Mellitah Oil & Gas BV- HSEQ Corporate Guidelines for HSE Requirements During Yearly Scheduled Shutdown

- Onshore

Rivision History

A major revision to simplify/clarify the A. Derkaoui A. Elasfar A. Ganidi M. M. Oun

A2 requirement in managing the scheduled
10/06/2009 11/06/2009 13/06/2009
shutdown activities.
A. Ellbusefi A. Elasfar A. Ganidi A. Amesh
A1 Issued for implementation
15/05/2008 18/07/2008 19/05/2008
A. Ellbusefi HSE Staff NA NA
P3 Issued for Departmental Review
20/04/2008 28/04/2008
A. Ellbusefi A. Elasfar NA NA
P2 Issued for in initial Review
16/03/2008 17/03/2008
A. Ellbusefi A. Elasfar N/A N/A
P1 Draft
11/01/2008 22/01/2008

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 Mellitah Oil & Gas BV- HSEQ Corporate Guidelines for HSE Requirements During Yearly Scheduled Shutdown

TABLE OF CONTENTS

1. INTRODUCTION........................................................................................................................ 5

2. OBJECTIVE ............................................................................................................................... 5

3. AREA OF APPLICATION.......................................................................................................... 5

4. REFERENCES ........................................................................................................................... 5

5. ABBREVIATIONS AND ACRONYMS ...................................................................................... 6

6. RESPONSIBILITIES .................................................................................................................. 7

7. WORK PLANNING AND DOCUMENTATION ........................................................................ 10

8. WORKSITE PREPARATION .................................................................................................. 11

9. REMOVING EQUIPMENT FROM SERVICE........................................................................... 12

9.1. ISOLATION PLAN & REQUIREMENTS ...................................................................... 12
9.2. POSITIVE ISOLATION ................................................................................................. 13

10. RISK MANAGEMENT PROCESS ........................................................................................... 13

10.1. JOB RISK ASSESSMENT (JRA) ................................................................................. 13

11. SITE VISIT & INSPECTION..................................................................................................... 15

11.1. PROVING ISOLATION INTEGRITY ............................................................................ 15
11.2. GAS TESTING/MONITORING ..................................................................................... 15
11.3. FIRE PROTECTION MEASURES / FIRE WATCHER ................................................. 16

12. EQUIPMENT ............................................................................................................................ 16

13. CLEAR ADJACENT AREA ..................................................................................................... 16

14. ACCESS / EGRESS CONSIDERATION ................................................................................. 17

15. WORK SITE BRIEFING / TOOL BOX TALK .......................................................................... 17

16. GENERAL PERMIT GUIDELINES .......................................................................................... 17

16.1. COMMENCE WORK .................................................................................................... 18
16.2. HOT WORK ACTIVITIES ............................................................................................. 19
16.3. LIFTING AND RIGGING ACTIVITIES .......................................................................... 19

17. HIGH RISK TASKS ................................................................................................................. 21

18. PPE / CLOTHING .................................................................................................................... 22

19. EMERGENCY RESPONSE ARRANGEMENTS ..................................................................... 22

20. ACTIVE MONITORING BY LINE MANAGEMENT ................................................................. 23

21. SHUTDOWN WASTE MANAGEMENT................................................................................... 24

22. RESCUE AND MEDICAL ........................................................................................................ 24

23. SHUTDOWN HSE TEAM ........................................................................................................ 25

24. SHUTDOWN HSE MATERIALS ............................................................................................. 25

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 Mellitah Oil & Gas BV- HSEQ Corporate Guidelines for HSE Requirements During Yearly Scheduled Shutdown - Onshore

25. COMMUNICATION AND RELEVANT REPORTS DURING THE SHUTDOWN ACTIVITIES 26

26. RETURN PLANT TO SERVICE .............................................................................................. 26

ATTACHMENTS................................................................................................................................ 27

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 Mellitah Oil & Gas BV- HSEQ Corporate Guidelines for HSE Requirements During Yearly Scheduled Shutdown - Onshore

1. INTRODUCTION

Mellitah Oil & Gas B.V. has the responsibility to secure the environment, health and safety of
its employees including seconded staff and contractors. Each year, scheduled shutdown
takes place in Mellitah Oil & Gas onshore Plants.

This document shall establish the HSE guideline for the yearly shutdown activities in order to
provide a reference for any similar shutdown and it does not override any mentioned
procedures such as: Permit to Work Procedure, Emergency Response Plans, etc.

Organizations and system preparedness can be benefit/ success for implementing the
relevant procedures prior or in the beginning of planned Shutdown activities, that shall gives
suitable period to measure/assess for achieving HSEQ objectives.

2. OBJECTIVE
The main objective of this document is to provide a simplified procedure to be used before,
during and after any shutdown operations. To determine the responsibility of persons from
different level (Manager, SPT, Coordinator, supervisor, individual, etc…) to successfully
achieve the SD planned activities with safety in mind, in order to meet the required
performance and compliance in accordance to the schedule target and implementation of
necessary measures to meet compliance with codes, standards, Company specification and
industrial safe practices.

