3RD Party WPR - 01a-Hr 2020 LTP 230305 135344

Hazard
Recognition
2020 LTP classroom edition

Change record
Date Reason
September 2020 First LTP edition
Developed by: Health, Safety, Environment Curriculum Development and Evaluation Group
© Copyright Saudi Aramco, 2016. All rights reserved.
No portion of this book may be reproduced, by any process or technique, without the express written consent of
Saudi Aramco.
Hazard
Recognition
Unit 1
Hazard recognition
and controls
HSECD & EG
September 2020
Module 1
Terminal
Hazards & conditions objective
that lead to incidents At the end of this course, you
will be able to recognize
common work site hazards
and related controls when
Enabling objectives issuing or receiving work
permits based on the
On completion of Module 1, you will be able to: information in General
Instruction 2.100.
• Describe the Stop Work Authority program.
• Identify practices, hazards and conditions that can

lead to an incident.
4
Hazards & conditions that lead to incidents | Module 1. 1
Introduction
The content this course is aligned to the 20
questions on the work permit hazard analysis
checklist and will prepare you for becoming a
certified work permit receiver.
Your work can be extremely hazardous and it
is important for you to know and practice
each task you do, to ensure it can be done
safely.
This means you must learn to recognize
possible worksite hazards and think about
suitable precautions to ensure your safety.
5
Instructional staff
Your safety instructor is your guide through this
training course and will help you get the
knowledge you need to understand the course
material and to prepare you for the on-line test.
The instructor will present the course material
to you, explain and illustrate the information,
and answer your questions.
If you do not understand the information, or if
you are not sure how to perform an activity,
then please ask for more information.
Stop Work Authority (SWA)

Before we start the Work Permit Hazard Recognition course, you must be fully aware of the
Saudi Aramco Stop Work Authority (SWA).
The Stop Work Authority is a program designed to provide employees and contract workers with
the responsibility and obligation to stop work when a possible unsafe condition or behavior may
result in an incident.
7
Stop Work Authority

All personnel have the authority to stop any unsafe work.
If you observe any unsafe work that has the potential to injure personnel, damage equipment, or harm
the environment, you are empowered to stop work and report your concerns to a supervisor.
8
SWA references
These publications outline the expectations for all personnel to stop work in the event that an unsafe act or
situation is observed.
• Construction Safety Manual, Chapter I-4, Work Permit System and Stop Work Authority.
• SMS Manual, Element 6, Safe Operations.
• Safety Handbook Rules 1 and 4.
9
SWA 5 step process

1. STOP unsafe work.
You are authorized to stop work immediately when coworkers, equipment or the environment are at
risk.
2. Notify affected personnel and supervision.
Don’t try to correct everything yourself. Notify your supervisor and any other organizations, as
required.
3. Investigate the cause for intervention and correct the hazard.

After a stop work action is in place, the proponent organization and those involved should:
•Discuss the situation and come to an agreement on the harmful behavior or condition and a
corrective plan.
•If needed, have an external subject matter expert evaluate the situation and confirm whether it
is safe to proceed.
If the SWA concern is valid:
• Suspend work until a resolution is in place.
• Verify that all safety issues have been properly resolved.
• Modify work practices or procedures when necessary. 10
SWA 5 step process

4. Communicate findings and resume work.
Notify all affected personnel about corrective actions to prevent similar issues from occurring.
5. Follow-up.
Promptly review all stop cases to identify any need for additional investigation or follow-up.
11
SWA Signs
Stop work signage, shall be mounted in clearly visible locations at worksites as per CSM 4.11.4 to remind
everyone of their SWA responsibilities.
12
Review questions
13
Identify hazards and conditions that lead to incidents

In Module 1 you will learn about the following:
• What is a hazard.
• What is safety.
• Unsafe acts and conditions.
• Safety policy, processes and programs.
• Safety hazards.
What is a hazard?
A hazard is anything that has the potential cause harm to:
• People.
• Environment.
• Assets.
• Business.
When we ask “Is it safe?” we are really asking, “What is the risk
of me getting hurt or suffering a financial loss?”
Safety does not mean “no risk”. It means that we know there is a
known and acceptable level of risk.
Some jobs will always have one or more hazardous components

that cannot be eliminated or control completely.
For example, flying in an airplane will always have some level of
LP Newsletter March 2010
danger and yet you accept the risks when you fly on vacation.
15
What is safety?
One definition of safety is:
‘Freedom from risk or harm’ (loss or injury)
Is it possible to do something 100% safely?
What about:
• Driving
• Flying an aircraft
• Scuba diving
• Crossing the street
• Working in an oil and gas plant
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Programs and processes

To help you prevent injuries and illnesses, Saudi Aramco has many programs, processes, procedures and
standards in place to protect you.
Programs, processes, procedures and standards Examples
Safety standards Employee evaluation.
• Safety courses, hazard recognition, gas testing etc.

Training programs
• Safety orientations.
• Job safety analysis.
Observation processes • Joint site inspection.
• Hazard analysis checklist.
Reporting processes Injury reporting, incident reporting
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Unsafe conditions and acts

You need to understand what causes incidents in order to prevent them.
Incidents are caused by:
• Unsafe acts (people chose to do something unsafe or not follow safety procedures)
• Unsafe conditions (equipment is not well maintain, missing safety guards)
Unsafe act examples Unsafe condition examples
Operating equipment without proper training or Inadequate guards or safety devices.

certifications.
Unsafe walkways and walking surfaces.
Removing or disabling safety devices.
Damaged/defective/incorrect equipment.
Using defective equipment.
Extreme weather.
Taking shortcuts and not following checklists or
procedures.
Failure to secure (LOTO, fall protection).
Improper use of equipment.
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Unsafe acts
Safety hazards and unsafe acts include:
• Operating equipment without authority or certification.

• Failure to warn.
• Failure to secure.
• Operating at an improper speed.
• Making safety device inoperable.
• Removing safety devices.
• Using defective equipment and poor maintenance.
• Using equipment improperly.
19
Hazards & conditions that lead to incidents
Safety policy
The Saudi Aramco Safety Policy reminds you that you
are responsible to:
• Know your safety responsibilities

