of 600-800 psi (43.8 - 58.4 kg/cm2) and up are subject to massive leaks in event of seal failure. Such pumps shall be fitted with a double seal with a pressure sensor between the seals arranged to activate an alarm in the Control Room. Where such pumps are installed at normally unattended locations, the sensor shall provide automatic shut down and alarm facilities. F&S Regulations Appendix 9

June 2004

Page 1

KOC F&S Regulations

SAFETY FACTORS FOR PRODUCT TRANSFER PUMPS

Where pumps handling "low flash" hydrocarbons or flammable gases are located at remote or normally unattended locations, seal leak, heat detection and vibration monitors shall be installed and linked to automatic shut down & alarm system. In the case of pumps handling flammable liquids, oil leaking from pump glands shall be piped to an oil drainage system or to a sump at a safe distance from the pumps. Centrifugal pumps must be fitted with non-return valves on the discharge side. Positive displacement pumps shall have a by-pass valve or other suitable protection against over pressure or overloading. Positive displacement pumps shall have suction and / or discharge pulsation suppression devices where required or when recommended by approved pump’s manufacturers. BASE PLATE FOR HORIZONTAL PUMPS: Base plates for all drivers in excess of 60 HP shall be provided with horizontal jacking devices to facilitate lateral adjustment of the driver. DYNAMIC BALANCE OF VERTICAL PUMPS: All double suction impellers shall be dynamically balanced. DRIVING UNITS: where pumps are driven mechanically, electric motors, diesel engines or gasoline engines commonly drive them. In all such cases, the driving units shall be sized for continuous duty at maximum rated capacity and in the climatic conditions prevailing in Kuwait. The motors and its ancillaries shall be suitable for respective hazardous area classification. Turbo charged diesel engines may cause high exhaust temperature, which must be taken into consideration for use in oil installations. Diesel engines shall be fitted with an overspend shutdown device on the air intake and additionally an approved type of spark arrestor shall also be fitted at the downstream of exhaust manifold. PROTECTIVE DEVICES: •

Thermal Protection of the motor windings shall be provided.

•

Over-current protection in the form of magnetic overloads (oil dashpot type) shall be provided.

Running Dry: A reliable level-detecting device must be provided with arrangement to deenergized the motor, if the liquid levels falls to such an extent that the motor fails to be flooded completely by the liquid being pumped. Earth Fault protection: An earth fault relay set at 15% of full load current and hand reset provision, connected to a ring type current transformer shall be provided. Flexible armoured cables exceeding 1m in length shall be mechanically protected. Indication & Reset: Visual indication and hand-reset feature shall be provided on each protective device. Motor Re-Acceleration: Control circuits developed to satisfy the above requirements shall include arrangements enabling the motor to re-accelerate after a momentary electricity supply interruption.

F&S Regulations Appendix 9

June 2004

Page 2

KOC F&S Regulations

SAFETY FACTORS FOR PRODUCT TRANSFER PUMPS

Terminal Boxes: All electrical competent exposed to atmosphere, such as terminal boxes, shall be of certified flameproof construction. Guards: All external moving parts shall be shielded to prevent accidents & injury to personnel. Shutdown: There shall be provision for rapid shutdown of the unit in an emergency situation.

F&S Regulations Appendix 9

June 2004

Page 3

Kuwait Oil Company

Fire & Safety Regulations

(K.S.C.)

Appendix No. 10 June 2004

ELECTRICAL WORK SAFETY APPEDIX – 10 ELECTRICAL WORK SAFETY

1.

DEFINITIONS: The terms used in the regulation are as defined hereunder. •

The "Company Power System" comprises all electrical equipment and apparatus utilized in the generation, transmission and distribution of electrical power up to & including the service fuses at consumer end.

•

An "Authorised Person" shall be duly nominated as such by the concerned Team Leader or his / her accredited representative, and shall be responsible for carrying out activities such as switching operations, isolating & earthing of apparatus within defined limits, under compliance to Company's Safety Rules and statutory Regulations relevant to the work in hand.

•

A "Competent Persons" is a person over 21 years of age, who has sufficient technical knowledge, skill and experience to assess potential hazards & corrective measures, and he / she has been duly nominated as such by the concerned Team Leader or his/ her accredited representative.

•

"High Voltage Apparatus”: - Any apparatus operated at high voltage.

•

"High Voltage": - A system voltage with 3300 volts and above.

•

"Medium Voltage": - A system voltage exceeding 440 volts up to 3300 volts.

•

"Low Voltage": -A system voltage not exceeding 440 volts.

•

"Substation": - refers to any premises, part of any premises, or outdoor erection with switchgear / transformer / other electrical equipment, in which electrical energy is controlled, transformed or converted.

•

The term "Earthed" applied to High Voltage Apparatus means that all phases have been connected to the general mass of earth in such a manner that will ensure an immediate discharge of electrical charges without danger.

•

A "Substation Log Book" is a book kept in a substation in which any operation performed or work done in the substation, (including its apparatus or feeders) are recorded.

•

A "Caution Notice" is urgent information or message attached to the apparatus, intended to warn against unauthorized interference, alerting about work in progress on the apparatus or conductors controlled thereby.

•

An "Earthing Notice" is urgent information or message attached to switchgear conveying to warn that the feeder or apparatus powered from this switch has been earthed at a point or points remote from the switch stating the location of the earths.

F&S Regulations Appendix 10

June 2004

Page 1

KOC F&S Regulations

ELECTRICAL WORK SAFETY

•

A "Danger Notice" is an urgent information or message attached to a live or energised apparatus calling attention to the danger involved, or interference with such apparatus.

•

A "Safety Padlock" is a device intended to immobilize the unauthorized interference or de-isolation of a switchgear, apparatus locked off / earthed for safe progress of work.

•

FAILURE OF ELECTRICAL POWER SUPPLY: During temporary failures of electrical power supply, all apparatus connected to the Company's power system must be regarded as being live or energised, unless isolated from the system in accordance with standard & proven practice.

2.ELERTICAL SAFETY CONSIDERATIONS: The following safety considerations shall be kept in view while carrying out any work associated with electrical power system in company premises: A.

B.

WORK INSIDE ELECTRICAL SUBSTATION: •

Any work inside electrical substation shall be carried out with due authorization of appropriate work permit. The work shall be performed under direct supervision of a competent electrical person, who shall record in the sub-station logbook the date, time and the extent of the work undertaken.

•

The competent electrical person shall remain present in the substation during the entire work period. He shall take every reasonable precautionary measure for the safety of workers under his supervision, satisfying himself that each individual understands the potential hazards associated with the work. The competent person in charge shall also record the date and time when the work is completed, in the substation logbook.

•

Prior to starting a work or inspection activity inside an Electrical Substation protected by CO2 flooding system (automatic fire extinguishers), a competent & authorized person shall override CO2 system and he will also ensure its proper re-commissioning immediately after the protected Zone is evacuated. The system override shall be also recorded in the substation logbook.

OPERATION ON HIGH VOLTAGE SWITCHGEAR:

F&S Regulations Appendix 10

•

Any work on High Voltage Switchgears or Fusegears installed on Company’s electrical power system shall be carried out by a nominated and authorised person only, who will take all necessary precautions against potential hazards in compliance to Work Permit System.

•

Every operation on High Voltage switchgears or fusegears must be recorded in the substation logbook, indicating the date and time of such operations. The record must be approved & countersigned by the authorised electrical person.

•

In an emergency situation, anyone may isolate a high Voltage switch; however such action must be immediately reported to the respective authority. June 2004

Page 2

KOC F&S Regulations C.

D.

ELECTRICAL WORK SAFETY

WORKS ON HIGH VOLTAGE APPARATUS: No persons shall, under any circumstances, do any work on high Voltage apparatus, unless such apparatus has been isolated and earthed in accordance with the precautionary measures as hereunder: •

When work is to be carried out on High Voltage Apparatus, it shall be isolated from all source of supply. Such isolations shall be perfumed by the nominated and authorised electrical person only.

•

The potential transformers shall be isolated from the feeder or apparatus on which work is to be carried out. .

•

Once isolated, each conductor shall be earthed, either through the circuit breaker, or by fixed earthing switches, or by means of installing a copper conductor of minimum cross section 25 sq. mm connected to the earth and fixed securely in contact with the conductor. The position of earths shall be secured such that it does get detached from earth during the work.

•

When circuits are earthed through a CB, the protective gears must be made operative when closing by insertion of jumped wires / plugs. After the CB has been closed the trips should be rendered inoperative and the mechanism locked off.

•

Proper screens barriers duly attached with Danger Notices shall be fixed inposition to prevent accidental contact with any adjoining live conductors.

•

Safety padlocks shall be applied to lock open all switches at points where the earthed circuit could be energised, to lock shutters over live spouts and lock switches in the earthed position. Caution notices shall be attached to each of such switches, or supply points.

•

An earthing Notice stating the location of all earths shall be attached to the switch.

•

When high Voltage Apparatus has been isolated and earthed and permit authorized & issued, such apparatus shall not be made alive until all works have been duly completed as per Permit to Work procedure.

•

After completion of the work, the authorized electrical person in agreement with Permit Issuer & Permit Applicant shall remove the earth connections, and where possible shall megger test the conductors to ensure that it is clear between phases, and to earth, before proceeding to High Voltage test or reenergise the apparatus, as may be required.

WORKS ON HIGH VOLTAGE CABLES: Before any work is carried out on High Voltage Cables, which have been isolated in accordance with Work Permit requirement, such cables shall be spiked at the point where it is to be cut, by means of a spiking gun or by having a wooden-shafted steel-shod spike earthed and driven into the cable. In a hazardous area a Hot Work Permit & Gas Free Certification shall be obtained and approved before spiking any cable.

F&S Regulations Appendix 10

June 2004

Page 3

KOC F&S Regulations E.

ELECTRICAL WORK SAFETY

WORK ON HIGH VOLTAGE OVERHEAD LINES & OUTDOOR APPARATUS: Before any work is carried out on a High Voltage overhead lines which have been isolated in accordance with Work Permit requirement, such overhead lines shall be proved dead by using: •

An earth stick to bring into contact with each conductor a length of copper wire previously connected to the pole earth.