3. AREA OF APPLICATION
These Corporate Guidelines for HSE Requirements during Yearly Scheduled Shutdown
areapplicable to all Mellitah Oil and Gas onshore facilities.

4. REFERENCES

[Rif.A1] MOG-HSEQ-SF-P-024 Corporate Permit to Work Procedure (onshore)

[Rif.A2] MOG-HSEQ-SF-P-110 Corproate Confiened Space Entry Procedure

MOG-HSEQ-SF-WI-
[Rif.A3] Confined Space Entry Mellitah Complex
058

MOG-HSEQ-SF-WI-
[Rif.A4] Confined Space Entry Wafa Field
062

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 Mellitah Oil & Gas BV- HSEQ Corporate Guidelines for HSE Requirements During Yearly Scheduled Shutdown - Onshore

Corporate Personal Protective Equipment

[Rif.A5] MOG-HSEQ-Q-P-112
Management

[Rif.A6] MOG-HSEQ-SF-P-109 Corporate Working at Height Procedure

[Rif.A7] MOG-HSEQ-SF-P-111 Corporate Lifting and Hoisting Operation Procedure

[Rif.A8] MOG-HSEQ-Q-WI-238 Electrical Isolation

[Rif.A9] MOG-HSEQ-Q-WI-239 Process Mechanical Isolation

[Rif.A10] MOG-HSEQ-IN-P-099 Corporate HSE Risk Management

MOG-HSEQ-SF-WI-
[Rif.A11] Work Instruction for Preparing Risk Assessment
057

Corporate Guidelines for Handling Radioactive

[Rif.A12] MOG-HSEQ-SF-G-028
Material

MOG-HSEQ-SF-P- Integrated Emergency Response Plans for all MOG

[Rif.A13]
032, 035,107 &108 sites (Onshore)

Communication Guidelines for Inspection and

[Rif.A14] MOG-HSEQ-Q-G-286
Maintenance Activities during Shutdown

5. ABBREVIATIONS AND ACRONYMS

Following is a list of abbreviations commonly used in this document.

BA Breathing Apparatus

ERP Emergency response Team

HAZOP Hazard and Operability Analysis

HSEQ Health, Safety, Environment & Quality

IRT Incident response Team

LEL Low Explosivity Limit

LOTO Lock-Out Tag-Out

JSR Joint Safety Review

JRA Job Risk Assessment

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P&ID Piping & Instrumentation Diagram

PCO Permit Control Office

PPE Personal Protective Equipment

PTW Permit to Work

QRA Quantitative Risk Assessment

RAM Risk Assessment Matrix

SCBA Self Containes Breathing Apparatus

SIMOPS Simultaneous operation

SD Shut-Down

TBT Tool Box Talk

SPT Superintendent

WWT Waste water Treatment

Safe System of work must include processes or systems that

SSW incorporate Hazard Identification, Risk Assessment, Permit to Work and
any other associated systems (isolation)

6. RESPONSIBILITIES

The responsibilities relevant to the present documentare outlined in the following

paragraphs:

Field/Complex Manager or his delegate

Field/complex manager or his delegate will control the overall job with coordination with
HSEQ and Maintenance departments.

Field / Complex HSE Coordinator or his delegate

He is responsible for monitoring the issued PTW, implementing the required measure/s of
control to ensure safe system of work for various shutdown activities include:
 Provide of expert technical safety advice to the operations and
maintenance/contractor, particularly when the risk is judged high or medium.
 Provide resources and HSE personnel to control/monitor safety requirements and
permit compliance.
 Approve, monitor and cancellation of Hot and Cold Permits to Work.

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 Ensuring that all safety measures/mitigation stated on the permit and its supported
document are implemented.
 Attend Daily Shutdown Meeting

Production SPT

 Monitoring the Shutdown operation sequences (According to Operation

Manual/Philosophy).
 Plan and assign resources as required.
 Maintain and updated the Shutdown operation progress/status report.
 Ensure the required operability and administration of the PTW system.
 Attend the Daily Shutdown Meeting.

Maintenance SPT

To coordinate with the Production SPT or his delegate and HSE coordinator or his delegate
in order to ensure compliance with HSEQ Requirements and :

 the provision of safety related documents, such as risk assessment, procedures, etc...
 all members (supervisors, work force) have full knowledge of the restriction, and
associated hazards include their individual responsibility.
 Applying PTW for planned activities.
 Personnel competency to perform the work include their HSE training needed.
 Attending Daily Shutdown Meeting.

Contractor Shutdown Coordinator

 Provide Company with relevant Documentation related to Shutdown activities

(Maintenance, Modification/Changes, procedures, etc…).
 Preparing and updating progression report status.
 Maintain adequate communication with the involved parties.
 Provide additional resources (equipment, material, manpower, etc…) if requested.
 Ensure that only safest and appropriate equipments and tools are used.
 Monitor, control the schedule in order to identify area/ geographical and timing
conflicting activities.