• Identify and eliminate hazards prior to starting a job
• Take safety courses
• Follow all safety procedures, standards and rules
• Be prepared to respond to emergencies
• Report incidents to help others avoid them in the
future
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Safety hazards
In the work place, an unsafe act is a task or a job done in a
way that may threaten the health and/or the safety of workers.
• Knocking on a valve with a wrench to open it is an example

of an unsafe act.
• Performing a job without the required certification, or not

having a required work permit is also an unsafe act.
• Taking shortcuts, trying to accomplish work in a hurry or to

try to save time.
Note:
Not following rules and procedures is the number 1 cause of incidents in Saudi Aramco.
21
Safety hazards
Why do people continue to take shortcuts on the job?
• Human nature to want to complete a task as quickly as possible.
• The demands of the job or the organization causing employees to act unsafely.
• The employee tries to impress the boss with their level of production.
• They are in a rush to get the job done.
22
Safety hazards
Should you use safety checklists?
Yes....but !
• If you are in a rush, you may run through a safety checklist without actually stopping to evaluate each item
properly.
• The hand and eye are checking off the boxes on the checklist, but the brain is not engaged or focused on
the task.
• Checklists are not foolproof, they may not have checkbox for every possible variation or situations or for all
safety hazard.
• Checklists and procedures can only work if they are followed and
completed properly and with all your attention.
23
Safety hazards
Poor hazard identification and control results in:
• Nearly 3,000.000 non-fatal and 4,000 fatal workplace injuries.
• The direct costs of injuries at work (e.g. workers’ compensation claims, medical costs) total approximately
$250 billion annually.
24
Safety hazards
We know that hazards exist in all that we do so to avoid incidents and injuries, we make sure that all
appropriate barriers are in place.
There are usually two types of barriers:
Equipment: all our facilities have barriers to incident and injuries such as fixed gas detectors,
emergency shut-down valves, emergency alerts, sensors, helmets, harnesses and much more.
Human: the second barrier relies on people, in other words –YOU. Humans are the front-line of defense in
normal operations and the last line of defense during non-normal operations. Both situations rely on the
human to avoid incident.
Review questions
26
Summary
In Module 1 you were introduced to the Saudi Aramco Stop Work Authority and the practices, hazards and
conditions that can lead to an incident.
You should now be able to:
Describe the Stop Work Authority program.

Identify practices, hazards and conditions that can lead to an incident, such as
• What is a hazard.
• What is safety.
• Unsafe acts and conditions.
• Safety policy, processes and programs.
• Safety hazards.
Your instructor will now start Module 2, methods to recognize and control
hazards.
27
Module 2
Methods to recognize
& control hazards
Enabling objectives
On completion of Module 2, you will be able to:
• List the methods to recognize and control hazards.
28
Methods to recognize & control hazards | Module 1. 2
Introduction
Hazards are everywhere.
They cause incidents, because we fail to see
them or to control them.
Hazard recognition is required every day across
Saudi Aramco.
It is a critical safety activity.
Failing to recognize and control hazards can
cause serious injury and even death.
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Methods to recognize & control hazards

• Common causes of incidents.

• Safety hazards.
• Health hazards.
• Recognize and controls hazards.
• What are control measures.
How to recognize and control

hazards
In this part you will learn about:
• Categories of hazards
• Recognizing hazards
• Controlling hazards
Remember, the purpose of hazard recognition…
It is to find hazards and put in place controls and precautions to eliminate or reduce hazards to an
acceptable level before they cause an incident.
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Common causes of incidents

Incident causes
Failure to follow rules and procedures.
Hazards not recognized or controlled.
Equipment is not properly isolated, powered off or depressurized.
Gas testing not performed or monitored.
No effective joint site inspection.
Improper responses when conditions change.
32
Types of hazards
There are two main categories of hazards that have the potential to cause harm to people, the environment,
assets and our business:
• Safety hazards.
• Health hazards.
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Safety hazards
A safety hazard is anything that can have an adverse impact on your safety.
Safety hazards Examples
power lines, transformers, static charge, lightning, energized equipment, wiring and
Electrical
batteries.
crane lifting operations, excavations, falling objects, collapsing roof, a body tripping of
Gravity
falling.
Mechanical rotating shafts, belts, pulleys, saw blades.
vehicles, marine vessels, equipment movement, flowing water, wind, body positioning
Motion
when lifting, straining or bending.
pressure piping, compressed cylinders, control lines, vessels, tanks, hoses, pneumatic
Pressure
and hydraulic equipment.
34
Health hazards
A health hazard is anything that can have an adverse impact on your health.
Health hazards Examples
animals, bacteria, viruses, insects, blood borne pathogens, improperly handled food,
Biological
contaminated water.
Chemical dust, fumes, gases, mists, vapors, liquids, hydrocarbons, solvents, lead.
Radiation lighting issues, welding arcs, solar rays, microwaves, lasers, x-rays, NORM scale
equipment noise, impact noise, vibration, high pressure release, impact of noise on
Noise and vibration communication.
open flame, sparks, hot or cold surfaces, liquids, gases, steam, friction, general
Temperature
environmental and weather conditions.
35
Recognize and control hazards

Methods to identify hazards in the work permit process are:
• Joint site inspection.
• Work permit system and forms.
36
Recognize and control hazards

You will need to complete work permit forms properly during the Joint Site Inspection for activities in:
• Construction
• Maintenance
• Inspection
• Repair
On Permit forms, you must identify and control hazards in the following
sections:
• Section 2, hazard identification and control.

What is a control measure

Control measures are steps that you are going to take to remove or reduce a hazard by:
Engineering
• Eliminate (change solvent paint to water based paint)

• Isolate (noise enclosure), LOTO, blinding
Administrative
• Reduce, rotate crew, use warnings

• Rules, policies, procedures
Protective equipment
• PPE
• RPE (Respiratory Protective Equipment) such as SCBA and SABA
38
Review questions
39
Summary
In Module 2 you were introduced to the methods used to recognize and control hazards.
List the methods to recognize and control workplace hazards such as

• Common causes of incidents.
• Safety hazards.
• Health hazards.
• Recognize and controls hazards.
• What are control measures.
Your instructor will now start Module 3, common workplace hazards.
40
Module 3
Common workplace
hazards
Enabling objectives
• List common Saudi Aramco workplace hazards and

associated controls.
41
Common workplace hazards | Module 1. 3
Introduction
In this module you will learn about
some of the common hazards you may
see in your workplace and what
controls are used to eliminate or
minimize the risk.
42
Common workplace hazards

• Slips, trips and falls • Confined space.

• Tools and equipment. • Pressure testing.
• Noise and vibration. • Weather conditions.
• Machine guarding. • Personal protective equipment.
• Plant isolation.
Slips, trips and falls

Slips, trips and falls account for the largest percentage of workplace and “off-job” injuries in Saudi Aramco.
Below are listed the 4 main causes of slips, trips and falls.
Hazards:
• Uneven floor surfaces and changes in levels.

• Unsuitable floor coverings.
• Wet floors and trailing cables.
• Poor housekeeping.
While they may seem simple to identify and control, they are commonly overlooked, resulting in many injuries.
44
Slips, trips and falls

Simple steps, such as erecting warning signs near recently mopped floors, or using handrails when
climbing or descending stairs reduces the potential of these slip, trip and fall injuries.
Below is the list the common control measures.
Controls:
• Use handrail when using stairs.