•

Or by throwing such a length of copper wire chain over line in such a way as to shorten and earth the conductors, at the point where the work is to be commenced, and temporary earth connections shall be made at each side of the work.

The earth lead shall be considered to be alive at full line voltage until after the line has been proved dead by the foregoing test. Work shall be carried out by a nominated and authorized person who can ascend on any pole or tower supporting live conductors provided that he does not ascend beyond a position where it is possible to bring any part of his body or any working tool within the following distances of any exposed live conductors: Not exceeding 11 KV .. Exceeding 11KV but not exceeding 33KV Exceeding 33KV but not exceeding 66KV F.

.. ..

1m 1.2 m 1.8 m

WORK ON MEDIUM & LOW VOLTAGE CABLES: Before work is carried out on any medium & / or low Voltage cables, it shall, be isolated and caution notices posted on the switchgears or fusegears feeding it. In unavoidable circumstances where work is carried out on a live cable, then only one conductor should be bared at a time and suitable protective equipment such as rubber boots, rubber mats or rubber gloves shall be used. The lead sheath shall be bonded across with an insulated conductor of appropriate acrosssection before cutting it to ensure continuity of earthing and shall be left in place while jointing.

G.

•

Any exposed metal work within the joint bay shall be suitably screened or barriered with rubber sheet or other insulating material before any live jointing is undertaken.

•

Before carrying out any jointing on underground cables, it is the responsibility of the authorised electrical person Incharge at worksite to positively identify the cables.

WORK ON MEDIUM & / OR LOW VOLTAGE OVERHEAD LINES: Before work is carried out on any medium & / or low voltage overhead lines, it shall, be isolated and caution notices posted on the switchgears or fusegears feeding it. The isolation can be proved dead by the use of approved testing equipment. No work shall be carried out on live overhead lines. H. ELECTRICAL WORK CERTIFICATE: It is strongly recommended that the concerned Electrical Maintenance authority should issue an “Electrical Work Certificate in the format as enclosed herewith for the purpose of record as well as certification that the specified equipment is safe to work on.

F&S Regulations Appendix 10

June 2004

Page 4

KOC F&S Regulations

ELECTRICAL WORK SAFETY

Kuwait Oil Company (K.S.C.) Electrical Work Certificate

Certificate No.

(Valid for the duration of Work Permit)

Permit No:

Location of Work: 1. Details of Electrical Isolation: The electrical equipment as detailed in this certificate as well as mentioned in respective Permit No. has been made safe for the work to proceed Equipment: ___________________________________________ Voltage: ___________ AC / DC

Work to be done: Isolations (State where isolated): Earths applied at: Caution Notice posted at: Danger Notice posted at: Control Fuses removed &placed at: Safety Lock Keys Nos: Other Precautions:

Name: _____________________________ Designation & Employee No. __________________ Company / Contractor: Team / Group: __________________ Signature: _____________ Date & Time______________ 2. Declaration from Authorized Electrical Person I have satisfied myself that the equipment as specified in Part 1 of this Certificate is isolated & safe to work on. No attempt will be made by me or by personnel under my control to work on any other equipment. I am personally responsible for asking the necessary safety precautions to avoid danger during work.

Name: _____________________________ Designation & KOC No. _____________________ Team / Group:__________________ Signature: _____________ Date & Time: _____________ 3. Declaration for Clearance: I hereby declare that the work specified in Part 1 is now COMPLETE / SUSPENDED and that all personnel under my control have been warned that it is no longer safe to work on the equipment. All tools, equipment and additional temporary Earth's have been removed.

Name: _____________________________ Designation & KOC No. __________________ Team / Group: __________________ Signature: ___________ Date & Time: _______________ 4. Cancellation (I) I declare that all Earth's listed have been removed & this Electrical Work Certificate cancelled. (ii) The equipment is ISOLATED / DE-ISOLATED (Strike which is not applicable) (iii) Reason for equipment to remain isolated: ________________________________________________

Name: _____________________________ Designation & KOC No.__________________ Team / Group: __________________ Signature: _____________ Date & Time: ______________

F&S Regulations Appendix 10

June 2004

Page 5

Kuwait Oil Company

Fire & Safety Regulations

(K.S.C.)

Appendix - 11 June 2004

RADIATION PROTECTION APPENDIX –11 RADIATION PROTECTION

Radiation Protection is an applied discipline. The purpose is to define the limits within which some human activities with potentially harmful consequence may safely be carried out. All classified workers should have valid licence / certificate issued by, Radiation Protection Department of Ministry of Health. At least two classified persons should be employed on every radiography job (One radiographer and the other an assistant with sufficient knowledge in safe working). The protection against exposure to source of radiation depends upon the following factors:

•

A)

Keeping longer safe working distance from the source of radiation as far as possible.

B)

Minimise the duration of radiation exposure by careful planning & execution.

C)

Interposing attenuating (protective) high dense barriers such as lead sheet, steel objects etc… between the source of radiation and the operator during exposure.

MAXIMUM PERMISSIBLE DOSE (MPLS) EXPOSED PART OF THE BODY Whole body

RADIATION WORKERS (CLASSIFIED) (DESIGNATED) 20 mSv (2rem) per year, Averaged over 5 yrs.

NON-RADIATION WORKERS (ASSOCIATED WORKERS-Students, Trainees between age 16-18) 6 mSv (0.6 rem)

Not exceeding 50mSv(5 rem) in any one year Except females (13mSv or 1.3 rems / calendar) quarter Lens of the eyes single or with other organs

150 mSv (15 rem)

50mSv (1.5rem)

Skin (100cm) single or with other organs.

500 mSv (50 rem)

150 mSv (15 rem)

Hands, Forearms feet and 500 mSv (50 rem) ankles single or with other organs

150 mSv (15 rem)

The maximum permissible dose listed above applies to a person of age 18 years or above

F&S Regulations Appendix 11

June 2004

Page 1

KOC F&S Regulations

RADIATION PROTECTION

In case of radiation workers it is based on the life time dose of the individual where: D = 5(N - 18) D = Dose (expressed in rems) absorbed by Tissue N = Age in years It will be noted that an individual may receive a relatively high dose of 20 mSv (2 rem) averaged over 5 years but must not exceed an accumulative dose in excess of 50 mSv or 5 rem in any one year. Dose limit for radiation worker in Kuwait is 1.6mSv/ Month (60 mr / month). It is vital that actual hours worked should be taken into account for assessing MPL. (N.B.: For detail information in this regard – refer to KOC Radiation Protection Manual) •

STANDING INSTRUCTIONS: The following instructions are to be rigidly adhered to by "Classified" users of "Radiography Equipment". 1.

Classified worker should check for the following prior to the Radiography work: Type of work, location, quantum of work, type of radiation source available & its strength, radiation monitoring, warning devices & tools such as remote operated Cee Vee tongs, transport containers to face any emergency.

2.

Film badges and dosimeters are to be worn at all times while handling or operating radiography equipment.

3.

Dosimeters readings are to be checked (prior to and following exposure to radiation), by the person(s) who is/are handling or operating the radiography equipment.

4.

Dosimeters readings are to be checked weekly by Inspection Engineer (Svcs) and a record kept of all such readings.

5.

A survey of camera and guide to be taken after each exposure to make sure that the source is in its shielded position.

6.

Use collimators whenever possible to reduce the useful beam to minimum size necessary for work. This is an important device for reducing the radiation dose.

7.

Should a dosimeter reading in excess of 0.1 rems be noted after any Radiography Equipment operation or at the end of working week, it is to be reported to Inspection Engineer (Svcs)

8.

When a dosage in excess of 0.1 rems is recorded, the person concerned shall cease, forthwith, to use the Radiography Equipment for an appropriate period of time (until the month end if it is with in the monthly dose limit 160 mr). Such a period will depend on the excess dosage received and determined by Preventive Medical Services.

9.

In case a person receives a single dosage of 3 rems or more, arrangements will be made through Health & Environment Team to get that person medically examined at Ahmadi Hospital. Also the film badge of the person should be sent immediately to Radiation protection department (RPD) to process & verify the dose received by the radiographer. RPD’s advice to be followed.

F&S Regulations Appendix 11

June 2004

Page 2

KOC F&S Regulations 10.

All classified workers who are authorized to carry out radiography work will be referred through Preventive Medical Services to Ahmadi Hospital for blood examination at six-month intervals and for physical examination every year.

11.

The radiation level at the boundary of defined barricaded (cordon off area) area must not exceed 2.5µSv / hr (0.25 m rem/hr)

12.

It is forbidden for personnel using radiography source to leave the equipment unattended.

13.

All vehicles used for the transportation or Radiography source or equipment shall have Warning Notice posted on the sides & back. On completion of radiography operations and before returning the source to X-Ray room pit (Safe Storage location) it is to be ensured that it is securely locked and there is no radioactive leakage in the area.

14.

15. 16.

•

RADIATION PROTECTION

Leakage tests shall be carried out for the radiography camera involved in any fall or damage during transportation or work to make sure the camera is safe for further use. Extra care shall be taken by the authorized personnel, while transferring newly acquired isotopes from "sealed storage" to "Operational Container".

17.

A monthly record of source movement along with used film badge will be sent to the Radiation Protection Dept., Ministry of Health before every 5th of the month, with a copy marked to Inspection & Corrosion Team.

18.

In case of emergencies involving radiation accidents Inspection Engineer (Svcs), TL Inspection & Corrosion (S&E), HSE team to be informed. Once the emergency has been recognized, the next step is to call the radiation protection department for assistance.

SAFE WORKING DISTANCE: THE INVERSE SQUARE LAW states that the intensity (dose rate) is inversely proportional to the square of the distance from the radioactive source. The safe distance for a classified (radiological) worker is that distance where the dose rate does not exceed 10 µSv / hr (205 mrh). For associated workers the dose rate must not exceed 0.75 mrh. This is the distance at which three dimensional control barriers must be set up for any situation involving unclassified workers.

