Hazards

Safety signs and signals are used in the workplace to warn and instruct
staff and others of risks to their health and safety.
Piping colour coding is used to identify the pipelines to avoid any
mishap.
If there is a significant risk to health and safety from a variety of hazards
including fire, electricity and hazardous chemicals there is an
obligation on each employer to reduce the risks arising by a variety of
means.
When, as an outcome to these efforts, the hazards remain it is
necessary to make use of certain signs and colour codes to alert staff
to the dangers and advise them of the precautions to take.
The absence of such signs and colour codes, or the use of
inappropriate or misleading signs and colour codes, could lead to
accidents and to the exacerbation of the injuries arising from such
accidents.
The laws
Provisions of hazardous material manufacturing act 1989 makes it
mandatory to post safety signs on hazardous chemicals and
materials to correctly identify their nature of hazard and exercise
necessary safety precautions in handling of such materials.

Besides, there are provisions under Indian Factories Act and rules
to display safety signs and notices on service buildings and office
premises in Factories.

Road safety signs and traffic safety signs are necessary to be

displayed to caution users of facilities and avoid accidents.

As per PETROLEUM ACT, 1976 section 177 “All above ground

pipelines and cables shall be identified by taping, stenciling,
colouring distinctively or by any other suitable method.

Pipelines and valve at loading and discharging berths shall be

prominently marked to identify the product”.
Scope of necessary action

The guidance given here represents checks needed to make to perform

an adequate review of safety sign & colour coding provision in an
office environment.

If there is anything unusual about the workplace and work activities a

specific risk assessment should be undertaken and the guidelines
adapted accordingly.

Policy on safety signs

Purpose of the policy –

To establish the way in which the organization deals with safety signs
& colour coding in its buildings.

Distribution of the policy –

This is a part of Fire & Safety policy on Safety signs & colour coding
and notices to be followed at Mathura Refinery.
Use of the policy –

The policy is to be used to establish standards and a commitment to

safety in this important area, and therefore it shall be briefed to all
employees and contractors,

as a reference document and the guideline to judge all relevant

activity. From time to time the policy will need to be reviewed to ensure
that it remains valid and useful.
Safety policy regarding safety signs

a) We are committed to reducing risks wherever practicable, but

accept that there will always be circumstances in which hazards remain
which require warning notices and signs. Piping color coding is required
to identify the pipelines to avoid any mishap.

b) The respective Area Manager shall ensure that sufficient and

appropriate building safety signs & color coding of pipes and those
required for hazardous materials, including fire exit routes and similar are
provided and maintained.

c) Each line manager shall ensure that appropriate safety signs are
affixed to equipment etc. in use within his/her area of control and/or by
his/her staff. And color coding of piping is as per standards.

d) Signs and color coding used shall be in accordance with the

relevant legislation or as notified by Fire & Safety dept from time to time.
Reviewing safety sign usage

Signage review programme

The following method shall be employed effectively to carry out a safety

sign review programme.

Checklist for safety sign review

The following items are to be checked routinely by line managers:

•During assessment of work activities check:

a) For each item of equipment (e.g. storage cupboards) is there a

significant risk of harm arising to staff which requires a warning in one
of the sign categories: Danger, Warning, Mandatory, Escape, First Aid?

b) If such a sign is required, check that it is suitable, affixed, clearly

legible

c) Check that staff understand what the signage means.

•For the premises manager:

a) For each part of the building check the arrangements for escape
routes and emergency exits, and ensure that fire exit signage is
visible at all locations

b) For each fire point for fire extinguishers, hoses, ladders, emergency
telephones ensure that the appropriate signage is affixed

c) For each toilet and similar facility ensure that appropriate signage is
affixed

d) For each first aid point ensure that appropriate signage is affixed

e) For each drinking water point (and/or if there is a risk of confusion at

appropriate non-drinking water points) the signage indicating
drinking water (or prohibiting drinking the water) is affixed.
Examples of hazards and signs

A list of typical hazards and the appropriate signs to be used is given in

the following para.

The summary is adapted from the HSE Safety Signs and Signals
Guidance on Regulations and OISD standard GDN……….
 FIGURE 3: Summary of hazards and signs
Type of Sign Signs to be used
Hazard
Prohibition - red circle Smoking and naked flames forbidden
Flammable materials
and red bar across (match lit with bar across)
Plant room with Prohibition - red circle No access for unauthorized persons
dangerous machinery and red bar across (palm of hand up)
Prohibition - red circle Not drinkable (tap, cup and across
Non-drinking water
and red bar across bar)

Electrical hazard - live

Yellow triangle Danger: electricity (lightning)
equipment
Obstacles (pictogram of person
Tripping hazard Yellow triangle
tripping)
Access gantry - head
Blue circle Safety helmet must be worn (hard hat)
injury
Ear protection must be worn (ear
Noisy plant room Blue circle
muffs on head)
Emergency exit Green sign Running person and arrow
First aid post Green sign White cross
Red border in yellow
Fire extinguisher Red letters
background
Head injury from low Black and yellow warning
beam tape
CLASSIFICATION OF HAZARDOUS SUBSTANCES
The hazardous substances are classified into eight classes. These are
as under :

CLASS 1 EXPLOSIVES
CLASS 2 GASES, COMPRESSED LIQUEFIED
DISSOLVED OR DEEPLY
REFRIGERATED, INFLAMMABLE GASES, POISON (TOXIC)
GASES.
CLASS 3 INFLAMMABLE LIQUIDS

CLASS 4 INFLAMMABLE SOLIDS, SUBSTANCES

LIABLE TO SPONTANEOUS CONBUSTION;
SUBSTANCES WHICH ON CONTACT WITH
WATER EMIT INFLAMMABLE GASES.
Division 4.1 Inflammable solids
Division 4.2 Substances liable to spontaneous
combustion.
Division 4.3 Substances, which in contact with
water, emit
inflammable gases.
CLASS 5 OXIDISING SUBSTANCES
Division 5.1 oxidizing substances
Division 5.2 Organic peroxides
CLASS 6 POISONOUS (TOXIC) AND INFECTIOUS
SUBSTANCES
Division 6.1 Poisonous (toxic) substances
Division 6.2 Infectious substances
CLASS 7 RADIOACTIVE SUBSTANCES
CLASS 8 CORROSIVES
Symbols of the United Nations Committee for the Transport of Dangerous Goods
These may be used provided that the source is mentioned (CIS/ILO).