• Report hazards immediately.
• Wear correct footwear.
• Good housekeeping.
45
Tools and equipment

Using the wrong or defective tools and equipment results in many injuries.
For example, if you work near live electricity use the wrong hand tool, it could lead to an arc flash incident
and even death.
Hazards:
• Using defective tools and equipment.

• Electrocution, electrical shocks and burns.
• Cuts, bruises and abrasion hazards.
• Flying objects.
46
Tools and equipment

Serious injuries have resulted from flying tool parts when they fail, choose the right tools for the right task and
ensure your tools are in good condition.
Controls:
• Immediately report defective tools and equipment to your Supervisor.

• Homemade tools are prohibited.
• Use correct tools and equipment.
• Inspect tools and equipment before use.
47
Noise and vibration

Noise and vibration can cause serious long term health problems.
They are often overlooked as the ill-health effects are not immediately obvious and are commonly irreversible.
Identifying a noise hazard is relatively easy, if you have to shout to be heard by someone nearby, then the
surrounding noise level is probably above 85 decibels (dB(A))
Nerve damage in the hands and vibration white finger are very painful injuries and have significant long
term quality of life effects.
Hazards:
• Noise induced deafness (above 85dB).

• Nerve damage due to vibration.
• Vibration white finger.
48
Noise and vibration

Reducing the noise or vibration at the source is always preferred method of control.
This might involve replacing a noisy piece of equipment with something less noisy or a
vibrating tool with a tool that vibrates less.
When this is not practical, reducing worker exposure by limiting exposure time, or wearing PPE
(i.e. ear plugs or muffs in high noise areas).
Controls:
• Noise reducing enclosures.

• Replace, equipment or processes with quieter ones.
• Limit employee exposure.
• Periodic breaks.
• Warning signs.
• Personnel protective equipment.
49
Machine (mechanical) guarding

Machine guarding prevents you from being pulled in, contacting hot or cold surfaces and prevents injuries
when machines fail and parts are ejected. Very serious injuries have occurred when pulled into machinery,
ranging from cuts and abrasions to amputations and even death.
Hazards:
• Entanglement (being pulled in).

• Cuts.
• Abrasions.
• Amputations.
• Hot surfaces.
• Cold surfaces.
Parts of machinery:
• Ejected.
• Striking workers.
• Impact with plant and equipment (e.g. fin fan blade failure).
50
Machine (mechanical) guarding

Machine guards prevent such injuries and must be maintained in good condition and be in place when
you operate the machine.
Controls:
Moving parts to be guarded if less than 2.5m (8.2ft) above the working surface.
Examples:
• Flywheels.
• Belt/chain drives.
Guards shall be:
• Installed before arrival on-site.

• In position during operation.
• Reinstalled before the equipment is returned to service.
51
Plant isolations (LOTO)

All plant isolations must be conducted following GI.6.012 Isolation, Lockout and Use of Hold Tags.
Hazards:
Release of energy types
• Chemicals.
• Mechanical.
• Electrical.
• Hydraulic.
• Pneumatic.
• Spring loaded.
• Gravity.
52
Plant isolations (LOTO)

There are three requirements before opening closed systems or lines.
Controls:
Before opening closed systems or lines they shall be:
• De-pressured.
• Drained.
• Purged.
Further information can be found in GI.6.012 Isolation, Lockout and

Use of Hold Tags.
53
Confined spaces
Confined space entry requirements are listed in GI 2.100, Work Permit System, as a mandatory critical activity
requiring a confined space entry permit (this applies to both restricted and non-restricted areas).
The core hazards associated with confined space entry are listed below.
Hazards:
• Oxygen deficiency.
• Oxygen enrichment.
• Flammable materials.
• Toxic materials, H2S, CO.
• Extreme temperature.
54
Confined spaces
You are not allowed into confined spaces without a Confined Space Entry Permit
(CSEP).
There are specific training courses for this topic to ensure you have the in depth
knowledge and skills required for entering and working in confined spaces.
The course covers the points highlighted in the previous page and covers the
control measure listed below.
Controls:
• Confined space entry permit.

• Proper preparation.
• Use checklist.
• Proper isolation.
• Gas testing.
• Mechanical ventilation.
55
Pressure testing
Pressure testing is conducted for new and existing mechanical systems such as piping, pipelines,
pressure vessels and power boilers.
Uncontrolled releases of energy from compressed air or other gases can explode. High speed streams of
fluid can be created or piping and equipment can move if pressure testing goes wrong.
Hazards:
• Mechanical or brittle failure of equipment under test.

• Relief system failure.
Uncontrolled release of pressure testing material.
• Treated water.
• Inert gas.
56
Pressure testing
Specific pressure testing controls are listed in GI 2.102, Pressure Testing Safely, and include using the correct
test medium, the correct test equipment and notifying others through barriers and signage.
Pressure testing of mechanical systems is listed in GI. 2.100, Work Permit System as a mandatory critical
activity requiring a work permit.
Controls:
Use the correct:
• Test material.
• Test equipment.
• Notify others with barriers and signage.
• Stay out of “the line of fire”.
57
Weather conditions
The weather can significantly contribute to the hazards associated with a work activity.
For example, high wind speeds are great hazards when personnel are working at height or when
using cranes.
Heavy rain can result in flooding, particularly in low lying areas

and excavations, and an electrocution risk increases if you work
with or near live electrical systems.
Hazards:
• High wind speeds.

• Extreme temperatures.
• High humidity.
• Heavy rain.
• Excavation collapse.
• Flooding.
Weather conditions
Many work permit activities are outdoors where weather, temperature and
humidity can be serious health hazards to workers.
Ensure heat stress programs include managing work schedules during

the hottest part of the day, and providing suitable rest/shaded areas and
enough drinking water.
Controls:
Wind speed limits for use of:
• Crane (max 32kph).

• Man-basket (25kph).
• Scaffolding (65kph).
Prevent entry into flooded excavations and remove water prior to entry.
Establish heat stress plans by providing sufficient drinking water.
59
Personal Protective Equipment

(PPE)
PPE is equipment that will protect you against health or safety risks at work.
It can include items such as safety helmets, gloves, eye protection, high-visibility clothing, safety footwear and
safety harnesses.
It also includes Respiratory Protective Equipment (RPE).
Even where safe systems of work have been applied some hazards might still
remain, PPE/RPE may be needed in these cases to reduce the risks to an acceptable
level.
60
RPE - breathing apparatus

Always wear Respiratory Protection Equipment (RPE) when one or more hazardous airborne
contaminants are present in the work area.
It is important to know the type of airborne contaminant and its quantity (or volume in air) so that you can
choose the correct type of respiratory protection.
You must ensure that your RPE protects you against the identified hazards and that you are trained to wear
and use it properly.
Self Contained Breathing Apparatus Supplied Air Breathing Apparatus