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Area/Shift supervisor (Production)

 Ensure adequate communication/coordination during shutdown operation.

 Carrying out regular checks of work sites to ensure adherence to the conditions and
safe working practices as stated in the Permits to Work.
 Liaison with the Safety Representatives on safety related issues.
 Ensuring the correct authorisation, issue of Hot and Cold Main Permits to Work in their
area.
 Ensuring required site work preparation as stated on PTW & its supported certificate or
document, such as draining, freeing/inerting, etc...
 Ensuring the mechanical, physical/positive and electrical isolation (LOTO) and their
cirtificates where/when needed.
 Work site has been inspected prior to work starting.
 Conduct HSE Toolbox meetings.

Area Operators

 Endorse operation of site work preparation such as draining, inerting, etc…

 Report any abnormal or anomaly issues in course of Shutdown operation.
 Supervise process line/equipment physical isolation or de-isolation.
 Ensuring that all conditions of Permits to Work are properly carried out and
maintained at all times that work operations are in progress.
 Carrying out regular checks of work sites to ensure adherence to the conditions
and safe working practices.
 Ensuring that immediate corrective actions are taking place.
 Ensuring that the proper safety equipment and work gear is provided.
 Reporting any non- compliance or safety related matter.
 Reporting any changes in work content or environmental conditions to the Area
Authority and ensuring that safe conditions for work are re-established.

Performing Party (Maint/contractor Supv)

 Instruct the work forces under his authority of the safety measures, mitigation,
the associated hazards and permit requirements.
 Reporting any changes in work content or environmental conditions to the Area
Authority and ensuring that safe conditions for work are re-established.

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 That housekeeping is maintained so that areas are orderly clean and tidy at all
the time.
 Ensuring that the Permit is revalidated if work is to continue longer than for one
shift.
 On completion of the work, the work site is left in a safe and tidy condition, all
tools and equipments are withdrawn, barriers and grating replaced.
 Work forces are made fully aware of the hazards associated with the task for
which a "Permit to Work" is issued and of the Safety precautions to be taken.
 Adequate PPE and appropriate safe equipment is provided.
 Conduct Toolbox Talk as well review JRA.

Note1: Enforce all HSE rules and regulations evenly and consistently whenever
and wherever violations or non-compliance are observed.

Note2: Compliance and execution are still in the hands of the Supervisors, work force
performing task and those individual roles/responsibilities to ensure the compliance and
implementation of all the requirements/safety measures.

7. WORK PLANNING AND DOCUMENTATION

The key objective in developing an adequate working plan and its relevant documentation is
to establish the necessary requirements of each sequential activity that will be undertaken
during initial or major shutdown within Mellitah Oil & Gas Onshore facilities. It’s helpful to
govern the various activities within geographical areas and time, by:

 Identifying shutdown work scope:

• anlayise relevant information for activities intended for the shutdown,
• complete a list of all activities intended for shut down and,
• Prioritise the list and identifying all essential work.

 Plan and schedule resources:

• Identify each individual task in the shutdown process,
• determine resources required for each task and assign appropriate owner,
• determine pre requisite tasks prior to shutting down process, ensuring
hazards are identified and controls are in place.
• ensure all safety and testing equipment is calibrated, certified and on site
prior to shutdown commencing.

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 Mellitah Oil & Gas BV- HSEQ Corporate Guidelines for HSE Requirements During Yearly Scheduled Shutdown - Onshore

• Compile a schedule to track shutdown and equipment preparation sequence.

It is essential that the work plan be placed into operation without confusion, to fully utilise the
knowledge, skills, experience, include coordination, communication (including stakeholders)
and capabilities of the entire organization.

Adequate engineering and safety documentation is required to the success of achieving the
target and safety preparedness; depending on the various activities nature, type and
complexity, taking in consideration the relevant document adequacy and quality. This will
include but not limited to:

 Scope of Work & Method of statement

 Specific Procedures
 Risk Assessment
 HAZOP study if modification/changes require so
 SIMOPS restricted or adjacent area
 Marked-up P&ID
 Blinding Tracking List
 Equipment/Item Documentation

Note: Safety interface documents shall be produced where relevant to demonstrate how
these safety requirements are met, e.g. between:
Train 1 and Train 2 or between modification/construction activities and storage facility

8. WORKSITE PREPARATION

Depending on the nature, type or complexity of the job requires PTW. Once the hazards
associated with a particular job have been identified, it will be necessary to consider how
they can be captured, separated, isolated from the process lines, equipment or plant to be
worked on. Flammable, toxic, pressurised, high temperature, or low temperature fluids must
be removed, including the electrical sources.