UN Transport symbol for explosives

UN Transport symbol for Class 1.4 Explosive substances which

present no significant hazard
UN Transport symbol for Class 1.5 Very insensitive substances which have a mass
explosion
Hazard

Inflammable gas
UN Transport symbol for poisonous substances (gases Class 2., other
poisonous substances Class 6.1
UN Transport symbol for inflammable gases (Class 2) or liquids (Class 3)

UN Transport symbol for inflammable solids

(Class 4)
 UN Transport symbol for substances liable to
spontaneous combustion

UN Transport symbol for substances liable to

spontaneous combustion
 UN Transport symbol for substances
which, in contact with water, emit
inflammable gases

UN Transport symbol for oxidizing

substances and for organic peroxides
 UN Transport symbol for infectious substances

UN Transport symbol for radioactive

substances, Category I
 UN Transport symbol for radioactive
substances, Category II

UN Transport symbol for radioactive

substances,
Category III
 UN Transport symbol for radioactive
substances

UN Transport symbol for corrosive

substances
PIPING AND COLOUR CODES
The following is the Comprehensive list of colour codes to be followed for offsite piping as per ANSI specifications

SERVICE BASE COLOUR IDENTIFYING

COLOUR BAND

STEAM
400psi and over White 1-Yellow
150 to 400 psi White 1-red
Below 150 psi White 1-green

Water ( Below 150 F )

Distilled, Blue 1- Aluminum
Demineralised
Raw Blue 1- Black
Chilled Blue 1-Grey
Condensate Blue 1-White
Treated (any Process ) Blue 1-Oxide Red
Sea, Salt or Brine Blue 1-Yellow
PIPING AND COLOUR CODES
The following is the Comprehensive list of colour codes to be followed for offsite piping as per ANSI specifications

SERVICE BASE COLOUR IDENTIFYING

COLOUR BAND

Hot Water ( 150 F & Over )

Distilled, Dimineralised Blue 2- Aluminum
Raw Blue 2- Black
Condensate Blue 2-White
Treated (any Process ) Blue 2-Oxide Red
Sea, Salt or Brine Blue 2-Yellow

Fire Protection
Water, Foam, or Other Red (Post office) -
fire Extinguishing
Material
 Petroleum Products

Gasoline (MS) Orange 1- White

LPG Orange 1- Oxide Red

Propylene Orange 2- Oxide Red

Naphtha Orange 1- Green

SKO ( Kerosene ) Oxide Red 1- Green

ATF Oxide Red 1- Yellow

SERVICE BASE COLOUR IDENTIFYING COLOUR

BAND
HSD Oxide Red 1- White

LDO, HVGO Oxide Red 1- Black

Fuel Oil, FO, LSHS, VB Feed Black 1- Yellow

Asphalt/ Bitumen Black 1- White

Slop & Waste Oils Black 1- Orange

 Lube & Crude Oils

Lube Oils Grey 1- Green

Sour Crude Grey 1- Orange
Sweet Crude Grey 1- Red
Chemicals
Acetylene Yellow 1- Purple
Acids Yellow 1- Red
Ammonia Yellow 1- Blue
Caustics Yellow 1- Black
Chlorine Yellow 1- Oxide Red
Inhibitors Yellow 1- Aluminum
Sodium Phosphate Yellow 1- Orange
Sodium Sulfide Yellow 1- Green
Sodium Sulfite Yellow 1- Grey
Sodium Dioxide Yellow 1- White
AIR AND OTHER GASES

Hydrogen Orange 1-aluminium

Gas (fuel & sour) Orange 1-gray

Gas (sweet) Orange 2-aluminium

Air (service) Green 1-red

Air (instrument) Green 1-black

Nitrogen Green 1-orange

Carbon dioxide Green 2-red

Oxygen Green 1-white

Location of Identifying Colour Bands
On each side of adjacent to Valves, tees and other fittings of importance.
Where the pipe enters & emerges from the walls and where it emerges from
road and walkway
Overpasses
At uniform Intervals along long sections of the pipe.
Adjacent to tanks, vessels, & pumps.
Specification of colour Band

Outside diameter of pipe or Width of colour band Size of legend letters

covering (MM) (MM) (MM)

19 - 38 200 12.5

38 - 50 200 16

63.5 - 150 300 32

200 - 250 600 63

Over 250 650 88

Training
Managers

Managers need to understand the application of safety signs and

colour coding to inform, warn, prohibit or require.

This method of providing information to staff is a crucial aspect of the

control arrangements determined by the risk assessment process.
Training is likely to be achievable by including Safety Signs and
identification of colour coding in the general training in risk
assessment.

All staff

Employees need to know:

•What each type of sign and colour code is for; and

•The importance of following the guidance, using the information and

complying with the prohibitions and requirements conveyed by the
signs.