F&S Regulations Appendix 11

June 2004

Page 3

APPENDIX – 12 KUWAIT OIL COMPANY (K.S.C) - MINA AL-AHMADI TERMINAL

KUWAIT OIL COMPANY (K.S.C.) HEAD OFFICE:

P.O. Box 9758, Ahmadi - 61008; Kuwait

Tel: 00965-3989111, 3984111 Fax: 00965-3983661 Telex: KUOCO 44211 KUWAIT Web site: www.kockw.com

EXPORT AND MARINE OPERATIONS GROUP 1. Manager Tel: 00965-3261558, Fax: 3262265 e-mail: [email protected] 2. Harbour Master: Tel: 00965-3262859, Fax: 3261329, e-mail: [email protected]

BERTHING DOCUMENTS MINA AL-AHMADI Vessel: ________________________ Date Berthed: ___________________

1 Fire & Safety Regulation - 2004

DECLARATION OF NAMES & ADDRESSES I declare as follows: 1. Name of vessel:

MV/SS

2. Name and address of Owners:

3. Name and address of Charterers

:

4. Name and address of Operators:

5. Name and address of Managers:

6. Name and address of agent:

Mina Al-Ahmadi Date and time Master’s name Signature

CONDITIONS OF USE OF KUWAIT OIL COMPANY (K.S.C.) TERMINAL FACILITIES 2 Fire & Safety Regulation - 2004

In addition to any other conditions which may be separately prescribed by regulation, law or enactment, all facilities and assistance of any sort whatsoever provided by the Kuwait Oil Company (K.S.C) (“KOC”), in or in connection with and in consideration of the use of KOC’s terminal facilities, are provided subject to the following conditions: 1. Neither KOC nor its servants (in whatever capacity they may be acting) shall be responsible for any loss, damage, claims or delay from whatsoever cause arising in consequence of any assistance, advice or instructions whatsoever given or tendered in respect of the vessel mentioned below (“Vessel”), whether by way of pilotage, berthing or un-berthing services, the provision of navigational facilities, including buoys or other channel markings, or otherwise howsoever. In all circumstances the Master of the Vessel, the Vessel’s owners, charterers, managers or operators shall remain solely responsible for the safety and proper navigation of the Vessel. 2. While KOC takes reasonable care to ensure that the berths, premises, facilities, property, gear, craft and equipment, provided by it are safe and suitable for the Vessel permitted or invited to use them, no guarantee of such safety or suitability is given, and KOC shall not be responsible for any loss, injury, damage, claims or delay of any sort that may be sustained by or that occur to the Vessel or its owners, charterers, managers, operators or cargo or any part thereof (whether such cargo is on board or in course of loading or discharging), by whomsoever and by whatever cause such loss, injury, damage, claims or delay is occasioned and whether or not it is due in whole or in part to any act, neglect, omission or default on the part of any servant or agent of KOC or by any fault or defect in any of KOC’s berths, premises, facilities, property, gear, craft or equipment of any sort. 3. KOC shall not be responsible for any loss, injury, damage, claims or delay directly or indirectly caused to the Vessel, the Vessel’s owners, charterers, managers or operators by or arising from strikes, lockouts or labour disputes or disturbances whether KOC or its servants are parties thereto or not. 4. If in connection with or by reason of the use by the Vessel, of any berth or of any part of KOC’s premises or of any gear or equipment or of any craft or of any other facility or property, of any sort whatsoever, belonging to or provided by KOC, any damage is caused to any such berth, premises, gear, equipment, craft other facility, property or pollution to the environment in or adjacent to the port including the territorial waters of Kuwait, from whatsoever cause such damage may arise, and irrespective of whether or not such damage has been caused or contributed to by the negligence of KOC or of its servants, and irrespective of whether there has been any neglect or default on the part of the Vessel or its owners, charterers, managers or operators and in any such event the Vessel and its owners, charterers, managers or operators shall hold KOC harmless from and indemnified against all such damage and against all loss sustained by KOC as a consequence. Further, the Vessel and its owners, charterers, managers or operators shall jointly and severally hold KOC harmless from and indemnified against all and any claim, damages, costs (including legal costs), and expenses arising out of any loss, injury, death, damage or delay caused to any third party by the Vessel or by its Master or crew or by any other servant or agent. 5. If the Vessel sinks or grounds or otherwise becomes, in the opinion of KOC, an obstruction or danger in any part of the port or the approaches thereto and the owners, charterers, managers or operators of the Vessel fail to remove the obstruction or danger within a period to be stipulated by KOC, KOC shall be empowered to take any steps it may deem necessary to remove the obstruction or danger and any expenses of such removal shall jointly and or severally be recoverable from the Vessel, its owners, charterers, managers or operators. 6. All disputes between KOC and the owners, charterers, managers or operators of the Vessel arising out of these conditions shall at the sole option of KOC be exclusively governed according to the laws of Kuwait and be dealt with exclusively by the Kuwaiti courts or by the laws of England and be dealt with by the English courts and the Vessel and its owners, charterers, managers or operators shall submit to either of the jurisdictions and laws that KOC elects to choose. I hereby declare that I accept the above Conditions of Use of Kuwait Oil Company (K.S.C.) Terminal Facilities.

Date and Time Master MV / SS

3 Fire & Safety Regulation - 2004

HIRING OF TUGS To The Team Leader Marine Operations, Kuwait Oil Company (K.S.C) I hereby authorize you to supply to and on behalf of MV/SS __________________________(“Vessel”) its owners, charterers, managers or operators, such tug or tugs as you consider necessary for the moving of the Vessel whilst entering within or leaving the area of the Kuwait Oil Company (K.S.C) (“KOC”) terminal facilities in consideration of the charges payable by the vessel. Such hiring shall take place on the following terms and conditions, to which the Vessel its owners, charterers, managers, or operators shall jointly and or severally be bound.

Terms and Conditions 1. The tug shall be considered engaged in towing operations, commencing from the time when the tug is in a position to receive orders from the Vessel to pick up ropes or lines, or when the tow rope has been passed to or by the tug, or when the tug is in a position to commence holding, pushing, pulling or moving the Vessel, or when the tug is in attendance upon or engaged on any maneuver for the purpose of rendering assistance to the Vessel, whichever is the earliest, and ending when the final orders from the Vessel to cast off ropes or lines have been carried out, or when the tow rope has been finally slipped, or when the tug has finally ceased holding, pushing, pulling or moving the Vessel or when the tug has ceased to attend upon or be engaged on any maneuver for the purpose of rendering assistance to the Vessel and when the tug is safely clear of the Vessel, whichever occurs last. 2. When the tug is engaged in towing operations, which shall include any or all of the operations mentioned in clause 1 above: a) The Master & crew of the tug become the servants of, and shall be identified with the Vessel, its owners, charterers, managers or operators and under their control and or of their servants or agents, and anyone on board the Vessel who maybe employed or paid by the tug owner shall be considered the servant of the Vessel and its owners, charterers, managers or operators. b) The tug owner shall not bear or be liable for, and the Vessel, its owners, charterers, managers or operators hereby undertakes to bear, pay for and indemnify the tug owner for, damage of any description whatsoever done by or to the tug or done by or to the Vessel, or any loss of or damage to anything on board the Vessel, or loss of the tug or the Vessel, or any loss of or damage to any other property, ashore or afloat, or any personal injury or loss of life, whatsoever may be the cause from which any of the foregoing may arise, including negligence at any time of the tug owner’s servants or agent’s, unseaworthiness, unfitness or breakdown of tug, its machinery, boilers, towing gear, equipment or hawsers, lack of fuel, stores or speed. 3. Nothing contained herein shall prejudice any claim the tug owner may have jointly and or severally against the Vessel, its owners, charterers, managers or operators. 4. The tug owner may substitute one tug for another and may also employ tugs owned by other tug owners, and such other tug owners shall have the benefit of and be bound by these conditions. 5. The tug owner shall not be liable or responsible for the consequences arising out of war, strikes, lockouts, riots, civil commotion, disputes or labour disturbances whether they be parties thereto or not, or anything done on contemplation of furtherance thereof, or delays of any description, however caused including negligence of their servants or agents. 6. All disputes between KOC (or the tug owner as the case may be), and the owners, charterers, managers or operators of the Vessel arising out of these conditions shall at the sole option of KOC (or the tug owner as the case may be) be exclusively governed according to the laws of Kuwait and be dealt with exclusively by the Kuwaiti courts or by the laws of England and be dealt with by the English courts and the Vessel and its owners, charterers, managers or operators shall submit to either of the jurisdictions and laws that KOC (or the tug owner as the case may be) elects to choose.

Date and Time

Master:

4 Fire & Safety Regulation - 2004

KUWAIT OIL COMPANY (K.S.C.)

GENERAL TOWAGE CERTIFICATE This is to certify that the following services have been rendered to: The MV / SS

by

tug(s)

the

: * assisting during berthing (Specify other operations)

*

{*: (√) Tick whichever is applicable}

Date and time

Master:

KOC COPY

KUWAIT OIL COMPANY (K.S.C.)

TOWAGE CERTIFICATE FOR TAILING OPERATION This is to certify that the following tug/tugs were employed as tailing tug/tugs while loading at the SPM Terminal No

:

Tug “

”from

hrs on

to

hrs on

Tug “

”from

hrs on

to

hrs on

Tug “

”from

hrs on

to

hrs on

Tug “

”from

hrs on

to

hrs on

Date and time

Master: SPM Pilot:

5 Fire & Safety Regulation - 2004

AGREEMENT ON SMOKING PLACES AND GALLEY FIRES It is agreed between Kuwait Oil Company (K.S.C) (“KOC”) and the Master of the vessel mentioned below (“Vessel”) as follows: 1. That while the Vessel is within 300 meters from any part of the KOC terminals and assets (“Danger Zone”), the under mentioned three rooms in the accommodation aft are approved and agreed suitable for smoking.

1) 2) 3)______________Master’s office__

____________

2. Galley fires, which use oil or solid fuels, shall not be used within the Danger Zone. 3.

This vessel may use galley fires. * This vessel shall not use galley fires. * {*: (√) Tick whichever is applicable}

4. The Master shall not permit smoking on board the Vessel and shall ensure that galley fires are extinguished when the Vessel receives a warning from the Harbour Master, Pilot or Loading Master of a probable presence of dangerous concentration of gas.

Date and time: Signed

Signed (Marine Officer)

(Master)

For: KOC

MV/ SS: NOTES: i. ii.