An essential ingredient of any safe system of work is the integrity of the isolation procedure
and the required supported specific plan. Whilst the Work Permit identifies the isolation
requirement it does not provide the specific isolation details. These are to be
formal/documented and attached to the permit as per Mellitah Oil & Gas Isolation and re-
instatement work instruction or procedures. Ensure that appropriate precautions,

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 Mellitah Oil & Gas BV- HSEQ Corporate Guidelines for HSE Requirements During Yearly Scheduled Shutdown - Onshore

safeguards, and control measures are fully implemented so that work can proceed and
completed safely.

To provide a safe working environment, a various worksite preparation shall be considered,

this include but not limited to:

 Depressurizing, draining, enerting and vent

 Disconnection piece/circuit pipe
 Isolation, blank, flanges or blinding
 Electrical isolation of power sources
 Removal and management of all combustible materials
 Provision of additional firefighting equipment
 Provision and erection of fire resistant tarps/blankets to limit spread of sparks from
welding/burning/grinding
 Safe sitting equipment, welding equipment, diesel driven air Compressors, etc…
 Gas testing, requirement for constant monitoring

9. REMOVING EQUIPMENT FROM SERVICE

9.1. ISOLATION PLAN & REQUIREMENTS

The plan of Isolations details used and the necessary precautions taken will depend on the
level of risk and/or the potential hazardous release that the job is likely to involve. As crucial
part of worksite preparation, the isolation requirements must identify, and provide control of
all hazardous energy sources within the defined system and/or equipment isolation
boundaries.

Based on the comprehensive suite of documented procedures and plan to ensure

containment of all hazardous sources such as electrical, process fluid, hydraulic, pneumatic,
thermal, chemical and mechanical systems. Therefore, a careful consideration when
reviewing the worksite preparation requirements by Production/operation coordinator, and
the Shift supervisor when handling the execution of the preparation is recommended. Refer
to: MOG-HSEQ-Q-WI-038 and 039.

Documentation of Isolation
There must be a clear description of the isolation plan and marked-up P&ID, including a
detailed list tracking all items and method (e.g. Valves, spades, blinds, pipe/piece of pipe
disconnection, blank flanges, vent and drain opened, breakers rack out, etc) utilised in the

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 Mellitah Oil & Gas BV- HSEQ Corporate Guidelines for HSE Requirements During Yearly Scheduled Shutdown - Onshore

isolation. The isolation plan together with any other supported document such as P&ID and
register must be kept in the Permit Control Office (PCO).
Log register should be maintained and updated for all electrical isolation/de-isolation.
Any changes to the Isolation plan or isolation boundaries shall be approved/initialled by the
Maintenance and Production superintendents. This should be done before any physical
changes at site.

9.2. POSITIVE ISOLATION

The only allowable isolation for intervention of a hydrocarbon system is a spectacle blind or
spade in the closed position. All of the isolation points must be identified on an appropriate
marked-up P & ID accompanied by the mechanical isolation certificate. All valves used in the
isolations must be given a secure locked status and record as such.

10. RISK MANAGEMENT PROCESS

The effectiveness of the risk assessment process depends largely on competency, skills and
experience of the persons. Those persons that have the capability to utilise techniques and
required methods in order to identify, evaluate/analyse the risks of the overall
activities/operation will be undertaken prior, during and after shutdown. Depend on the
nature and the complexity of various activities, using as support the necessary study such as
HAZOP, QRA, etc, and that in early time of the scheduled shutdown to promote an adequate
Safety preparedness system and readiness in order to identify the necessary safeguards,
precautions, specific procedure , training needed and their implementation in the real time.
Refer to : MOG-HSEQ-IN-P-099.

The following aspects shall be also considered:

• Impact of the tasks affected facility/unit to its surrounding.

• Interference between unit/train in shutdown and other in operation.
• Unplanned release from isolatable system/unit.

10.1. JOB RISK ASSESSMENT (JRA)

The process of identifying the hazards, evaluating risks and applying controls and specifying
any recovery measures will be referred to as Job Risk Assessment (JRA).

The initial JRA should be undertaken before the origination of the Work Permit, and any
supporting permits or certificates. Whenever work has to be undertaken by Company, Third
party or contractors on Mellitah Oil & Gas facilities, it is necessary to perform a JRA.

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Risk Assessment Matrix (RAM) is used as tool that provides a standard approach to the
qualitative assessment of risk. All activities, which fall in the High, Medium-High sector or
level, require documented evidence (MOG-HSEQ-F-115) in objective to:

 Identify the potential hazards associated with the job

 Assess the consequences and the likelihood (risk evaluation/analysis)
 Implement the necessary safety control measures and mitigation to eliminate the risk or
reduce the risk by demonstrating “As Low As Reasonably Practicable” (ALARP)
 Determine recovery measures in case the control fail.
(Is the process by which the results of a risk analysis are considered against judgment,
standards and criteria, to show that measures in place are adequate)

It is essential that Production Supervisor take a lead roll in the risk assessment process, the
HSEQ team will assist in this event. This will ensure continuity over 24 hrs operation with the
risk assessment being discussed during each shift hand over.

