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SAFETY GUIDELINE
Merak, Indonesia
TO REPORT AN EMERGENCY
0254-269100
Ext 6666 for Latex Plant
7777 for Polystyrene Plant
“SAFE BEHAVIOUR”
TRINSEO MERAK SAFETY GUIDELINE BOOK –2018
DO IT SAFELY
OR DON’T DO IT!
TRINSEO MERAK SAFETY GUIDELINE BOOK –2018
TABLE OF CONTENTS
Page
I. Introduction ............................................................................................. i
INTRODUCTION
This safety book contains the minimum safety guideline and procedures for performance
of work by all employees, suppliers, visitors, and contractors. Subsequent to publication,
should any rule or procedure set forth herein differ from applicable government or local
laws, the more stringent will apply. Trinseo Merak site has developed these rules and
procedures to enable us to attain an injury-free workplace.
These rules and procedures represent the foundation for safety in Trinseo Merak Site and
are an integral part of every job.
DEFINITIONS
G. Owner's Designee - An employee who is extended the rights and privileges of an owner
by the owner for specified purposes. These designations shall be documented.
Employees acting, as backs up do not receive designee privileges unless extended and
documented by the owner.
H. Trinseo Supervision - An individual who has been given the authority to direct and
oversee the specific actions of a worker or work group.
J. Prompt Medical Attention – Immediately dial 6666 (Latex Plant) and 7777
(Polystyrene Plant) to request emergency guidance.
All individuals while on the Trinseo Merak Site must comply with Trinseo
safety standards, site safety rules, and facility safety policies or procedures in
which they are working.
2. Individual Actions
All personnel are expected to act with respect, responsibility and common sense.
Do not engage in horseplay.
3. Personal Clothing
a. Where protective work clothes are not provided, each employee is expected
to wear personal clothing that is safe and proper for the job. Individuals
other than those working in an office type environment shall wear as a
minimum, a shirt with long sleeves, long trousers and closed-toed leather
or leather like shoes while on the job.
b. Loose clothing, jewelry or unconstrained long hair must not be worn around
machinery or moving equipment.
c. Individuals, other than those working in an office, shall not wear any type
of jewelry (including rings, necklaces, etc.) that is exposed. Small stud type
earrings worn in the lower part of the ear are allowed for those individuals
making observations or performing laboratory work. Another exception is
a wristwatch, as long as the individual is not working on or near
electrically energized equipment or welders wearing long cuff welding
gloves.
4. Contact Lenses
5. Wearing of Rings
a. Rings must not be worn while in plant process areas and laboratories or in
other locations while engaging in activities related to process operation,
maintenance, construction, trucking operations or food service.5.....Gate
Pass requirement
Positive identification for entering and leaving a Site / facility gate is required for
personnel and goods (Vehicle, tools, product , raw material, etc)
6. ID Badge Requirement
7. Safety Orientation
Safety orientation / Induction is required for every one prior to work at Trinseo
premises. Safety induction will be given by a qualified facilitator
8. Visitor
Visitor must be escorted by a Trinseo representative. The host will ensure that
the visitor is safe and visitor’s activities are in compliance with Trinseo safety
requirement.
9. Weapons or Ammunition
Voiding Safety devices must follow MOC process. Contingency plan shall be
required before voiding safety devices
1. Traffic Rules
b. Drivers must obey all traffic signs and rules in the plant.
f. Drivers while driving on Trinseo roadways will not use cell phones,
including hands free cell phones..
a. All occupants in passenger Trinseo or Trinseo lease vehicles shall wear seat
belts.
b. All occupants in the cab of pickups and other trucks shall wear seat belts.
d. Vehicles used to transport people shall have seats for the number of people to
be carried.
c
3. Motorcycles
a. Motorcycles shall not be ridden in plant and all motorcycles shall be parked
in Admin Parking area
4. Bicycles
a. bicycles shall not be ridden in Trinseo Merak Site, Except for Security Patrol
in the plant
5. Fork Trucks
b. Fork trucks shall not be driven on main plant roadways at night unless
equipped with headlights, a taillights and a flashing yellow light(s).