(SCBA) (SABA)
61
Personal Protection Monitor

If you work in areas where H2S is present you must be trained on the hazards and effects of H2S exposure
and the proper use of PPE, this includes the use of a personal protection monitor.
Personal protection monitors, such as the T40 Rattler, warn the wearer of high levels of H2S.
You must wear these where you may be exposed to 10 ppm or higher of H2S.
You must wear a T40 rattler in areas such as oil/gas plants and facilities that store and process hydrocarbons
and in non-hydrocarbon areas such as sewage treatment plants/sewer lift stations.
T40 Rattler for illustration/demonstration

Review questions
63
Summary
In Module 3 you were introduced to the common workplace hazards.
List common Saudi Aramco workplace hazards and associated controls, such as
• Slips, trips and falls.
• Tools and equipment.
• Noise and vibration.
• Machine guarding.
• Plant isolation.
• Confined space.
• Pressure testing.
• Weather conditions.
• Personal protective equipment.
Your instructor will now start Module 4, working at height.
64
Module 4
Working at height
Enabling objectives
• List common working at height hazards and

65
Working at height | Module 1. 4
Introduction
In this module you will learn about some
of the common working at height
hazards you may see in your workplace
and what controls are used to eliminate
or minimize the risks.
66
Working at heights
• Elevated work platforms.

• Ladders.
• Scaffolding.
• Fall protection.
Elevated work platforms

It is not the height that matters, it is the potential fall distance and what surface will brake your fall.
Working at ground level, but next to a deep excavation may also be considered as work at height.
The names of various elevated work platforms include cherry-picker, MEWP, scissor lift, or man-basket.
Hazards:
• Unauthorized use.
• Uncertified operators.
• Tipping over.
• Structural collapse.
• Mechanical failure.
• Falls from height.
Elevated work platforms

As you can see from the previous page, regardless of the name or type of equipment, the hazards
are generally the same.
Common control measures for elevated work platforms are listed below.
Controls:
• Certified operators.
• Inspection before use.
• Used only on even surfaces.
• Occupants must remain inside at all times.
• Harnesses worn and attached to anchor point.
Ladders
Ladders come in many shapes and sizes. However, if you use
them incorrectly a fall from a ladder can be very serious.
Hazards:
• Ladder in poor condition.

• Falls from height.
Incorrect:
• Size.
• Type.
• Use.
70
Ladders
Basic control measures when using ladders include:
Controls:
• Inspect before use.

• Secure the top.
• Provide stable and secure footing.
• Slope ratio of 4 to 1.
• Face ladder when climbing.
• 3 points of contact when working from ladder.
• Never work off the top step of step ladders.
71
Scaffolding
Scaffolding, when built and used correctly, provide a temporary and safe means of access to elevated work
areas.
If scaffolds are not built and used correctly, there is an increased risk of falls from height, the potential for
being stuck by materials falling from scaffolds or scaffolding failure and collapse.
Hazards:
Falling:
• Objects.
• Equipment.
• People.
Scaffold collapse.
72
Scaffolding
GI 8.001 and the Construction Safety Manual specify requirements for all types of scaffold work.
They set out specific requirements for the safe design, erection, supervision, inspection, use, alteration, and
dismantling of stationary and mobile scaffolds with fixed platform heights used for personnel access.
Some of the main controls and precautions are:
Controls:
Safe means of entry and exit:
• Gates.
• Drop bars.
Fall protection:
• Safety lines.
• Harnesses.
• Nets.
Tools and equipment secured.
73
Scaffolding
Controls:
Regular inspection.
Use of SCAFF-TAGS:
• Valid inspection date.

• 2 weeks maximum between inspections.
74
Scaffolding
Basic checks:
• Scaffolding materials in good condition.
Scaffolding looks:
• Straight.
• Not leaning.
• No evidence of collision damage.
• No gaps in the planks.
• Toe boards fitted.
• Materials or tools not stored close to open edges.
75
Scaffolding
Basic checks:
Ladder:
• In good condition.
• No damage or missing parts.
• Correct length.
Safe means for getting on/off the ladder:
• Gate.
• Drop bar.
• Posts (standards) on level surface and on sill boards.
76
Scaffolding Tags
Scaff -Tags are required at all scaffold access points.
Red tag: do not use scaffold.
Yellow tag: full body harness required.
Green tag: scaffold complete, no harness required.
77
Scaffolding Tags
Tag Checks:
Ensure scaffold tags (Scaff -Tags) are present and they are clearly visible at all access points.
Using tags properly requires the following:
• The tag and holder number should match and not be re-used.
• Mount the holders through a component of the scaffold.
• The scaffold supervisor must sign the tags for all scaffolds
above 1.8m.
• The scaffold inspector must sign the tags for all scaffolds above
6m.
• Scaffolds must be re-inspected every two weeks or after any

alteration.
78
Fall protection
Sometimes work permit activities mean working where a potential to fall exists.
This might be when working close to unprotected edges, in mobile elevated work platforms, or when
erecting a scaffold.
In these cases approved fall protection controls are required if the potential fall is greater than 1.8m, (6ft).
Hazards:
• Failure to wear.
• Failure to secure to a fixed point.
• Poor quality equipment.
• Damaged harness or line.
79
Fall protection
Controls:
• Users trained in wearing and fitting.

• Inspect before each use.
• Protect from sharp edges.
• Remove damaged equipment.
• Waist belts are prohibited.
• Shock absorbing lanyards, must be attached at least
5.5m (18ft) above the impact surface.
• Use suspension trauma straps (foot stirrups) with body
harness
80
Fall protection
Wearing the correct fall protection equipment might save your life.
Lanyards must be either a “Y” lanyard (i.e., two lanyards sharing a common deceleration device) or
double- leg lanyard (i.e., two lanyards each with their own individual deceleration device.
81
Review questions
82
Summary
In Module 4 you were introduced to common working at height hazards.
List common working at height hazards and associated controls, for equipment such as
• Elevated work platforms.
• Ladders.
• Scaffolding.
• Fall protection.
Your instructor will now start Module 5, heavy equipment.
83
Module 5
Heavy equipment
Enabling objectives
• List common heavy equipment hazards and

84
Heavy equipment | Module 1. 5
Introduction
of the common heavy equipment hazards
you may see in your workplace and what
controls are used to eliminate or minimize
the risks.
85
Heavy equipment
• Movement of heavy equipment.

• Certification.
• Cranes.
• Fork lifts.
Movement
Common hazards associated with the of the movement of heavy equipment are listed below:
Hazards:
• Run over by heavy vehicle.

• Struck by or crushed by material being moved.
• Crushed: Caught between equipment and object.
Electrocution by contact with:
• Overhead power lines.