Cargo Control Room shall not be designated as a smoking place No place on board the vessel shall be considered suitable for smoking or to be used as galley unless: a) it is an enclosed space aft having no openings, doors or ports which open directly on the cargo loading tank decks and all openings to weather decks are closed. b) The Master ensures that mechanical ventilation and air conditioning are stopped if there is any likelihood of dangerous gas being drawn into the smoking space or galley.

6 Fire & Safety Regulation - 2004

KUWAIT OIL COMPANY (K.S.C.)

SAFETY CONDITIONS I the Master of the vessel mentioned below (“Vessel”) declare and accept that the Vessel shall comply with all industry safety rules, safety regulation and safety measures, including the following Kuwait Oil Company (“KOC”) Mina-Al Ahmadi Safety Conditions: 1. Safe Operations: Responsibility for the safe operations on board the Vessel within 300 meters from any part of the KOC terminals and assets (“Danger Zone”), rests with the Vessel. 2. Infringements: The Master or the officer of the watch shall take appropriate corrective action when infringement on board the vessel or associated with it of any of these conditions are brought to their attention. Where corrective action is not taken within a reasonable time, KOC may take necessary measures to rectify the infringement. The Master on observing infringement of these conditions by KOC shall bring these to the notice of the loading master. The Master may have all operations stopped where there is immediate threat to the safety of the Vessel from any action or equipment under the control of KOC. 3. Moorings: The Vessel shall be securely moored and in the correct position at all times. Auto-tension winches shall not be used in automatic mode. 4. Readiness To Maneuver: Main engines, personnel and all equipment shall be kept in a state of readiness at all times so as to enable the Vessel to maneuver under its own power in an emergency. 5. Incidents: in the event of an incident which warrants cessation of cargo operations, the Vessel’s manifold valves and at-least one tank filling valve shall be left open to facilitate hose draining prior to activating quick release hose coupling, in preparation for unberthing. 6. Fire Alarm: In the event of an outbreak of fire, on the Vessel within the port, the Master shall arrange for an immediate signal, either by a prolonged sounding of the ship’s whistle or by the ringing of a fire bell and shall promptly notify the loading master, as well as arrange for the report to be sent to him. 7. Emergency Escape: In addition to the normal means of access between Vessel and shore, a safe and quick emergency escape route shall be available and maintained in the form of a gangway on the offshore side, or a lifeboat etc. 8. Routine Inspections: In order to assure compliance with these Safety Conditions, KOC may, from time to time, instruct a member of its staff to visit the Vessel, who will report to the Master or the officer of the watch. One of the Vessel’s officers shall join the KOC staff in a routine inspection of cargo decks and accommodation spaces, and record the findings. 9. Overboard Discharge Valves: All the Vessel’s sea valves shall be closed, lashed or blank flanged, except those required for water circulation. 10. Cargo Watchman: One watchman shall be stationed at the Vessel’s manifold / gangway, visible from ashore at all times during cargo operations, to report any abnormalities. At the Single Point Mooring (“SPM”) an additional watchman shall be stationed on the bow in accordance with the SPM Conditions (item 34). 11. Pollution and Overviews: The Master shall make himself aware of the laws concerning overflows and pollution of Kuwaiti waters and environment. 12. Air Boiler Tube Cleaning: Boiler tubes shall not be cleaned while the Vessel is in the Danger Zone. 13. Ballast: The water ballast, which is intended to be discharged, shall be entirely free from oil, foreign organisms and other substance that might pollute the port and Kuwait waters. The higher over board discharge shall be used and the discharge shall be monitored continuously for any pollutants. 14. Over Loading: The International Load Line Regulations shall be strictly followed. In the event of overloading considerable delay may occur before facilities are available for pumping surplus cargo ashore, any resultant costs or delays shall be to the Vessel’s account. 15. Smoking: Except as provided in the Agreement on Smoking Places and Galley Fires, smoking shall not take place on board the vessel. 16. Naked Lights & Electrical Equipment: All naked lights, flames, unconfined fires, incandescent elements, unsafe electrical equipment or any equipment likely to cause sparking, shall not be used within the Danger Zone. 17. Electrical Cables: On all exposed decks, vulnerable cables to any portable or fixed machinery, lights, etc., shall be disconnected from the electrical source. 18. Radio and Radar Aerials: All radio and radar aerials shall be switched off and earthed. 19. Hand Torches: Gastight torches approved to British Standards Institute (“BSI”) or equivalent standards and duly certified for use in explosive atmosphere shall only be used. 20. Portable R/T Sets: Portable R/T sets approved to British Standards Institute (“BSI”) or equivalent standards and duly certified for use in explosive atmosphere shall only be used. 21. Fire-Wires: Fire wires (emergency towing wires) shall be rigged as follows:

7 Fire & Safety Regulation - 2004

(i) (ii) (iii) (iv) (v) (vi)

Two fire-wires, on the offshore bow and quarter of the ship, shall be rigged as far forward and aft as practicable. For Vessels moored at the SPM’s, fire wires shall be rigged on the starboard side. Fire wires shall be properly made fast on the ship’s bollards with the slack arranged on deck, ready for free running. All means shall be provided to prevent the slack from accidentally running into the water, and so arranged that the tugboat’s crew can easily break them. The eyes shall be maintained at the waterline throughout the cargo operation and regularly checked and adjusted as necessary. Minimum lengths and diameters of fire wires shall be as follows: -

DEAD WEIGHT TONS (MT) Below 30, 000 Between 30, 000 & 200, 000 Over 200, 000

DAIMETER (MM)

LENGTH (M)

28 38 42

70 110 110

Minimum 5 turns on the bits 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32.

From bits to waterline 70 or 110 m Rope lashing

Hoses: Hoses shall be in good condition and shall be properly attached and supported during cargo operation. Loading Line-up: All necessary valves shall be opened and the Vessel shall be in a proper condition to receive or discharge cargo. This shall include an inspection of ship to shore loading connections, which shall be made to the Master’s satisfaction. External Ports & Doors in Accommodation: All doors facing the loading deck shall be closed during cargo operations. Ventilators: Where any ventilators are likely to admit cargo vapour to enclosed spaces, they shall be trimmed back to the wind or effectively plugged. Air Conditioning Intakes: All powered ventilation systems likely to admit cargo vapour to enclosed spaces shall not be used or kept closed. Window Type Air-Conditioning Units: No window type air- conditioning units shall be operated within the Danger Zone and shall be disconnected from electrical source. Unused Cargo & Bunker Connections Including Bow or Stern Cargo Lines: All unused connections and lines shall be securely blanked when not in use. Scuppers: All scuppers shall be effectively plugged. Accumulation of water during cargo operations shall be drained off periodically. Cargo, Bunker and Ballast Tank Lids: All cargo, bunkers and ballast tank lids shall be securely closed. Fire Hoses & Equipment: All fire-fighting equipment and steam or inert gas smothering system shall be ready for immediate use. Hoses on the loading deck, at least one forward and one aft of the manifold shall be connected to fire main. Venting: Release of cargo tank vapours shall conform to one of the following: *Through respective ullage ports, fitted with suitable flame screens *Fixed vents as part of closed venting system *Vented ashore through vapour collection system

33. 34.

{*: (√) Tick whichever is applicable} Inerting and Cooling: Inerting and cooling (LPG) operations shall not be carried out while the vessel is within the Danger Zone. S.P.M. Conditions: The following additional conditions shall be observed if the Vessel is allocated to load at the S.P.M: (i) The Pilot, will stay on board during the Vessel’s stay at the terminal, and shall be provided with suitable accommodation. He shall be informed of the loading operations, and any emergency action required to be taken to safeguard both the ship and shore installation. (ii) The pilot will carry two portable radios by means of which all communications regarding approach, mooring and cargo handling will be made. The cargo handling radio shall also be fitted with means to activate the emergency shut down system. The pilot will also carry battery charger for these radios operating on 220V only. (iii) The Vessel shall provide 1 Vessels’ portable radio to the pilot during maneuvering, and throughout the Vessel’s stay at the SPM, for continuous communication with the Vessel CCR / Bridge / Manifold.

8 Fire & Safety Regulation - 2004

(iv)

The Vessel’s crew shall be responsible for the connection and disconnection of the floating hoses. However shore crew will be available on board to provide necessary assistance and shall be provided with a shelter within the accommodation. (v) A watchman from Vessel shall be stationed with a portable radio on the forecastle to report any defects in the moorings or leakage of oil, and shall report immediately if the Vessel rides onto the SPM. (vi) A continuous cargo watch shall be maintained at all times both on deck and in the cargo control room. (vii) To avoid excessive freeboard, especially in adverse weather conditions the vessel may need to handle cargo and ballast simultaneously. (viii) The Vessel shall provide a suitable fibre towing rope for the tailing tug, which will be used as advised by the Pilot. (ix) `The Vessel’s engines shall be on continuous stand by and ready for immediate use when required by the Pilot. At times, subject to tide, wind and weather conditions, revolutions of the Vessel’s propeller may be required throughout the Vessel’s stay at the SPM. If for any reason, this cannot be complied with the pilot must be immediately informed, who shall take such action, as he deems necessary. Any delays so incurred will be to the Vessel’s account.

Date and time Master: MV / SS

NOTES i.

Senior Terminal Representative: The Senior Terminal Representative on duty is: *Harbour Master - His telephone number is 00965-3262859, or VHF Ch 69/17 *SPM Pilot who is on board the Vessel *MAB Sea Island Pilot – VHF Ch 71 {*: (√) Tick whichever is applicable}

ii.

Shore Liaison: Loading master will board the Vessel on arrival at berth. He will act as liaison between the Vessel and the shore installation. At the SPM, the pilot acts as the loading master as well.