7. Vehicle Accidents
8. Parking
9. Unattended Vehicles
A motor vehicle engine must not be left running if the vehicle is unattended. This
does not include parking brakes on automobiles or pickups.
NOTE: "Unattended" means that the driver has left the normal control position
of the vehicle.
The total load shall not exceed the capacity of the vehicle.
a. A vehicle shall not be pushed by another vehicle. Vehicles can only be pulled
or carried by those designed for vehicle towing purposes.
b. In the event that a wrecker must be called, prior permission must be received
from Security before it will be allowed to enter the plant.
b. Authorization shall be obtained from EHS Delivery for all cranes above the
50-ton capacity outside of block perimeters. Axle loads and spacing shall be
calculated for all cranes above the 50-ton classification prior to crossing any
bridge.
d. When moving retractable boom cranes on Trinseo roads, the boom shall be
fully retracted.
e. The following rules pertain to all mobile cranes shall follow crane work
check list :
g. Cranes and Tractor-Trailers must abide by all traffic rules while in the plant.
1. General Requirements
a. The Facility Leader must establish the required minimum protective clothing
and equipment for their area of responsibility in accordance with the
Personal Protective Equipment Standards.
b. Personnel must wear protective clothing and equipment in the correct manner
as required.
c. Unless required for work being done, protective clothing and equipment is
not mandatory while in an office, control room, lunch room, change room,
going to and from parking lots and buildings by designated routes, or
walking main roadways.
d. All personal protective equipment shall meet the appropriate PPE standard
and in good condition
2. Foot Protection
a. All protective footwear shall comply with ASTM F2413 (formerly ANSI
Z41).
b. Canvas, cloth, high heels (>1”), open-toed or open-back shoes must not be
worn in any non-office environment. Office workers must have shoes
available to wear that are suitable for an emergency evacuation, crossing
parking lots, uneven surfaces and climbing stairs if necessary. No bare
feet / flip-flops are allowed in Trinseo Merak Site other than in a
change/shower room.
3. Eye Protection
c. Safety glasses, chemical goggles with dark tint lenses should not be worn at
night or in indoor locations during the day unless wearing protective eyewear
for gas or electrical cutting or welding, or unless there is a prescribed medical
requirement for the dark tint lenses.
e. Side-shield safety glasses are required under a welding hood while arc
welding.
f. Welding goggles shall be used for all gas welding or cutting, and welding
hoods shall be used for all electric welding and cutting.
4. Head Protection
e. Safety hard hats whose structural integrity has been altered by cracks, holes
or contact with organic solvents shall not be used. Intentional painting of
hard hats is not permitted.
f. Wearing of a welding hood does not preclude the use of a hard hat. The
wearing of a hard hat under a welding hood is dependent on the nature of the
job, and the Facility Leader will define its requirement.
5. Respiratory Protection
6. Hearing Protection
7. Hand Protection
b. The types of gloves used are to be established by the site / plant and must be
specified in PPE Grid, in specific written job procedures or during the work
permitting process.
c. Job procedures or work permitting process may specify the exceptions for
those activities when wearing gloves may pose a greater hazard to the
individual. Examples include, but are not limited to:
working with high torque rotating equipment (this may not include
some hand-held power tools)
heavy equipment operation (e.g., forktrucks, cranes, etc.)
working with small parts requiring high dexterity
a. When working over or near water and the danger of drowning exists, an
approved life jacket must be worn or fall protection must be used.
b. When working over open water, ring buoys with at least 25 meter of line
shall be readily available for emergency use. Distance between ring buoys
shall not exceed 60 meter. Also, at least one lifesaving skiff shall be
immediately available.
9. Fall Protection
Fall protection must be used for elevated work. Fall protection must be used all
the time when working on elevation (high of 1.8 m or greater) and follow Fall
prevention procedure in elevated work standard
a. Any late developing (or aggravated) injury or illness must receive prompt
approved medical attention as soon as the conditions or symptoms are
recognized.
1. Piping Specifications
a. The complete requirements for Safe Work Permits are in the Global Safe
Work Permitting Standard.
Excavation work,
Radiography,
Critical Lifts,
Lifts of personnel on suspended work platforms which are held or
supported by cranes,
jobs required by department policy, or
jobs when requested by the personnel doing the work.