Below diagram show steps to perform JRA.

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11. SITE VISIT & INSPECTION

Following preparation of the plant and equipment and prior to the task commencing, the
work site should be inspected by the relevant Production Supervision to ensure that all
aspects of the work have been considered and that the site, plant and equipment are in a fit
state for the work to proceed.

11.1. PROVING ISOLATION INTEGRITY

With the aid of the marked-up P&IDs or schematics and Blind tracking list, all boundary
points of the isolation should be inspected and a final check on the integrity of the isolation
carried out. Upstream and downstream valve integrity for the associated positive isolation
must be re-checked by "Pressure build-up" whenever practicable. Valve isolation tags and
locks should be confirmed.

Note: For positive isolation such as spectacle blinds / blanks, the check includes ensuring
that correctly rated gaskets are in place and the flanged studs and bolts have been
tensioned correctly. Isolation integrity checks must also include a check on the use of
secondary isolation where appropriate by ensuring that they are properly engineered and
installed correctly.

11.2. GAS TESTING/MONITORING

Gas Test should be made for;

A. Flammable gas test (LEL)

B. Toxic gases
C. Oxygen deficiency or enrichment

The Gas testing and monitoring is a crucial element. Therefore, the following should be
considered:

a. The qualification of the person who takes the measures

b. The choice of the appropriate measuring equipment
c. The calibration and the maintenance of the measuring equipment
d. The measuring equipment limits
e. The frequency and locations of sampling or testing
f. What to measure and in which order?
g. The interpretation of the results

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Test should be carried out:

a. Just prior entry
b. Continuously as required
c. When it is suspected that conditions have changed
d. Before a permit extension/re-validation is granted

Note: Initial gas testing of the internal atmosphere must be carried out from the outside of
the confined space at different level, If the gas tester is required to enter the confined space
to make further tests such as large vessel or storage tank, breathing apparatus, harness and
safety line must be worn. Further safety attendant must be present.

11.3. FIRE PROTECTION MEASURES / FIRE WATCHER

A suitable trained fire-watcher will be nominated for the task and fully briefed during the Tool
Box Talks (TBT) conducted by operations person in charge or by safety specialist, who will
address responsibilities, procedures and hazards associated with the work , especially in
case of Hot Work activities.

FIRE WATCHER

The trained fire watcher must be fully aware of his duties and responsibility assigned for:

 Use the protection equipment on site (fire extinguishers, charged hoses, etc..
 Raise the alarm in the event of fire or problem inside a vessel or tank.
 Use the available means of communication.

12. EQUIPMENT

All equipment to be used for the work must be suitable and in a good condition. Welding
equipment must be sited securely, adjacent to the work area and safely positioned. Effective
earthing arrangements should be in place. Gas cylinders must be secured in position (up-
right) and have isolation keys in place with the associated hoses depressurised during work
stoppages.

13. CLEAR ADJACENT AREA

It is essential that there is no conflicting work in adjacent areas. This is of course a prime
consideration in PTW preparation and issue. It is also important to consider the area or unit
above and below the work site. This is especially important on lower levels, where falling
sparks, slag or even hydrocarbon fluid could drop and accumulate. The effects of air

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movement / wind direction within open units or outside decks / walkways should be
considered.

14. ACCESS / EGRESS CONSIDERATION

Suitable access to and egress from the work site must be available all times. Where
temporary access / egress is provided , such as scaffolding , it will be constructed , certified
and used in line with approved company procedures.

15. WORK SITE BRIEFING / TOOL BOX TALK

TBT or Work site briefing play a vital part in communicating responsibilities, procedures to
be followed and any hazards associated with the undertaking task. The work team leader
(foreman) will conduct a pre-job safety briefing prior to work commencing and to be
delivered to personnel involved with the work in hand.

16. GENERAL PERMIT GUIDELINES

 Work permits can be prepared in advance but will not be issued to the site
performing Supervisor until the job site (where the task will be performed) has been
visited and assessed shortly before work is to start.
 The site operating authority must be assured that the site performing Supervisor
understands the conditions / limitations laid down in the permit
 It is important to make sure that one activity under a permit to work does not create
danger for another. Cross-referenced permits should be jointly authorized.
 All personnel involved with the authorization of the permit or doing the work must be
alert to the possible changes in conditions and if they occur, shut down the operation.
Work will only be resumed when safe conditions have been re-established and the
original permit reactivated or possibly a new one issued.
 When work is completed the site must be left in a safe and tidy condition. This needs
to beverified by the Operating authority.
 Under No circumstances will the same person sign any PTW as Area Authority and
Task Supervisor (site performing authority).
 Simultaneous work and PTW limitation must be consider
 Conditions must becontinuouslymonitored

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 The Area or Equipment affected by the work is clearly defined and prominently
marked by advance visual displays and barriers as necessary to warn of associated
hazards and restrictions.
 Personnel are fully notified of the controlled operations planned and the associated
restrictions resulting from such operations.
 Personnel are fully apprised of their responsibility and authority when under the
control of a PTW.