9 Fire & Safety Regulation - 2004

KUWAIT OIL COMPANY (K.S.C.) SHIP/SHORE SAFETY CHECKLIST (To be filled in after the vessel is all made fast and subsequently as appropriate) MV / SS: _______________________

Berth: _________________

Time of Arrival: __________(first line ashore)

Date of Arrival: _________________

Instructions for completion: All Questions should be answered affirmative by clearly ticking (√) the appropriate box. If an affirmative answer is not possible, the reason should be given and agreement reached upon appropriate precautions to be taken between the vessel and the terminal. Where any question is considered to be not applicable, then a note to that effect should be inserted in the remarks column. A box (1) in the column ‘Vessel’ or ‘Terminal’ indicates that the check should be carried out by the party concerned. Codes A, P or R indicate the following: A: any procedures and agreements should be in writing in the remarks column of this Checklist or other mutually acceptable form. In either case, both parties should sign. P: in the case of a negative answer, the operation should not be carried out without the permission of the Port Authority. R: indicated items to be rechecked at agreed intervals

PART ‘A’: BULK LIQUID – GENERAL No

General

01 02 03 04 05

Is the tanker securely moored Are emergency towing wires correctly positioned Is there safe access between tanker and shore Is the tanker ready to move under its own power Is there an effective deck watch in attendance on board and adequate supervision on the vessel and terminal Is the agreed ship/shore communication system operative Is the emergency signal between vessel & shore explained, understood & agreed Have the cargo, ballast and bunker handling procedures been agreed Have the hazards associated with toxic substances in the cargo being handled identified and understood Has the emergency shutdown procedure been agreed Is the fire-fighting equipment on vessel & shore rigged and ready for immediate use Are cargo & bunker loading arms/hoses in good condition, properly rigged and appropriate for the service intended Are scuppers effectively plugged and drip-trays in place, both on board and ashore Are unused cargo and bunker connections properly secured with blank flanges fully bolted Are sea and overboard discharge valves, when not in use, closed and visibly secured Are all cargo and bunker tank lids closed

06 07 08 09 10 11 12 13 14 15 16

Vessel Terminal Code

1 1 1 1

1 1 1 1

R R R PR

1

1

R

1

1

AR

1

1

A

1

1

AR

1

1

1

1

A

1

1

R

1

1

1

1

1

1

1

1

1

1

Remarks

R

10 Fire & Safety Regulation - 2004

PART ‘A’: BULK LIQUID – GENERAL (…continued) No

General

Vessel Terminal Code

17 Is the agreed tank venting system being used 18 Has the operation of P/V valves and/or high velocity valves been verified using checklist facility where available 19 Are hand torches of an approved type 20 Are portable VHF/UHF transceivers of an approved type 21 Are the vessel’s main radio transmitters earthed & radars switched off 22 Are electric cables to portable electrical equipment disconnected from power 23 Are all external doors and ports in the accommodation closed 24 Are window type air conditioning units disconnected 25 Are air conditioning intakes that may permit entry of cargo vapour closed 26 Are galley/cooking equipment requirements being observed 27 Are smoking regulations being observed 28 Are naked light regulations being observed 29 Is there provision for an emergency escape 30 Are sufficient personnel on board and ashore to deal with an emergency 31 Are adequate insulating means in place in ship/shore connection 32 Have measures been taken to ensure sufficient pump room ventilation 33 If the vessel is capable of closed loading, have the requirements for closed operations been agreed 34 Has a vapour return line been connected 35 If a vapour return line is connected, have operating parameters been agreed 36 Are vessel’s fire control plans located externally 37 Is the Inert Gas system fully operational and in good working order 38 Are deck seals in good working order 39 Are liquid levels in P/V breakers correct 40 Have the fixed and portable oxygen analyzers calibrated and working properly 41 Are fixed IG pressure and Oxygen content recorders working 42 Are all cargo tank atmospheres at positive pressure with oxygen content of 8% or less by volume 43 Are all individual tank IG valves (if fitted) correctly set & locked

Remarks

AR

1

1

1

1

1 1

1 1

1

1

1

1

1

1

1

1

1

1

1

1

R

1 1 1

1 1 1

R R

1

1

R

1

1

1

1

R

1

1

R

1

1

1

1

1

1

1

1

P

1 1

1 1

R R

1

1

R

1

1

R

1

1

PR

1

1

R

R

11 Fire & Safety Regulation - 2004

PART ‘B’: ADDITIONAL CHECKS BY LPG VESSELS No

General

Remarks

Vessel Terminal Code

01 Is information available giving the necessary data for the safe handling of the cargo including, as applicable, manufacturer’s inhibition certificate 02 Is the water spray system ready for use 03 Is sufficient suitable protective equipment (including selfcontained breathing apparatus) and protective clothing ready for use 04 Are hold and inter-barrier spaces properly inerted or filled with dry air as required 05 Are all remote control valves in working order 06 Are the required cargo pumps and compressors in good order, and have maximum working pressures been agreed between vessel & shore 07 Is reliquefaction or boil off control equipment in good order 08 Is the gas detection equipment properly set for the cargo, calibrated and in good order 09 Are cargo system gauges & alarms correctly set & in good order 10 Are emergency shutdown systems working properly 11 Does the shore know the closing rate of vessel’s Automatic valves; does the vessel have similar details of shore system 12 Has information been exchanged between vessel and shore on the maximum and minimum temperatures / pressures of the cargo to be handled 13 Are cargo tanks protected against inadvertent overfilling at all times while any cargo operations are in progress 14 Is the compressor room properly ventilated, the electrical motor room properly pressurized and the alarm system working 15 Are cargo tank relief valves set correctly and actual relief valve settings clearly and visibly displayed

1

1

1

1

1

1

1 1

1

1

1

A

1 1

1

1

1

1

1

1

1

A

1

1

A

1

1

1

1

1

DECLARATION We have checked, where appropriate jointly, the items on this checklist, and have satisfied ourselves that the entries made are correct to the best of our knowledge, and repetitive cheeks will be made as necessary.

For Tanker Date Time (All-fast or later)

No

Date

For Terminal

Name:

____________________

Name:

______________________

Rank:

____________________

Rank:

______________________

Signature: ____________________

Time

Signature: _____________________

SUBSEQUENT CHECKS Name/Sign Name/Sign (For Tanker) (For Terminal)

Remarks

1 2 3

12 Fire & Safety Regulation - 2004

KUWAIT OIL COMPANY (K.S.C.)

STOP LOADING CERTIFICATE

I, the Master of MV/SS

do

hereby

declare that I have requested Shore Terminal to stop loading my vessel at

hrs

(Kuwait

Local Time) on

(date) and confirm having received the full nominated

cargo quantity on board the Vessel.

Date

Master

13 Fire & Safety Regulation - 2004

KUWAIT OIL COMPANY (K.S.C.)

SMOKING ROOM KUWAIT OIL COMPANY (K.S.C.)

SMOKING ROOM KUWAIT OIL COMPANY (K.S.C.)

SMOKING ROOM 14 Fire & Safety Regulation - 2004

Form No. MP 810

KUWAIT OIL COMPANY (KSC) PILOT / MASTER INFORMATION EXCHANGE AND OPERATIONAL CHECKLIST 1 GENERAL INFORMATION Vessel's Name (M/T or S/T) Tide: Pilot's name POB Time / Date Wind Dir x Speed: Berth No. : B S Mooring Arrgt. Ready to load Yes / No Deballasting Time Cargo Requirement / Ldg. Rate / Manofold nos. Bunker Requirement / Ldg. Rate / Manofold nos. Name of Tugs: Any other info:

Flood / Ebb Draft Arrival F&A Draft Dep. F&A Master's name SDWT LOA Max. Displ. At berth Max. Height of Manifold Bunkers Arrival Slops Propeller: RH / LH / CPP / Other

2 CHECKS BEFORE BOARDING a b c d e f

Has operation been discussed with HM and Terminal Supervisor informed Are vessel's dimensions / draft suitable for the allocated berth Are hoses & ropes in readiness ( for SPM only ) Are fenders & hoses in good condition & correctly rigged ( for STS only ) Has vessel's draft been checked visually & hull condition been checked for any damage/dents Report on item e (if any):

3 CHECKS AFTER BOARDING a b c d e f g h i j k l m n

Is vessel upright and trim suitable Are all overboard discharges, gangways, cranes etc. clear for tugs and berth Are mooring points on the vessel suitable/adequate for the tugs Report on item c (if any): Has Pilot-Master information been exchanged Has maneuvering plan & emergency escape procedure been discussed with Master Have berthing papers been signed Are the appropriate anchors prepared (or secured) as required Are vessel's engines in readiness and tested Are the steering / rudder and RPM indicators in working order Are appropriate signals / lights displayed Is communication with HM,Tugs,Supvr.,&Craft established and maintained Are tugs made fast in safe condition Has the master been made aware of the procedures to follow upon completion of cargo operations

4 MANEUVERING PLAN ( A rough sketch of the planned maneuver and emergency escapes)

Pilot Signature_________________

Master Signature__________________

Notes: 1. To be filled for every operation. 2. After completion to be forwarded to Marine Admin. 2. ( ) if checked OK, (x) if not OK, (-) if not checked

Date / Time ____________

Kuwait Oil Company

Fire & Safety Regulations

(K.S.C.)

Appendix - 13 June 2004

NOISE CONTROL APPENDIX - 13 NOISE CONTROL

GENERAL: Harmful exposure to sound intensity in working areas shall be eliminated or minimized by proper planning and careful designing. Noise Control considerations include substitution with quieter sources, isolation, enclosure, baffling, resilient mounting, sound absorption, or such other measures as appropriate. 1.

PROTECTION: When the sound intensity in a working area exceeds 85 decibels (dBA) overall, then appropriate personal ear protective devices shall be required. When the sound intensity in a working area exceeds 115 dBA, suitable personal protective equipment in combination of earplugs and earmuffs shall be required to reduce the resultant affect on the workers exposed.

2.

NOSE MEASUREMENT: Measurement of sound intensity shall be taken by qualified personnel in consultation with Health & Environment Team. Moreover the measurement of sound intensity should be carried out at 1 meter away from the source and 1.5 meter above the ground level.

3.

OCCUPATIONAL NOISE EXPOSURE: Protection against the noise exposure shall be provided when the sound intensity exceeds the level (measured at slow response) as indicated in the table hereunder.

TABLE – 1 Duration per day (Hours / Minutes / Seconds)

Sound Intensity (dBA at slow response)

24 hrs.

80

16 hrs.

82

8 hrs.

85

4 hrs.

88

2 hrs.

91

1hr.

94

30 min.

97

15 min

100

7.5 min

103

3.75 min

106

1.88 min.