Personnel must determine where the nearest Safety Shower and Eye Bath
facilities are located before commencing work. Testing of the nearest safety
shower or eye bath should occur before commencing work.
Compressed air shall not be used to clean clothing or skin. If air is used for
cleaning work areas, etc., the pressure must be controlled at 30 psi or less.
6. Dropping/Throwing Tools
Tools, materials, or equipment shall not be dropped or thrown from one level to
another unless precautions have been taken against possible injury to personnel
or damage to equipment.
7. Barricades
8. Walking on Pipe
1. General Requirement
Fire or smoke detection systems shall not be disabled without prior notification
of the Production Leader.
b. Fire suppression systems (e.g., deluge systems, halon systems, etc.) that are
taken out of service must not be tagged or locked with a lockout/tagout
system.
1. General Requirement
Defective tools and equipment shall be removed from service for repair or
disposed of immediately. Tools and equipment that are to be repaired must have
a tag attached stating the nature of the defect(s).
3. Moving Machinery
Machinery with moving parts or process equipment in service must be shut down
and isolated from the power source before making adjustments or repairs. If shut
down is not feasible, a written procedure specific for the job must be followed.
Machinery, tools (including portable grinders and buffers), and equipment with
exposed gears, belts, power transmission couplings, etc., shall not be operated
without effective guards, unless approval for specific jobs is obtained from the
department head or owner’s representative.
5. Refuel of Equipment
a. Vehicles or equipment with gasoline engines shall not be refueled with its
engine running or while it is near any predictable source of ignition, such as
welding operations.
b. Fuel tanks on equipment powered by diesel engines shall not be filled with
the engine running if during the process it is possible to spill fuel on a hot
engine or manifold.
c. Portable fuel containers must not be filled in the bed of pickup trucks or
inside vehicles.
6. Knives
a. Safety Knives must use and follow the Cut Prevention/Knife Policy.
b. Kevlar cut resistant gloves must be worn when using knives on the job.
.
c. All portable electric tools or equipment shall be isolated from the power
source before making adjustments or changing drill bit, blade, etc.
8. Pneumatic Tools
a. Excess flow valves must be placed at the air source when using hoses greater
than 1/2" I.D. on portable tools.
c. All pneumatic hand tools will have a block and bleed or quick connect
within 3 meter of the tool and at the header.
a. Tool rests on grinders shall be set not more than one-eighth inch from the
wheel and level with the center line of the wheel. Tongue guards on grinders
shall be set not more than one-quarter inch from the wheel.
b. Buffers are not to be operated with tool rests. Guards on buffers shall be cut
back at the bottom approximately 30 degrees behind the vertical center line
of the guard.
Wrenches must not be used to rotate a pump shaft or similar rotating equipment
unless covered by a specific written procedure.
a. Quick connectors used for air and cold water (under 140F) must not be
compatible with quick connectors used for nitrogen or other services.
12. Cheaters
Cheater devices, such as a pipe used as an extended handle on a tool, must only
be used with written approval of the Production Leader.
Quick opening valves – such as, quarter-turn ball valves, butterfly valves, etc. –
on the end of process or product lines containing hazardous materials must be
plugged or blinded when not in use.
Powder actuated tools must not be used without written approval of the
Production Leader.
c. All leads and lead connections shall be in good condition and free of any
exposed conductors, and must be inspected prior to use.
Chemical goggles must be worn when installing jumpers or handling wet cell
batteries, including the "maintenance-free" types.
A face shield, double hearing protection, toe and metatarsal protectors must be
worn when using a hand-held jack hammer for breaking concrete. Personnel in
close proximity of jack hammer operations shall also wear a face shield, double
hearing protection, toe and metatarsal protectors.
Toe and metatarsal protectors must be worn when using hand-held soil
compacting equipment such as a dirt tamper or packer.
Hand tools and parts may only be lifted by devices designed for this purpose
(example: canvas-lifting bags, etc.). Buckets are not to be used for lifting tools
and parts with any means other than a person’s hand.
b. Storage tanks located outside a process area must be labeled with the Owner
Department Name and 24 hour phone number or control center.
c. All non-Trinseo owned storage tanks except those on service vehicles must
be identified with NFPA Fire Hazards and Materials symbols and be labeled
with owner company name and 24 hour phone number.