• Buried cables.
87
Movement
The information below lists heavy equipment controls for both the operator and the equipment itself.
Controls:
• Equipment inspected.
• Operated by certified operator.
• Maintain safe distance.
• Keep eye contact with operator.
• Exclusion zones.
• Spotter (or a signal person).
• Wear high-visibility clothing.
88
Certification
Many types of heavy equipment require certification by Saudi Aramco.
GI. 7.025, specifies the requirements for testing and certification of Saudi Aramco and contractor heavy
equipment operators.
It also identifies personnel authorized to operate and/or drive Heavy Equipment and Industrial Vehicles, as
well identifies personnel authorized to rig/sling loads in support of lifting operations.
Hazards:
• Equipment used by uncertified operators.

• Loads rigged incorrectly resulting in dropped objects.
Certification
If you are a heavy equipment operator, you must immediately provide your heavy equipment operator
certificate and SAG license (if license is required), to any authorized Saudi Aramco representative (e.g. the
work permit issuer) on request.
Controls:
•Authorizations for higher risk activities.
Examples:
• Man-basket.
• Tandem lifts.
• Critical lifts.
Cranes
Crane operations can cause significant incidents if specific hazard controls are not established.
Some of the outcomes from improper crane operations might be:
Hazards:
• Failure of rigging, ropes and slings.

• Contact with overhead power lines.
• Toppling over.
• Contact with people and equipment.
• Overloading.
91
Cranes
GI.7.028 specifies the crane lifts types and procedures to be followed when using various types of cranes.
Some common hazard controls measures include:
Controls:
• Inspection by operator.
• Barriers and signs.
• Valid inspection sticker.
• Certified crane operators.
• Critical lift plans.
92
Critical lift plans

High risk crane lifts require a critical lift plan. Some examples of critical lifts are shown over the next two
pages.
Approved critical lift plans must be on site prior to the lift.
Local work permit requirements such as attaching the critical lift plan to the work permit, must also be
followed.
Any part of a crane whose boom is within 10 meters (33 feet) of any:
• Hydrocarbon piping.
• Pressurized piping areas.
• Populated traffic area.
• Crane lift that requires attachment(s) to main boom.
93
Critical lift plans

• Loads of 40 tons or greater.
• Loads that exceeds 85% of the crane’s rated capacity.
Any crane lift with hazards from:

• Explosion.
• Fire.
• High heat.
• Any crane working near energized power-lines.
Note:
Saudi Aramco certified Rigger 1 approves critical lift plans
94
Fork lifts
Some of the common hazards from fork lifts and their operation include:
Hazards:
• Unauthorized use.
• Uncertified operators.
• Roll-over.
• Impact with personnel or equipment.
• Dropped materials.
95
Fork lifts
Some of the common control measures for fork lifts and their operation include:
Controls:
• Trained and certified operators.

• Daily inspection checklist.
• No standing or riding on forks.
• No walking under the raised forks or loads.
• Backup warnings.
• Seatbelt and safety devices operational.
96
Review questions
97
Summary
In Module 5 you were introduced to the common heavy equipment hazards.
List heavy equipment hazards and associated controls, such as

• The movement of heavy equipment.
• Certification of equipment and operators.
• Cranes.
• Fork lifts.
Your instructor will now start Module 6, excavations and shoring.
98
Module 6
Excavations &
shoring
Enabling objectives
• List common excavation and shoring hazards and

99
Excavations & shoring | Module 1. 6
Introduction
of the common excavation and shoring
100
Excavations and shoring

• Excavations.
• Shoring.
• Types of soil.
• Buried cables.
Excavations
Unsafe excavations have caused many accidents and even death, common excavation hazards are
listed below:
Hazards:
• Collapse or cave in of side walls.

• Toxic gas.
• Flammable gas.
• Striking underground cables or pipes.
• Flooding.
102
Excavations & shoring |
Excavations
Controls:
• Confined space entry permit if more than 1.2m (4ft).

• Proper planning and design.
• Barriers and warning signs.
Exclusion zones:
Do not operate motor vehicles and heavy equipment within 2 m (6.5 ft) of
the edge of the excavation or the depth of the excavation, whichever is
greatest.
Only excavating and backfilling equipment is permitted within 2 m (6.5 ft)

of the edge of an excavation.
Do not operate mechanical excavators within 3 m (10ft) of

underground pipes, cables or other obstructions.
103
Excavations
Everyone working in an excavation must be properly trained for an emergency.
Make sure that safety or rescue equipment, if needed, is nearby and

working properly. Some examples include SCBAs, safety harnesses,
lifelines, basket stretchers, and mechanical lifts.
Excavation work should be carried out carefully and follow Saudi Aramco
Standard and Work Permit requirements for safe digging practices.
Saudi Aramco Standard excavation safety checklist is required.
Checklists to be used for all excavations.
• Pre-excavation checklist.
• Excavation inspection checklist.
• Attach checklists to the work permit.
104
Shoring
Shoring means supporting the sidewalls of an excavation with an engineered structure of cross braces,
vertical uprights and horizontal rails. Shoring can be made from wood or metal. It may be a hydraulic or
mechanical system.
Shoring is the third best choice to prevent sidewall collapse.
Sloping and benching are safer protective methods.
Good shoring inside excavations protects workers from:
• Cave-in of side walls.

• Ground collapse.
• Slippage of spoil.
Spoil to be at least 60cm (2ft) from the edge.
105
Know the soil types

A qualified person shall:
• Design the excavation method.

• Determine the appropriate soil type.
Sloping or benching more than 6m (20ft):
• Designed by a qualified engineer.
106
Buried cables
Electric, gas, sewer, water, telephone lines, cables or process
piping are all found underground.
If underground equipment is damaged, an injury or death

could occur.
Hazards:
• Digging up live cables with backhoe.

• Jack hammer contacting live cables.
• Hand digging around live cables.
107
Buried cables
When underground utility lines are known or suspected, the work permit issuer
must get countersignatures from Power Distribution, Communications or Utilities.
Excavation work should be properly managed to control hazards, you must

look for the warning signs like the yellow tape, red tiles and sweet sand, these
are signs to indicate that a cable may buried below.
Controls:
• Identify and mark cables and services before digging.