109

F&S Regulations Appendix - 13

June 2004

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Appendix No. 13 June 2004

NOISE CONTROL

0.94 min.

112

28.12 sec.

115

14.06 sec.

118

7.03 sec.

121

3.52 sec.

124

1.76 sec.

127

0.88 sec

130

0.44

133

0.22 sec

136

0.11

139

When workers are exposed to sound intensity exceeding the limits as listed in the table, then feasible administrative or engineering controls shall be applied. If such controls fail to reduce sound levels within the desirable limit, then the workers prior to entering the area shall wear appropriate personal protective equipment. No exposure is allowed to a continuous, intermittent or impact noise in excess of 140 dBA. Sound level in decibels are measured on a sound level meter, conforming as a minimum requirement of American National Standards Institute Specification for Sound Level Meters S1.4 Limited to the noise source but not as an administrative control measure; it is recommended to use a dosimeter or integrating sound level meter for sounds intensity above 120 decibels If the sound intensity reaches peak values at an interval of one second or less, the noise level is considered to be continuous. In all cases where the sound intensity exceeds the values shown herein, a continuous & effective hearing conversation program shall be administered. 4. CONTINUOUS OR INTERMITTENT NOISE: The sound pressure level should be determined by a sound level meter or dosimeter conforming, as a minimum requirement to American National Standards Institute (ANSI) Specification for Sound level Meters, S1.4-1983, Type S2A, (2) or ANSI S1.25-1991 Specification for Personal Noise Dosimeters. (3) The measurement device should be set to use the A-weighted network with slow meter response. The duration of exposure should not exceed the limit as mentioned in the above table. These values apply to total duration of exposure or a number of shortterm exposures. 5. COPUTING NOISE LEVELS: When the daily noise exposure is composed of two or more periods of noise exposure of different levels, their combined effect should be considered rather than the individual effect of each. F&S Regulations Appendix - 13

June 2004

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Appendix No. 13 June 2004

NOISE CONTROL

If the sum of the following fractions exceeds unity: C1 ____

T1

+

C2 ______

T2

+

Cn …… ……. ______

Tn

then the mixed exposure should be considered to exceed the TLV. Where C1 = indicates the total duration of exposure at a specific noise level, T1 = indicates the total duration of exposure permitted at that level. •

All on job noise exposures effect of 80 dBA intensity or above should be considered based on the above calculations.

•

While measuring with sound level meters, the above formula should be used for sounds having steady levels of at least 3 seconds.

•

Where this condition can not be met, a dosimeter or an integrating sound level meter must be used.

•

The TLV is considered exceeded when the dose is more than 100% as indicated on a dosimeter set with a 3 dB exchange rate and 8-hour criteria level of 85 dBA.

•

The TLV is considered exceeded on an integrating sound level meter if the average sound level exceeds the values as indicated of Table – 1 of this Appendix.

F&S Regulations Appendix - 13

June 2004

Page 3

Kuwait Oil Company

Fire & Safety Regulations

(K.S.C.)

Appendix No. 14 June 2004

HYDROGEN SULPHIDE APPENDIX - 14

HYDROGEN SULPHIDE Introduction: One of the most common hazards associated with production and processing of oil & gas is the potential for exposure to Hydrogen Sulphide (H2S). Accidents and incidents involving H2S can be prevented by good engineering practice, job planning and the proper use of personal protective equipment Hydrogen Sulphide can be encountered in oil & gas wells, production facilities and processing plants. It can also be found in sewers, landfills or other areas where breakdown or deterioration of organic materials takes place. Concentrations may vary from negligible to extreme. Low concentrations of H2S are perhaps more dangerous than higher concentrations, because personnel may become complacent about low concentrations. This complacency is misplaced – exposure to even low concentration of H2S can be fatal.. Level or concentrations of H2S are usually measured in PPM – Parts Per Million in air. Properties of Hydrogen Sulphide: The properties of H2S is tabulated as hereunder: Chemical Name Formula Physical Makeup Colour Odour Boiling Point Vapour Density Auto Ignition Temperature Flammable Limits Solubility

Properties of H2S Hydrogen Sulphide H2S Gas at Ambient Conditions Colourless Distinctive “Rotten Egg” odour at low levels - 60 Degree C 1.189 260 Degree C 4.3% to 45.5 % by Volume. In water & other Liquids

All personnel who may be exposed to H2S must be aware of and understand the significance of these properties. The concentration of H2S will vary from one operation to another and affect of a particular concentration may vary from one individual to another. Managers of Operations should arrange for the preparation of contingency plans to deal with potential escaped of H2S. In particular, plans should include: (i) (ii) (iii) (iv)

Responsibilities and duties of persons involved. Evacuation of affected area. First aid and medical facilities required. Adequacy and suitability of breathing apparatus sets.

TOXICITY: (a) H2S is an irritant and an extremely toxic gas. It is almost as toxic as hydrogen cyanide and between five and six times as toxic as carbon monoxide. Although personnel working

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June 2004

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KOC F&S Regulations

(b)

(c)

HYDROGEN SULPHIDE

in areas where hydrogen sulphide is present may become accustomed to the smell of the gas so as not to notice it, a hyper-susceptibility may result from exposure to the gas. Toxic effects produces by H2S vary considerably with the concentrations encountered. In low concentration it has an irritant action on the air passages, mucous membranes and the cornea of the eye. At high-concentrations it has systemic effect and in case of acute poisoning, death is as rapid as poisoning by cyanide. Very low concentrations of H2S can be recognized by distinctive odour of rotten eggs but this is only true when the gas is first encountered and moreover persons may differs in their ability to detect smells. Smell is not a reliable warning for the presence of H2S particularly at higher concentration. H2S at higher concentrations rapidly paralyse the olfactory nerves and the gas cannot be detected by odour.

EFFECTS OF HYDROGEN SULPHIDE: The following is a summary of the physiological response to various concentrations of H2S. Concentration of H2S in air (ppm)

Effect

Less than 1 ppm

- Rapidly detectable by smell.

10 ppm

- Current Threshold Limit Value (Time Weighted Average concentration for a normal 8 hours work-day or 40 hours work-week to which nearly all workers maybe repeatedly expose, day after day, without adverse effect).

70 - 150 ppm

- Eye and respiratory tract irritation after onehour exposure.

150 - 400 ppm

- Dizziness, headache, nausea, abdominal pain within 15 minutes. Loss of consciousness and possible death after 30 minutes exposure if not rescued.

400 - 700 ppm

- Unconsciousness and cessation of breathing, causing death if artificial respiration not given immediately.

700 – 1000 ppm

- Rapid unconsciousness. Immediate threat to life. Brain damage possible.

Above 1000 ppm

- Immediate unconsciousness, death follows quickly.

PRECAUTIONARY MEASURES: The precautionary measures against possible exposure to H2S is summarised as hereunder (a)

Sufficient numbers of escape masks shall be kept in areas where H2S is liable to present. Suitable resuscitation equipment should also be available, kept in areas, which can be expected to be safe from H2S release.

(b)

In case H2S presence is suspected in an area, the persons must put on escape masks immediately and toxic gas tests must be made immediately with appropriate detector to determine the concentration of H2S in air.

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KOC F&S Regulations

HYDROGEN SULPHIDE

(c)

No attempt shall be made to monitor concentration by smell.

(d)

Persons working in areas where H2S is liable to be present should be equipped with personal detectors and alarming device to alert in case of H2S presence. In production facilities where sour crude oil or gas is processed or gathered, the area asset owner should ensure the installation of fixed detection devices at suitable locations to provide continuous monitoring of the atmosphere. Possible monitoring points are: • Crude Oil Storage Tanks • Crude Oil / Gas Separation Plant • Mud Pit Area • Oil water Interceptors • Water Draw-of points from Effluent Treatment Plant • Storage Blast Tanks • Drill Floor • Bell Nipple (Drilling) • Shale Shaker (Drilling)

(e)

In case of H2S alarm, all personnel should vacate the area after donning the escape sets / breathing apparatus and report to the designated Assembly Point for mustering.

(f)

Persons required to work in an H2S contaminated atmosphere must wear suitable BA set and work in pairs to support and rescue each other in the event of difficulties.

(g)

Pipes, tanks and vessels where H2S is known to be present must be appropriately colourcoded. Pipes will be marked with yellow identification at flanges and banded with yellow strips at intervals. Vessels and tanks will be marked with a yellow band. Valve glands and drain points will also be marked in yellow.

REPORTING PROCEDURE: The presence, or suspected presence of H2S in any part of the plant or sewer shall be reported immediately to the supervisor and to respective area Fire Stations for arranging rescue and support. WARNING NOTICES: Once the source of H2S and the extent of the contaminated area have been identified, the person responsible for safety shall post warning notices at the parameter of the danger area, worded as follows: "TOXIC GAS (H2S) DANGER. ALL UNAUTHORIZED PERSONNEL KEEP CLEAR" SULPHATE REDUCING BACTERIA: H2S can be generated by bacterial action in sulphate containing water (usually seawater) where oxygen is simultaneously in low concentration. H2S may be present in water storage tanks or inside underground sewer. Since it is readily soluble in water, considerable quantities of H2S may build up and be released when the water is discharged. The activities of sulphate-reducing bacteria can be inhibited by the maintenance of a moderate oxygen concentration in water, either by aeration or by the use of fresh seawater. Test for the presence of H2S shall be undertaken whenever it is necessary prior to entering a confined space where seawater is or has been present. TREATMENT OF PERSONS AFFECTED BY H2S: Persons affected by H2S inhalation require prompt medical attention due to the highly toxic nature of the gas. The rescue measures to be taken following an accidental exposure is listed hereunder: F&S Regulations Appendix 14

June 2004

Page 3

KOC F&S Regulations

HYDROGEN SULPHIDE

(i)

Positive pressure breathing apparatus must be worn by any persons attempting a rescue.

(ii)

The victim must be immediately moved to fresh air, possibly in the upwind direction of the gas leak. The rescuer must be outside the contaminated area before removing his / her personal BA set.

(iii)

If the victim has stopped breathing, resuscitation must be started immediately, using artificial respiration or a resuscitator if available. Resuscitation must be continued until the victim starts breathing unaided or until qualified medical assistance arrives. Medical help must be summoned as soon as possible.