2. Glass Containers
I. PORTABLE LADDERS
1. General Requirements
b. The design capacity shall not be exceeded (total weight of person plus
materials).
c. The user is responsible for visually inspecting a ladder before use and
ensuring that the ladder capacity is not exceeded. Any ladder found defective
shall be tagged with a “Warning” tag, removed from service, and repaired or
destroyed.
f. Both hands must be used for climbing or three point of contact is used.
h. A ladder shall not be used to gain access to a roof unless the top of the ladder
exceeds at least 1.8 meter above the point of support at eaves, gutter, or
roofline.
2. Stepladders
a. Stepladders over 3 meter must be tied off at the top or held by another worker
if side supports are not provided for the ladder.
b. Personnel must not stand on the cap or the step below the cap.
a. Top sections of extension ladders shall not be used by themselves except for
restricted entry into vessels, furnaces, and for scaffold access when properly
tied off.
b. Straight and extension ladders must be tied off within three rungs of the top.
Ladders must be held by another person while being tied off.
c. Extension ladders shall have one of the lower rungs of the upper section tied
to the adjacent rung of the lower section when in use.
e. Straight and extension ladders shall be placed at such an angle that the base
is one-fourth of the working length of the ladder out from the top support
(e.g., 6 meter up, 1.5 meter out, or 1 rung out for each 4 rungs up).
f. The maximum length for straight ladders is 7.5 meter, and the maximum
length for extension ladders is 7.5 meter.
1. Platforms
a. Make shift platforms, such as stacked material, chairs, boxes, or drums shall
not be used.
2. Scaffolds
f. Scaffolds must not be used as material hoist towers or for mounting derricks
without first determining the loads and stress involved.
g. The maximum loading for a “standard” scaffold – i.e., erected from the
ground or a floor of a structure – is three people and a dead load not to
exceed 90 kg or a total distributed load not to exceed 360 kg. The maximum
loading for a suspended scaffold is two people and a dead load not to exceed
90 kg or a total distributed load not to exceed 270 kg.
h. All scaffold platforms and tubes shall be free of tools, trash, etc., before
calling in removal.
i. Scaffold tubes must not to be used to store tools (knives, wrenches, welding
rods, etc.).
j. Scaffolds shall be equipped with handrails, midrails, and toe boards except
on owner representative's written approval.
l. When toe boards are missing the area around the scaffold must be barricaded
with warning tags stating “Danger overhead – No toeboards on scaffold.
For detail please refer to Elevated Work Standard and Job safety analysis for
erection and dismantle scaffolding (Attachement
K. ELECTRICAL
g. Portable generators, greater than 50 volts but less than 700 volts, which
are not part of a permanent wiring system, must be inspected before use
and annually. For detail please refer to Electrical Work Practice guideline
2. Receptacles – 380V
Receptacles of 380volt plugs must not be plugged into or unplugged unless they
are de-energized by an open switch.
L. RADIATION
M. ASBESTOS
All asbestos work in Trinseo Merak Site will be accomplished in accordance with
the government regulation regarding Asbestos.
N. LEAD
All work in Trinseo Merak Site associated with lead or lead containing substances
will be accomplished in accordance with the government regulation.
Non-Trinseo Company that will be working at Trinseo Merak Site shall follow all
applicable safety rules related to their scope of work that written in Non Trinseo
Service standard.
Mobile phone usage for Non Trinseo and Non Routine Contractor will be minimized
on site.
- Mobile phone is prohibited to be used during driving or walking around the
site.
- Mobile phone is prohibited to carry out in Process area.
- Project contractor and transporter driver shall store a Mobile phone in
Security office.
- Visitors shall get permission from It’s project managers to carry out their
mobile phone beyond the security office.
The Responsible Care Leader must approve variances to Trinseo Merak Site Safety
Standards and Rules in writing. All variances must be issued for a specific length of
time and may be renewed. The Site is responsible for maintaining a current list of all
variances, which have been approved. (Refer to the Global Variance Standar