• Use cable drawings and plans.
• Use cable locating devices.
• Safe digging practice (by hand).
Hand digging should continue for at least 3 meters (10 feet) away from
exposed underground equipment.
Mechanical digging may resume 3 meters (10 feet) away.
108
Review questions
109
Summary
In Module 6 you were introduced to excavation and shoring hazards.
List common excavation and shoring hazards and associated controls, including
• Excavations.
• Shoring.
• Types of soil.
• Buried cables.
Your instructor will now start Module 7, hazardous materials.
110
Module 7
Hazardous materials
Enabling objectives
• List common hazardous material hazards and

111
Hazardous materials | Module 1. 7
Introduction
of the common hazardous material
112
Hazardous materials
• Hazardous materials.
• Compressed gas cylinders.
• Asbestos containing material.
• Painting and coatings.
• Abrasive blasting.
• Ionizing radiation.
Hazardous materials
In Saudi Aramco, we handle, produce and store a wide range of materials, many of
them are hazardous.
A product’s hazardous nature is usually attributed to their health hazard, flammability

and reactivity.
Health hazard is a broad term that includes potential hazards based on how the
material enters your body (e.g. through the skin, by inhalation or by injection).
Hazards:
• Toxic.
• Flammable.
• Reactive.
• Chemical burns.
• Irritant.
• Corrosive.
114
Hazardous materials
Chemical Hazard Bulletin
CHB: 155
HYDROGEN SULFIDE GAS

INGREDIENTS CAS NO % 8HR OEL
hydrogen sulfide 7783-06-4 >98 14 mg/m3
NFPA Rating:
0: Minimum
1: Low
UN No: 1053
2: Moderate
Hazchem Code: 2WE
When controlling exposure to these materials you must understand

3: High
DG Class: 2.3
Subsidiary Risk: 2.1 4: Extreme
Packing Group: Not Applicable

Poisons Schedule: S7
PROPERTIES
their hazardous properties. This information is in the Chemical Hazard Gas.

Mixes with water.Extremely flammable.
Bulletins (CHB), the HAZCOM label or the Safety Data Sheet (SDS).
HEALTH HAZARD INFORMATION
EMERGENCY
Acute Health Very toxic by inhalation.

Effects: Irritating to eyes and skin. FIRST AID
These will help you determine how to correctly handle and store PRECAUTIONS FOR USE
Skin:
Remove contaminated clothing. Wash with soap &
water.
For cold burns, immerse in cold water. Wash with
materials, their reactivity with other materials, correct PPE and RPE
soap & water, apply dressing. MEDICAL
ATTENTION.
Keep containers cool.
Glasses: Consider full face-shield. Fire Fighting: Water spray/ fog.
and the recommended first aid steps if the material is released.

Storage and
Restrictions on Storage apply. Refer to Full Report. Eliminate ignition sources.
Transportation:
Spills and Consider evacuation.
HIGHLY FLAMMABLE. Disposal: Prevent from entering drains.
Fire/Explosion Vapours/gas heavier than air. Contain spillage by any means.
Hazard: Toxic smoke/fumes in a fire.
Risk of explosion if heated under confinement. SAFE STORAGE WITH OTHER CLASSIFIED CHEMICALS
Controls:
Very toxic to aquatic organisms.Avoid release to
Environment: the environment. Refer to special
instructions/Safety data sheets.
Flammable Explosive Toxic Radioactive Oxidizing

x x x x x
• Chemical Hazard Bulletins (CHB).

x — Must not be stored together
• HAZCOM labels.
• Eliminate or substitute the material.
• Correct storage.
• Correct PPE/RPE.
• Spill containment equipment.
Compressed gas cylinders

Compressed gas cylinders are often used in our plants and facilities.
They can contain inert gases such as Nitrogen to highly flammable gases such as Acetylene.
Hazards:
May contain:
• Flammable materials.
• Toxic materials.
Poor storage:
• Full and empty stored together.

• Lack of separation for incompatible materials.
• Exposure to heat and sunlight.
• Explosion and projectile.
• Transportation.
116

Common controls when storing and using compressed gas cylinders.
Controls:
• Identify contents (CHB).

• Store out of direct sunlight.
• Separate incompatible materials.
• Separate full and empty cylinders.
Cylinders containing Oxygen and Oxidizers:

MUST be stored at least 6.1 m (20 ft) from flammable
gas cylinders.
or
MUST be separated by a 30 minute fire rated barrier at
least 1.5 m (5 ft) high.
117

Controls:
• Store in upright secure position, use cylinder rack wherever possible.

• Secure during transportation.
• Flash back arrestors for O2 and Acetylene cylinders.
118
Asbestos Containing Material

(ACM)
Asbestos becomes dangerous when disturbed. Inhalation of asbestos fibers results in the potential for long
term ill-health and potentially death.
Asbestos is not easy to identify, but when it is, you should take all the steps required to ensure that it is not
disturbed causing hazardous fibers to be released into the air.
Hazards:
• Difficult to identify.
• Airborne fibers, dangerous to the lungs.
• No short term health symptoms.
• Long term permanent health effects.
119

Once identified and decisions are made to keep it or remove it, then specific controls are
required. These are explained in GI.150.001 and the Construction Safety Manual.
Controls:
• Clearly identified and warning signs posted.

• Wet Methods used for removal.
• Eating, drinking and smoking prohibited when working with ACM.
120

Controls:
PPE and RPE to be used for ACM work.
Dry cleanup methods prohibited, such as:
• Sweeping.
• Shoveling.
GI 150.001: how to manage and control asbestos waste.
121
Painting and coatings

Paints and painting may seem like common/low risk type work activities but some paints and paint thinners
can be very hazardous.
Some types are flammable and some have significant inhalation hazards (dangerous to the breathing),
and some are irritants (dangerous to the skin).
Hazards:
• Flammable atmosphere.
• Skin and breathing hazards.
• Long term permanent ill-health effects.
• Storage.
122
Painting and coatings
Paints and coatings require specific hazard controls:
Controls:
• Trained operator.
• Check CHB or Safety Data Sheets for precautions.
• Wear correct PPE.
• Containers closed or sealed when not in use.
• Good Housekeeping.
If you paint or coat inside a confined space, regularly measure

the atmospheric conditions to ensure Oxygen or flammable
limits are not exceeded.
Abrasive blasting
You must be Saudi Aramco certified to perform abrasive blasting.
Abrasive blasting equipment requires specific safety checks before work begins.
Hazards:
• Considered to be hot work.

• May create an ignition source.
• High noise levels.
• Health hazards from silica sand.
• Low skilled workforce.
Abrasive blasting
Abrasive blasting hazard controls measures include:
Controls:
• Hot work permit in restricted areas.
Operators to be tested and certified by:
• Certified coatings inspector (level 2).

• Wear PPE including hearing protection.
• Good Housekeeping.
• Use of Silica sand is prohibited.
Full details of abrasive blasting controls are described in GI 6.021 and

the Construction Safety Manual.
Ionizing radiation
Ionizing radiation can be extremely hazardous to your health, resulting in short and long term ill-health. Do
not work with ionizing radiation without a Saudi Arabian Government issued radiation practice license.
Ionizing radiation work must always be performed under the control of an appointed Radiation
Protection Officer (RPO). Due to its extremely hazardous nature, it is tightly controlled through GIs and
standards.
You must never use or operate ionizing radiation equipment without being trained and competent in the safe
handling of ionizing radiation sources related to your job.
Hazards:
• Radiation sources have different strengths.