BREATHING APPARATUS: Any escape mask duly approved by Health & Environment Team shall be used to protect against H2S exposure. A canister type respirator is not a substitute for BA set. TRAINING: Where H2S has been encountered, all persons must be informed of the potential danger due to possible exposure of H2S and of the required rescue procedure will be adopted in H2S is detected. The assets owner of the facility should ensure the provision of training for deploying a person in H2S prone area. H2S rescue drill should be conducted at least once a month inside the facility or plant where production, processing or dispatch of sour crude oil, gas or water takes place.

F&S Regulations Appendix 14

June 2004

Page 4

Kuwait Oil Company

Fire & Safety Regulations

(K.S.C.)

Appendix - 15 June 2004

SAFE GUARDING OF MACHINE APPENDIX - 15

SAFE GUARDING OF MACHINE The fundamental concept of machine safeguarding is to identify potential hazards and associated risks and accordingly provide safeguards to protect employees from the prevalent danger. In most of the operations, the hazards will be usually involved with machines, equipment; its point of operation, power transmission apparatus, energy sources, surrounding areas around the machines, operational as well as maintenance activity, and neighbouring facility. BUILT IN SAFEGUARDS: The manufacturer's safeguards are usually designed to be an integral part. The basics principles of safeguarding are: 1.

Engineer the hazard out of the job as much as possible.

2.

Guard against residual hazards.

3.

Train and monitor safety performance of workers.

4.

Proper use of safeguards provided in the facility.

If such precautions are not taken, the consequences can be serious in terms of injury and property damage. The following points must be kept in view while considering machine safeguard provision: *

Safeguarding is often thought of as being concerned with the point of operations or with the power transmission device. The safeguards can prevent accidents from direct contact with exposed moving parts, works in process, machine failure, electrical failure and operator error or human failure. The primary benefits of safeguarding are reducing the possibility of injury as well as machine downtime.

*

Various standardized devices and improvised barriers, enclosures as well as tools, have been developed to protect operators from hazards associated with powered machine or hand-operated equipment. Establishing effective means of safeguarding power transmission is easier than guarding points of operation as power transmissions are more standardized.

*

An acceptable safeguard should (i) conform to established standards (ii) be incorporated as permanent part of the machine, (iii) afford maximum protection, (iv) prevent access to the danger zone, (v) be convenient, (vi) be specifically designed for the machine and job, (vii) be resistant to fire, corrosion, wear and shock (viii) be durable (ix) not be generating additional hazards. Built-in safeguards are generally more effective and less costly in the long run than "homemade" barriers.

*

Supervisors should make every effort to match equipment for operations in terms of work location, working height, controls, materials handling aids, operator’s fatigue, adequate lighting, noise levels, and other environmental factors.

F&S Regulations Appendix 15

June 2004

Page 1

KOC F&S Regulations *

*

SAFE GUARDING OF MACHINE

Machines have certain basic mechanisms, which if exposed, will require safeguarding. These include mechanisms such as rotating, cutting or shearing, running nip points, screw or worm, forming or bending and impact mechanisms. Each of these mechanisms parts must have special safeguarding covers, barriers or other devices to protect workers and adjacent facilities. Power press consists of primary and secondary operations in which workers are exposed to potential injury. Wherever possible, high production or long-run dies should be guarded to shut off the press, or prevent normal operation if workers hand clothing or tools become caught in the press.

*

Automatic or semiautomatic feeds, if used, are generally successful safeguards. It can also increase production and reduce costs. The main advantage of such safeguards are that the operator does not have to access the point of operation to feed the press as well as the die can be enclosed completely, and the operator can leave the press untended for short periods of time.

*

The safe removal, or ejection, of materials is as necessary as safe feeding. Various methods of ejection include use of compressed air, punch, knockouts, strippers, and gravity. Operators should not be required to remove the finished product or scrap material manually.

*

Controls should be designed such that the machinery can be operated without endangering the workers. For example foot controls should be covered by stirrup-type covers to prevent accidental tripping. Dangers involved in machine operation can be eliminated either by enclosing the hazardous parts of the machine, or by redesigning it to eliminate exposed parts.

*

Safeguards used to ensure safe production include the fixed guard or enclosure, the interlocking guard or barrier, and the automatic protection device. Fixed guards or enclosures are preferred to all other types, as workers cannot remove it. When such safeguard is not practicable, interlocking guard or barrier can be fitted on to the machine preventing operation of control device until the guard or barrier is moved into position. Where neither the fixed nor interlocking safeguard can be used, then it is recommended to provide an automatic protection device. Such safeguard prevents the operator from coming into contact with the dangerous part of the machine while it is in motion, or it can stop the machine in an emergency.

*

Although machine automation has minimized various hazards associated with manual stock feeding & removal; however it has brought forward its own hazards. Automated machinery must be completely de-energized and locked out from the power source before anyone is allowed to service or reset the machines.

*

In addition to the use of effective safeguards, supervisors must instruct workers on safe operating practices to prevent accidents and injuries. All workers, before permitted to operate machinery, should be thoroughly trained on the use of machine safeguards. Positive safety procedures should be established and vigorously enforced.

*

Supervisors must set up a schedule for inspection and maintenance of machine safeguards as a regular part of their operations. Proper handling, watchful supervision, attentive employees, and regular maintenance can reduce wear and tear of such device. Before allowing workers to service a machines, Supervisors should establish precise lockout /

F&S Regulations Appendix 15

June 2004

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KOC F&S Regulations

SAFE GUARDING OF MACHINE

tagout procedures to isolate or shut off machines from power source. Any worn out, corroded, or damaged machine parts or safeguards should be replaced or repaired immediately. The following definitions are important: •

Device: A device is a mechanism or control designed for safeguarding at the point of operation.

•

Enclosure: An enclosure is safeguarding by fixed physical barriers that are mounted on or around a machine to prevent access to the moving parts. Enclosures are most effective when designed as part of the machine, as it can be bolted or welded to the frame or the floor.

•

Fencing: Fencing is safeguarding by means of a locked fence or tail enclosure that restricts access to the machine, except by authorized person.

•

Location: Safeguarding by location results when a hazard is physically inaccessible under normal operating conditions or use. Both fencing and location have limited use as safeguarding techniques and are permitted only if precautionary restrictions are met.

•

Nip Points or Bites: A nip point or bite is a hazardous area created by two or more mechanical parts rotating in opposite directions within the same plane and in close interaction.

•

Pinch Point: A pinch point is any place where a body part can be caught between the two or more moving parts.

•

Point of Operation: The point of operation is the area on a machine where material is positioned for processing - where work is actually being performed on the material.

•

Power Transmission: Power transmission includes all mechanical parts, such as gears, cams, shafts, pulleys, belts, clutches, brakes and rod, that transmit energy and motion from the source of power to the equipment or machine.

•

Safeguarding: Safeguarding is any means of preventing personnel from coming in contact with the moving parts of machinery or equipment, which can cause physical harm. The word guard is often used exclusively, referring to barriers designed for safeguarding at the point of operation; whereas enclosure is a barrier or cover that protects workers from other danger zones in the operation.

•

Shear Points: A shear point is a hazardous area created by a cutting movement of a mechanical part past a stationary point on a machine.

F&S Regulations Appendix 15

June 2004

Page 3

Kuwait Oil Company

Fire & Safety Regulations

(K.S.C.)

Appendix - 16 June 2004

INDUSTRIAL SAFETY TERMINOLOGY APPENDIX - 16

INDUSTRIAL SAFETY TERMINOLOGY INTRODUCTION: There are various terms (related to Industrial Safety), which are commonly used but carry specific definition other than its non-technical meaning. Some of such terminologies are defined as hereunder: •

Hazard and Risk:

Hazard:

A state or condition having the potential to cause a deviation from uniform or intended behaviour which, in turn, may result in damage to property, people or the environment.

Risk:

It is the likelihood of a hazard occurrence resulting in an undesirable event. Risks can be quantitively expressed in teams of probability or frequency. .

Risk Management:

It includes value judgements concerning the significance of risk measurement results.

•

Consequences

Explosion:

A mechanically or chemically generated rapid release of energy, which in turn generates a blast (or shockwave) capable of causing considerable damage due to velocity, impact or pressure pulses transmitted from it.

Fire:

A combination process, which generates heat, smoke or flame, or any combination of these.

Upper & Lower Flammability Limits:

The concentrations of flammable substance in air or oxygen above or below which respectively, combustion will not be sustained.

Fire Prevention:

Measure adopted to prevent an outbreak or escalation of fire in a particular location.

Fire Protection:

Design features, systems or equipment (e.g. sprinkler installation) that prevent or limit damage from fire in a particular location.

Toxicity:

The ability of Toxic (poisonous) substance, when absorbed by living tissue (through absorption, inhalation or ingestion) to cause injury or loss of life.

Threshold Limit Value: There are numerous categories of TLVs, each specific to a timerelated human exposure to toxic substances. The term is used to regulate the proximity of workers to a material of known toxic effects.

F&S Regulations Appendix 16

June 2004

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KOC F&S Regulations •

INDUSTRIAL SAFETY TERMINOLOGY

Assessment Techniques & Criteria:

Loss Prevention:

A systematic, often rigorous, procedure aimed at prevention of incidents, or estimation and minimising of their consequences.

Hazard Analysis

It is a systematic and quantitative assessment of potential hazards and its probable consequences.

Safety Audit:

It is critical review of a facility or its part, carried out at periodic interval with the intention to find out the unsafe act or unsafe condition. It is usually conducted internally.

Safety or Hazard Review / Survey:

These are teams of wide interpretation, sometimes implying the assessment standards but more often confined to a search for potential hazards.

Frequency:

The number of occurrences of a specific event over a time period (usually a year). The number of accidents occurring to a group in a stated environment during a specific period of exposure (manhours or mandays)

Accident Rate: Fatal Accident Rate: (F.A.R.)

The number of deaths recorded or predicted per specific period of exposure.

•

Categories of Risk: There are two main categories of risk: Risks to life. Risk to plant and productivity.