16.1. COMMENCE WORK

During the execution of the shutdown, the following must be respected in order to carry out
the activities according to the prescribed local legislation as well as the current procedures:
 Review shutdown documentation
 Coordinate plant shutdown as per procedures (Shutdown philosophy procedure)
 Track plant shutdown progress.
 Coordinate execution of critical function test during shut down phase
 Coordinate equipment preparation
 Perrform safety audits during shutdown work
 Record/report HSE non conformance
 Communicate as and when required
 Monitor shutdown work against critical path
 Monitor resource usage and take appropriate action
 Identify barriers to achieving shutdown critical path and negotiate solution.

Below is the execution of the activities following the pre-work site preparation and checks,
the documentation is completed and signed, an initial gas testing is carried out, then the
planned activity can proceed (for example hot work (HW) / CSE):

 The task is authorized to commence by the production supervisor and checked

by the permit controller and the safety specialist for possible conflict prior to
issue.
 The Hot work permit with the cross referenced isolation certificate attached is
issued and accepted by the team work leader.
 The team work leader conducts the pre- job briefing prior to starting the work.

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16.2. HOT WORK ACTIVITIES

Whenever hot works are to be carried out, it is necessary to follow strict procedures.
 Arc and acetylene welding or cutting equipment must be inspected for
any defect before transferring to operation site.
 Work can not proceed before the on site safety specialist accomplish
his inspection, gas testing and PTW final on site review.
 All welding equipment must be equipped with 9 kg powder type fire
extinguishers , more fire extinguishers and fire watchers will posted
around operation location by the on site safety specialist.
 Shielding will be used to prevent welding sparks and heat from igniting
flammable / combustible materials.
 When welding or cutting near flammable / combustible materials, be
sure to check for smoldering fire after the work is completed. Always
use water to wet the material before and after the work, a water circle of
3 to 5 meter will be made under the targeted part of plant / equipment,
to prevent any event had the potential to cause a fire / explosion.
 Remove all rubbish and scrap from the site at the end of each worked
operation, empty rubbish and trash bins at the end of each work day.

16.3. LIFTING AND RIGGING ACTIVITIES

Before beginning crane operations, the following instructions must be taken into
consideration:

LIFTING:

 Valid Certifications for Lifting Equipments, Gears, Operators & Riggers/Banksman

 The crane safety inspection checklist must be completed by the operator. The
checklist will include the anti-over winding device; the operator must be
competent to carry out such inspection.
 All crane outriggers will be fully extended; pads will be placed under all trigger
jacks.
 Workers will not ride on loads, crane hooks, work or walk under crane loads.
 Crane operators will use extreme care when operating near to high voltage utility
wires. Crane booms, load ropes / loads will not be moved closer than 6 meters to
high voltage utility wires.

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 The working radius of each crane will be roped off and warning signs erected on
all four sides.
 The crane operator will not leave the crane until the lift is completed or returned
to ground.
 When the crane is not in operation, the operator will secure the hook and switch
off the engine.
 A load chart and radius of lift chart will be displayed in the operator cab.
 Each crane will display a valid inspection and load test sticker on the operator
cab.
 Before each crane operation, pre lift planning and safety meeting will be held on
location.
 Before commencing any lifting operation, all the necessary valid certifications for
both the machine and the operator should be inspected by onsite operations
person in charge and company safety specialist for more detialis, refer to
document MOG-HSEQ-Q-P-248 Corporate safe lifiting Operations.

Following the initial pre-start gas tests, the HW / CSE site will be subjected to continuous
gas monitoring and only qualified person (safety specialist) should conduct this task.
Monitoring of the work site will be conducted by using a suitable automatic multi gas
detector.

RIGGING

The following safety instructions are to be taken into consideration when carrying out rigging
activities:
 All rigging work should be done by qualified riggers.
 Standard crane hand signs will be used, only signal man will give signals to the
operator.
 Wire ropes, slings and web slings will be checked before work starting for frayed
ropes and slings, excessive rust or rot, kinks or bleeding from over stressing.
Ropes and slings with defects will be removed from service. Ropes and slings
will be tagged or colour coded to show inspection date.
 Crane lift loads will not exceed 80 % of the crane and rigging rated load capacity.
 All loads must be rigged properly; a minimum of two slings will be used. Sling
angles will never exceed than 60 degrees.
 A minimum of two guide lines will be used for each lift.

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Standard hand signals will be used for crane operations, our mega-phone unit may also be
used .Only vertical lifts will be made, loads will not be dragged or pulled.

17. HIGH RISK TASKS

The yearly shutdown is containing some risky jobs which have potential harm to persons,
asset, and environment. It requires the use of Competency, skill and experience in capturing
those risks and to set method/techniques in providing the necessary elements and special
measures/mitigation and control to complete the job safely.