• Extremely hazardous to your health.
• Short and long term ill health effects.
• NORM (Naturally Occurring Radioactive Material).
Ionizing radiation
You must obtain work permit(s) for any NORM (Naturally Occurring Radioactive Material) related work and
personnel working with or around NORM contaminated piping, equipment, materials (e.g., filter cartridges),
soil or wastes must be trained in NORM hazards.
All tasks involving NORM contaminated equipment or materials must be covered by a Job Safety Analysis
(JSA), which must identify the hazards and associated controls.
Controls:
• Time, distance and shielding.

• All work under the control of a Radiation Protection Officer (RPO).
• Use personal monitoring and protection when using or handling ionizing
• radiation. Use warning signs.
GI’s: 150.003, GI 150.005, GI 150.006 and GI 150.007

Review questions
Summary
In Module 7 you were introduced to hazardous material hazards.
List common hazardous material hazards and associated controls, including

• Hazardous materials.
• Compressed gas cylinders.
• Asbestos containing material.
• Painting and coatings.
• Abrasive blasting.
• Ionizing radiation.
Your instructor will now start Module 8, Hydrogen Sulfide.

Module 8
Hydrogen Sulfide
(H2S)
Enabling objectives
• List common Hydrogen Sulfide (H2S) hazards and

130
Hydrogen Sulfide | Module 1. 8
Introduction
of the common Hydrogen Sulfide (H2S)
131
Hydrogen Sulfide (H2S)

• Properties of H2S.
• Health effects.
• Detection methods.
• H2S Precautions.
• Emergency arrangements.
Where is H2S found ?

H2S is often contained in the oils and gases that are extracted by Saudi Aramco.
Many Saudi Aramco industrial processes and facilities contain potential sources of H2S, such as:
• Producing Operations.
• Exporting operations.
• Stabilization.
• Refining.
• Storage.
• Drilling & work-over rigs, GOSP’s.
• Pumps.
• Compressors.
• Pipelines.
• Sewage treatment areas.
133
H2S properties Chemical Hazard Bulletin

CHB: 155

INGREDIENTS CAS NO % 8HR OEL
• Extremely toxic.
hydrogen sulfide 7783-06-4 >98 14 mg/m3
NFPA Rating:
0: Minimum
1: Low
UN No: 1053
• Extremely flammable.
2: Moderate
Hazchem Code: 2WE
3: High
DG Class: 2.3
Subsidiary Risk: 2.1 4: Extreme

PROPERTIES
• Highly reactive with oxidizers.

Gas.
EMERGENCY
• Colorless. Acute Health

Effects:
PRECAUTIONS FOR USE

Very toxic by inhalation.
Irritating to eyes and skin.
FIRST AID
Remove contaminated clothing. W ash with soap &
water.
For cold burns, immerse in cold water. Wash with
• Heavier than air.

Skin:
soap & water, apply dressing. MEDICAL
ATTENTION.
Glasses: Consider full face-shield. Fire Fighting:
W ater spray/ fog.
Storage and
• Soluble in water, forms a weak acid.

Transportation:
Spills and Consider evacuation.
HIGHLY FLAMMABLE. Disposal: Prevent from entering drains.
Fire/Explosion Vapours/gas heavier than air. Contain spillage by any means.
Hazard: Toxic smoke/fumes in a fire.
• Reacts with metals to form Sulfides.

Environment: the environment. Refer to special
Flammable Explosive Toxic Radioactive Oxidizing

x x x x x
• Asphyxiates – causing suffocation.

• Soluble in hydrocarbons.
• Rotten egg smell.
Smell is misleading at higher concentrations as you will not be able to
•
smell it.
• Travels with wind, and will settle in low areas.

H2S properties
• Flammable: LEL 4.3% - UEL 46%.
• Irritant: eyes, nose and throat.
• Reacts with strong oxidizers.
• May explode when in contact with Nitric Acid.
• Reacts with steel – produces Pyrophoric Iron Sulfide.
Health effects
The effects of H2S varies depending on your size and condition, the
information on this page are general guidelines that apply to most
people.
136
Inhalation
Low concentration through nose and mouth:
• body breaks it down over time.
High concentration through nose and mouth:
• body unable to break it down.

• paralyzes your breathing.
Low concentration over time:
• bronchitis
• pneumonia
• migraine headaches
• pulmonary edema
• loss of motor skills coordination.
137
Monitoring equipment
There are 4 main methods of detecting H2S in the air.
Fixed detection systems, potential release locations should be equipped with continuous fixed
monitoring systems where a significant leak could occur.
Continuous area monitors, transportable devices that can be used to monitor work areas, confined spaces
or areas with potential leaks for an extended period of time.
Portable gas monitors, you will use portable gas monitors to check that your work area is safe.
Personal protection monitors, such as the T40 Rattler will warn you of a potential H2S risk.
138
Hazardous effects
The table below lists the concentrations and company policies for H2S.
You can see from the table below that you must wear breathing apparatus if the H2S concentration reaches
10ppm.
No work or confined space entry can be permitted if the H2S levels reach more than 100ppm.
Concentration Policy
Permitted to enter a confined space without wearing breathing

Less than 10 ppm apparatus.
Permitted to enter a confined space.

10 ppm but less than or
Continuously wearing breathing apparatus.
equal to 100 ppm
Division head approval.
More than 100 ppm No entry permitted.
139
Engineering controls
Wherever possible, H2S exposure should be minimized by introducing engineering control measures such as:
• Ventilation.
• Cleaning.
140
Personal Protective Equipment

(PPE)
Saudi Aramco CHB 155 details the PPE that you must wear when working near H2S.
• Breathing apparatus.
Chemical Hazard Bulletin
• Gloves. CHB: 155

• Safety glasses/goggles/full face shield. ING REDIENT S CAS NO % 8 HR O EL
hyd ro g e n s ul f i d e 7783-06-4 >98 14 mg / m3
• Coveralls. NFPA Rating:

0: Minimum
1: Low
U N No : 1053
• Safety boots or shoes.

2: Moderate
Ha z c h e m Code: 2 WE
3: High
DG Class: 2.3
4: Extreme
Subsidiary Risk: 2.1
PROPERTIES
Gas.
EMERGENCY
Acute Health Very toxic by inhalation.