•

Risk to Life: Risk can be sub-divided into two main groups. 1. Ordinary Risks: These are common to all facilities and arise principally from human activity on or around the plant. Falling off the structure. Tripping over obstacles. Impact by falling objects. Contact with moving parts of equipment. Physical operations such as lifting, scaffolding, flexing, or carrying out maintenance. 2.

Process Risk: It varies from plant to plant, the main classes of risk are : Fire or explosion due to emission of flammable material. Emission of toxic or corrosive materials. Discharge of hot scalding fluids. Discharge of cold sub-zero fluids. Blast effect or projectiles arising from equipment rupture/fragmentation. Asphyxiation risks.

The process risks usually arise in the event of loss of containment from plant inventory, and consequently general public as well as plant personnel can be at risk in such situations. •

Risk to Plant & Productivity: These are the risks, which are concerned with damage to the plant or unavailability of plant due to other reasons. It can also be conveniently classified into two sub - groups.

F&S Regulations Appendix 16

June 2004

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KOC F&S Regulations

INDUSTRIAL SAFETY TERMINOLOGY

1.

Risks due to Incidents with Risk to Life: The main risks falling into this category are certain "process risks" which may lead either to plant unavailability (e.g. equipment rupture, fire explosion) or to a plant shutdown pending an investigation (e.g. toxic release or other dangerous occurrences). Even "ordinary risks" to life may sometimes call for plant shutdown pending investigations.

2.

Risks due to Incidents without Risk to Life: The risk falling into these categories are purely operational risk. e.g. Equipment breakdown or unavailability. Blockages of equipment or pipe work. Fouling of equipment. Some of hazardous substances frequently handled in oil industries are: Gases (flammable, non flammable, toxic, compressed) Liquids (flammable, toxic, acidic, alkaline). Solids (flammable, volatile). Viscous Materials. Oxidizing, reactive & corrosive substances.

•

ACCIDENT: Accident is an unplanned or unwanted occurrence, leading to any one, or combination of: Personal injury. Damage to property (including fire) or environment. Traffic accident, when a person is injured or a vehicle damaged. Spill of hydrocarbon, oily water or chemical. Theft or misuse of Company property.

•

NEARMISS: An occurrence that, under slightly different circumstances, could have resulted or lead to an accident. Such incidents include: -

•

Finding Ordnance (EOD) Fire or Explosion threat An occurrence or series of occurrences that could lead to an accident.

INCIDENT: An event or chain of events, which has caused or could have caused, personal injury, damage to property or environment. . (A dangerous occurrence includes both accident and Nearmiss cases. In other words all accidents and nearmiss cases are incidents.)

F&S Regulations Appendix 16

June 2004

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Kuwait Oil Company (K.S.C.)

Appendix – 17 June 2004

Fire & Safety Regulations

GUIDELINES FOR THE USE OF TOOLS WITH EXPLOSIVE MATERIALS (Nails, Cable Spiking Guns, etc.) APPENDIX – 17

GUIDELINES FOR THE USE OF TOOLS WITH EXPLOSIVE MATERIALS

(Nails, Cable Spiking Guns, etc.) The tools using explosive materials shall not be operated in a flammable or explosive atmosphere. The personnel trained in the use of such tools may operate it with due authorization under appropriate work permit and compliance to the Company as well as Kuwait State Regulations in this regard. Prior to its use, a certified & trained operator shall thoroughly inspect such tools in accordance with the manufacturer's instructions. Any fault or failure noticed at the time of inspection shall prohibit the use of the tool. The following precautionary measure shall be observed during test as well as operations of the tools: a.

The tools using explosive materials shall NEVER be pointed at persons.

b.

Adequate ear and eye protection must be worn whilst operating the tool.

c.

Tools shall be loaded only just prior to being used.

d.

Such tools shall not be left unattended and must be unloaded if not being fired.

e.

Fasteners and cartridges to be used must be appropriate for the intended job. It must not be used against hard or brittle material, or very soft material without adequate protective backing.

f.

Cartridges, which vary in explosive strength, shall not be mixed or carried loosely. It shall be stored and used only from the manufacturer's packages / boxes.

g.

If not in use, tools and cartridges will be kept under lock and key in a safe place under the control of a responsible person.

h.

A record of explosive materials, its receipts & issuance etc. shall be maintained with the detail as indicated in Explosive Material Record Register.

F&S Regulations Appendix 17

June 2004 Page 1

KUWAIT OIL COMPANY (K.S.C) EXPLOSIVE MATERIALS - RECORD REGISTER Part 1 to paragraph 7.5

Name of the Contractor: ........................…………………… Controlling Team / Group: ……………………. Location: ............................................... Details Receipts Issuance & Place of Use Explosives Returned Explosives removed from site of disposal or destroyed Details of Explosives used in each operation Details of Misfired Shots

Description of Explosives

Week Ending ................ Quantity

Date

Total Stock

Remarks

KUWAIT OIL COMPANY EXPLOSIVE STORAGE PRECAUTIONS Store No.:.....................

Licensed Capacity:........

Location: ..................... 1.

STORE ONLY THOSE EXPLOSIVES, which includes shaped charges, detonating cord, boosters but NOT detonators.

2.

KEEP the storage interior CLEAN and free from grit. If you enter the store, check your footwears are clean. .

3.

AVOID HAVING OPEN BOXES, LOOSE CARTRIDGES or SPOOLS in the store.

4.

Do not PACK tightly - the store should be large enough for its storage capacity and have air space around the contents.

5.

Use only NON SPARKING TOOLS and protect explosives from IMPACT or ROUGH HANDLING.

6.

KEEP THE STOCK FRESH by regular turnover.

7.

Maintain adequate VENTILATION, and PREVENT ingress of rainwater.

8.

Any maintenance inside the storage facility shall be carried out ensuring the contents are removed to a safe place and the store is decontaminated as required.

9.

DO NOT SMOKE in or around the store. Any source of ignition such as matches, lighters, flammable materials etc. shall not be allowed inside the store.

10.

If artificial light is needed inside the store, use only APPROVED (intrinsically safe) FLASHLIGHT.

11.

MAINTAIN an efficient housekeeping in the storage area, prohibiting accumulation of combustible materials or debris in the vicinity.

12.

Ensure required WARNING signs are posted at prominent locations and maintained.

13.

Maintain an accurate INVENTORY of explosive stocks.

14.

Accompany users and oversee withdrawals.

15.

Keep the store LOCKED - ensure only AUTHORISED PERSONS have access to keys.

16.

In case of inclement weather such as thunderstorm, the store should remain close & vicinity evacuated.

17.

Any accident incident such as FIRE, BREAK-IN, ATTEMPTED BREAK-IN, and THEFT etc. shall be immediately reported to BURGAN FIRE STATION as per Accident / Incident Reporting Procedure.

KUWAIT OIL COMPANY DETONATOR STORAGE PRECAUTIONS Store No.:.....................

Licensed Capacity:......

Location: ..................... 1.

Store ONLY DETONATORS.

2.

Do not keep any LOOSE DETONATORS in the store.

3.

Keep the interior of the store / annex Clean, tidy and free from obstructions ensuring detonators readily accessible for issuance and inventory checking..

4.

DO NOT SMOKE in or around the store. Any source of ignition such as matches, lighters, flammable materials etc. shall not be allowed inside the store.

5.

If artificial light is needed inside the store, use only APPROVED (intrinsically safe) FLASHLIGHT.

6.

Prevent the ingress of MOISTURE or rainwater in the storage facility.

7.

MAINTAIN an efficient housekeeping in the storage area, prohibiting accumulation of combustible materials or debris in the vicinity.

8.

Any maintenance inside the storage facility shall be carried out ensuring the contents are removed to a safe place and the store is decontaminated as required.

9.

Ensure required WARNING signs are posted at prominent locations and maintained.

10.

Maintain an accurate INVENTORY of explosive stocks.

11.

Accompany users and oversee withdrawals.

12.

Keep the store LOCKED - ensure only AUTHORISED PERSONS have access to keys.

13.

In case of inclement weather such as thunderstorm, the store should remain close & vicinity evacuated.

14.

Any accident incident such as FIRE, BREAK-IN, ATTEMPTED BREAK-IN, and THEFT etc. shall be immediately reported to BURGAN FIRE STATION as per Accident / Incident Reporting Procedure.

KUWAIT OIL COMPANY REQUEST FOR EOD AWARENESS PRESENTATION TO:

TEAM LEADER - SAFETY

REQUESTING TEAM / GROUP: ---------------------------------------------NAME OF REQUESTOR:-----------------------------------------------------------TARGETED AUDIENCE: -----------------------------------------------------------PROPOSED DATE OF PRESENTATION: -------------------------------------PROPOSED TIME OF PRESENTATION: --------------------------------------VENUE OF PRESENTATION: -----------------------------------------------------APPROX. NO. OF ATTENDEES: ----------------------------------------------SIGNATURE: ------------------------------------------------------------DATE: ----------------------------------------------------------------------TELEPHONE: -----------------------------------------------------------RADIO CHANNEL: ----------------------------------------------------N.B.

1.

The duration of EOD Awareness session will be between 30 minutes to 1 hour.

2.

The requesting team should provide a list of attendees indicating their, designations, parent Company / Contractor and sponsoring Team.

3.

The requesting team may have to arrange Interpreter wherever required.

4.

For further detail, Safety Team is to contacted on Telephone No. 71522..

KUWAIT OIL COMPANY REQUEST FOR EOD SERVICES (For Internal Use only)

To, Team Leader – Safety NAME & DESIGNATION OF REQUESTOR: __________________________________ CONTACT NO.: __________________________________________________ RADIO CHANNEL: _______________________________________________ TEAM / GROUP: _________________________________________________ LOCATION OF EOD SERVICE: ___________________________________ NATURE OF WORK AT LOCATION: ______________________________ DATE OF EOD REQUEST: _______________________________________ TAEGETTED DATE OF EOD CLEARANCE: ________________________ TASK LOCATION:

____________________________________________ (GC, BS, Oil Field Area etc.)

SUB-LOCATION:

_____________________________________________ (Well No. Flowline, Street No. Etc..)

OTHER DETAILS OF WORK SITE (Attach Site, Layout Drawings for the area)

ORIGINATOR’S SIGNATURE:__________________________________________