CONFINED SPACE ENTRY (CSE)

Before entering confined space, the following arrangements should be taken into
consideration:

 Entry into confined space must be under authority of CSE Permit.

 Before entering confined space, tank, vessel or machine, they must be checked
for hazardous gases and oxygen deficiency.
 Work in confined space requires a source of continuous ventilation.
 When work is required in confined space with oxygen contents of less than 21 %,
self contained breathing apparatus (SCBA) or air line breathing equipment will be
used.
 Excavations and trenches of more than 1.5 meter deep must have an access /
exit ladder at intervals of 7.5 meter. A rope and bucket is to be used to carry tools
or materials up or down.
 A trained stand by person (safety back-up) will be used for confined space entry
and work.
 When welding or cutting in confined space, exhaust ventilation is required. Never
use pure oxygen for ventilation purposes.
 Always follow the instructions of your supervisor.
 For more details, refer to document #: MOG-HSEQ-SF-WI-058, 062

SCAFFOLDING AND WORKING AT HEIGHTS

All the cranes / lifting /movable equipments shall be free from defects, maintained and
operated to Comply with the standards required by national, International Legislation and
Regulations, also the lifting Appliances and gears must not be issued or used, without a
current test certificates issued by the inspector and related valid certification must be

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introduce. Refer to MOG ducoment: MOG-HSEQ-SF-P-074 Rev A1 Coporate Safe

Scaffolding.

The following instructions are to be considered when working at heights:

 When working at heights, safety belt / harness must be checked for defects or
damage and must be used.
 Life line is to be used if secured place to attach safety belt or harness can not be
found. (Remember… safety belt/harness is only as strong as the point where it is
attached).
 The top of an erected ladder will extend at least 60 cm above the landing. The
ladder will be properly secured to the landing to prevent falling or slipping.
 Where erected handrails, toe boards, safety nets, platforms or scaffolds are to be
removed immediately after performing the work.

18. PPE / CLOTHING

Personal Protective Equipment (PPE) must be worn as required for each type of jobs within
shutdown activities as per the conducted JRA where a potential exposure to hazardous
conditions is. Hard hats, safety goggles and safety foot wear as a minimum is mandatory
when working on the site. Other PPE such as eye, face, hand, and body and ear protection
are necessary when required.

Fall restraining / arresting devices; the two commonly used ones are the full body harness
and the safety belt; harness is used for above ground work, where restraining and arresting
protection is required, safety belts are used to restrain the wearer at his place of work on
horizontal surfaces. Full body harnesses are required when working in areas with no guard
rails at heights above 1.8 meter. Fall restraining devices must be stored in clean and dry
conditions away from sun radiation and must be thoroughly inspected both on issue and at
the start of each shift.

19. EMERGENCY RESPONSE ARRANGEMENTS

In responding to foreseeable emergencies. Specified personnel are assigned duties within
an Incident Response Team (IRT), on scene commander, fire brigade, resumption of
operation, rescue team, HSE representatives/Medical staff and their duties defined.
Emergency procedures should be established together with details of action plans
regardless of the type or level.

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Supervisors shall ensure that the workforces under their direct authority understand what to
do if an emergency situation arise, that will be briefed in Tool Box Talk, e.g. determine
escape route of working place area taking in consideration the wind direction and
safest/nearest assembly point.

A. Sound the alarm

B. Use the fire extinguisher or hose reel to fight the fire if you are trained
to do so, but do not put your self in danger. The on site fire watcher will
do the job.
C. Call the emergency services, remember emergency number 119.
D. Inform your supervisor.

If someone injured, do the following:

A. Give first aid.

B. Minor injury, go to the clinic.
C. Serious injury, do CPR and call for ambulance, remember emergency
phone number each in his area.
 Always get treatment for and report all injuries, regardless of how minor the
injury is.
 When requested, give help in fire fighting and other emergencies.
 If it becomes necessary to evacuate the area, listen to the evacuation siren
or watch the flashing lights, then go to nearest mustering point and wait for
further instructions, roll call has to be done to make sure everybody is
present.Refer to: MOG-HSEQ-SF-P-032, MOG Corporate Emergency
Response Plan (ERP)

20. ACTIVE MONITORING BY LINE MANAGEMENT

It is essential that 'active monitoring' of work site is undertaken by the appropriate level of
supervision, namely:
 Work leader
 Nominated area supervisor
 Production shift supervisor
 The on site safety specialist.

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Such monitoring is conducted to ensure that: the work is being carried out safely, the
appropriate personnel are involved, the work place circumstances have not changed and
that the stipulated conditions on the PTW are being adhered to.

21. SHUTDOWN WASTE MANAGEMENT

Spillages may occur during the shutdown at the waste water treatment (WWT) during
dealing with knock out drums and no oil spillage is expected during working on gas trains. It
is accepted policy that whenever such a spill occurs, immediate action should be taken to
prevent further spillage, to prevent fire and to implement cleans-up operations.

Spills on land are the simplest to handle. They normally require collection and transfer of the
oil by means of removing the oil spillage that accumulated on ground by applying dry soil
/sand to absorb the oil and then transfer the oily sand to approved dumping area.

The oil that accumulated on the oily water surface in the evaporation pond needs to be
collected by a special tool, like a fishing net made from wire mesh material) and then the
collected oil will be put into open empty container of appropriate size to be recycled again in
the system.

“Where there is a need to empty and refill the molecular sieves, an appropriate container will
be put on truck under the knock out drums at gas trains to collect all the used molecular
sieves and then transferred and stored on cement slabs available for some time for drying
these materials”.

22. RESCUE AND MEDICAL

During shutdown operations, the HSEQ Department will carry out the following actions
promptly:

 Set up fire watch on site during commencing hot work activities.

 Assign ambulance at site or assembly point (the nearest one).
 Summon first aiders and auxiliary first aiders on emergency call list (clinic nurse
and some volunteers whom been trained on site).
 Prepare the clinic for emergencies.

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23. SHUTDOWN HSE TEAM

The following table shows the HSE team needed for the yearly shutdown on day and night
shifts:

No. of Job title Job description

persons

3 HSE Specialist Review and confirm the isolation points

Inspecting the work site and adjacent areas
Conducting gas tests and keep monitoring all
relevant (HSEQ)issues
3 Safety technician To assist HSE Specialist
3 Firewatchers Stand-by
1 First aid Stand-by
2 Rescue team members Stand-by
1 Ambulance driver Stand-by

24. SHUTDOWN HSE MATERIALS

The following table contains the materials needed for the shutdown:

No. of item/equipment Item/equipment Job description

1 Ambulance Stand-by
5 MSA gas detectors Multi gas detectors to test / monitor
gas condition before, during and after
hot works/CSE activities.
5 Intrinsically safe To be used during inspecting confined
torches spaces
20- to 40 pcs its Pad-locks To lock-out the identified isolated
depend on each site valves
20 pcs to 40 pcs Small size metal chain To lock-out the identified isolated
(1 meter each depend valves
on each site )
20 to 40 pcs Tag-out labels For valves not to be open
3 – 5 rolls Safety tapes To isolate work sites
1 roll Nylon rope (life line) To be used for rescue purposes
of 1.5 inches diameter
size
2 Megaphone with siren For rescue purposes
10 Full body harnesses For inspector , maintenance crew and
stand-by rescue team
4 sets Breathing apparatus For stand-by rescue team
sets BA
From 10 to 20 pcs Disposable coveralls For inspecting / cleaning inside
confined spaces
30 – 50 pcs Scaffolding green tags To confirm safety inspection
30-50 pcs Scaffolding red tags For stop working
25-50 pcs Gas mask (MSA- For rescue purposes

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smoke hood)
4 Clear safety glasses For shutdown personnel during
(for day shift) inspecting confined space inspection
20-50 pcs Dark safety glasses For shutdown staff

25. COMMUNICATION AND RELEVANT REPORTS DURING THE SHUTDOWN

ACTIVITIES

It is very important to maintain a communication plan during a shutdown by the relevant

team in charge of activities as and when required to:
 Communicate shutdown plan/schedule to operations team
 Attend and contribute to regular shutdown progress meetings
 Record and report daily shutdown activities.
 Ensure all authorisations required for tasks have been obtained
 Identify, communicate and manage HSE issues arising during execution of shut
down activities
 Report on HSE Non conformities and audit results
 Contribute to post shutdown review to draft all lesson learnt

26. RETURN PLANT TO SERVICE

It is important to realize that all activities in a complete and accurate way to make sure all
issues have been resolved and closed out with no significant errors or consequences. The
following have to be verified:
 Confirm that all scheduled work on equipment is complete before hand back is
accepted
 Ensure equipment hand back documentation complete per site protocol
 Coordinate pre-start equipment integrity checks
 Coordinate and validate plant de-isolation and preparation for service
 Ensure appropriate plant start up authority is obtained
 Coordinate start up critical function tests as required
 Coordinate and record plant start up progress
 Ensure that all generated waste is removed and disposed as per MOG procedures
for contractors and suppliers/Waste Management Procedure/Site handling and
disposal of waste procedure.

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ATTACHMENTS

 MOG-HSEQ-F-144 Rev A2 Daily Permit Statues Worksheet

 MOG-HSEQ-F-145 Rev A2 Job Hazard Analysis Worksheet
 MOG-HSEQ-F-146 Rev A3 Job Safety Analysis Checklist
 MOG-HSEQ-F-147 Rev A2 Shutdown Matrix Area
 MOG-HSEQ-F-148 Rev A2 Permit Issue Matrix
 MOG-HSEQ-Q-G-286 Communication Guidelines for Inspection and Maintenance
Activities during Shutdown

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