Irritating to eyes and skin. FIRST AID
Effects:
Re mo v e contaminated clothing. W a s h with soap &
PRECAUTIONS FOR USE water.
Skin: For cold burns, immerse in cold water. W a sh with
soap & water, apply dressing. MEDI CAL
ATTENTION.
Glasses: Consider full face-shield. F i re F i g ht i ng : W ater spray/ fog.
St o ra g e a nd
T ransportation:
Sp i l ls a n d Consider evacuation.
HI G HL Y FLAMMABLE. Prevent from entering drains.
Di s p os a l:
F i re / Ex p l o s i on Vapours/gas heavier than air.
Contain spillage by any me a n s .
Ha z a rd : Toxic s mo k e / f u me s in a fire.
Envi ro nme nt : the e n v i r o n me n t . Refer to special
Flammable Explosive Toxic Ra d i o a c t ive Oxidizing 141

x x x x x
H2S precautions
• Post warning signs.
• Monitor for H2S.
• Know wind direction.
• Conduct Gas test before issuing permits.
• Work with a ‘standby man’.
• Wear SCBA/SABA.
• Ventilation of work area.
• Emergency response plan & responsibilities.
142
Emergency arrangements
In this section of the course you will be made aware of the emergency arrangements and response
required in relation to H2S.
Emergency
Arrangements
143
The ‘buddy system’ is mandatory when responding to H2S emergencies.
Use the ‘buddy system’ for:
• Emergency response.
• Alarm response.
• Working in Immediately Dangerous to Life or Health (IDLH) conditions.
144
Standby personnel
Standby personnel must constantly monitor the work area, be aware of the hazards of H2S, and know how to
summon help.
Responsibilities of standby personnel include:
• Monitoring personnel for H2S exposure.

• Proper use of H2S detection equipment.
• Monitoring strategy.
• Securing the work area(s).
• Monitoring wind direction.
• Notification for emergency assistance if required.
145
Emergency actions
There are 7 steps to take during a Hydrogen Sulfide emergency:
Evacuate Immediately:
An H2S alarm means there may be hazardous concentrations in the building or area.
Get to a safe new area immediately by moving crosswind from the release until you know that you are
in clean air by checking your personnel gas monitor.
Move to higher ground if possible.
Sound the Alarm:
Immediately notify someone that there is an H2S release, relay any information you may have and tell
them that you require assistance.
146
Emergency actions
Assess the Situation:
Locate the log of personnel in the area, do a head count. Consider other hazards.
Protect Rescue Personnel:
Use SCBA/SABA to protect rescue personnel. H2S is an extremely rapidly acting, highly toxic gas.
Rescue Victims:
First ventilate the area with fans and/or open all the doors.
If safe, you may perform the rescue, but remember to wear breathing apparatus and follow the buddy system.
Enter the area and remove the victim too fresh air.
147
Emergency actions
Revive Victims:
Apply artificial respiration or CPR until the victim revives or until additional help arrives.
Only qualified personnel may use mechanical resuscitators or oxygen or perform CPR.
Get Medical Aid:
All H2S victims require medical attention.
Even if they revive quickly, there is still a possibility that the lungs may collect fluid some hours after
exposure.
Arrange transport of the victim to a medical facility and provide the necessary information to the
emergency medical services.
148
To rescue victims, the first responder(s) should:
• Remove contaminated clothing.

• Flush eyes with water for at least 15min.
• If qualified administer oxygen.
• Wait for qualified medical help.
149
Review questions
150
Summary
In Module 8 you were introduced to the hazards from Hydrogen Sulfide (H2S).
List common H2S hazards and associated controls, including

• Properties of H2S.
• Health effects.
• Detection methods.
• H2S Precautions.
• Emergency arrangements.
Your instructor will now start Module 9, fires and explosions.
151
Module 9
Fires & explosions
Enabling objectives
• List common fire and explosion hazards and

152
Fires & explosions | Module 1. 9
Introduction
of the common fire and explosion hazards
you may see in your workplace and what
controls are used to eliminate or minimize
the risks.
153
Fires and explosions

• Fire and explosions.

• Cutting, welding and brazing.
• Hot work permit controls.
• Fire watch.
• Electrical fires.

•Fire and explosions commonly occur due to the uncontrolled release of
flammable materials (liquids and/or gasses).
Once materials are released they look for a source of ignition.
This could be nearby hot work activity (e.g. welding or cutting), a vehicle
engine running or a smoker.
Hazards:
• Fire and explosion.

• Hot work.
• Liquid hydrocarbon or gas leaks.
• Sources of ignition.
• Accumulated trash.
• Smoking in non designated areas.
155

To prevent fires and explosions it is important to establish hot work controls.
For example, restricting vehicle access to high risk areas, establishing safe areas for smoking,
keeping workplaces and storage areas tidy, and sheeting in areas (with fire resistant materials) where
welding/burning/grinding activities are undertaken.
Controls:
• Hot work permit.

• Monitoring of work.
• Gas testing.
• Areas wetted.
156

In addition to the controls listed on the previous page, also consider the firefighting ability.
Most large fires start as small fires. Having a fire watch and extinguisher available are controls aimed
at preventing fires from growing.
Controls:
• Fire barriers or shields in place.

• Combustible materials removed.
• Fire extinguisher(s) and equipment.
157
Cutting, welding and brazing

Flammable atmospheres and combustible material can be easily ignited by welding, cutting and
brazing tasks.
Performing these in confined spaces also increases the risk of Carbon Monoxide (CO) exposure
and/or low Oxygen levels.
Hazards:
• Fires and explosion.
Build up of:
• Flammable gas.
• Toxic vapors.
• Oxygen depleting gases or vapors.
• Extreme light, electric welding flash.
• Defective equipment.
• Unskilled operators.
158
Cutting, welding and brazing

Control measures for cutting, welding and brazing include:
Controls:
• Equipment inspections before use.

• Ventilate area.
• Gas testing in confined spaces.
• Welding screens for electric welding.
• Flashback arrestors on oxy/acetylene cylinders.
• Equipment turned off or isolated at shift end.
159
Hot work permit controls

Hot work controls include ensuring the area is well prepared before activities begin.
In hydrocarbon facilities:
• Cover or water seal sewers within 23 m (75 ft) of all ignition sources.
• Hot work is not permitted above 0% LEL.
• Fire protection equipment shall be readily available.
• Cutting, welding or open flame, fire watch shall remain for no less than
30 minutes after work is finished.
• Combustible material shall be protected against sparks, welding slag or
heat.
• Open fires and/or open burning require an authorization from Saudi
Aramco Fire Protection Department.
Fire watch
A fire watch can be an Saudi Aramco employee, SMP or a Contractor employee.
He must be designated on the hot work permit form by the Work Permit issuer.
The fire watch must understand the following:
• Hazards from hot work.

• Precautions to prevent fires.
• Procedures for raising the alarm.
• Monitors hot work activities.
• Ensures fire equipment readily available.
• Trained in using fire equipment.
161
Electrical arc flash fires

Many arc flash incidents across the company have resulted in serious consequences, including injuries
(and in some cases death) resulting from electric shock, exposure to arc flash and arc blast, and
excessive light and sound energies.
Hazards:
• Fires.
• Electric shock.
Exposure to:
• Arc-flash.
• Arc-blast.
• Extreme light and sound energy.
162
Electrical arc flash fires

Where ever practicable, do not work on electrical systems while still live. Where live electrical work is
required, GI 2.721 details specific requirements, such as approach boundaries and specific PPE.
GI 2.721 Electrical Arc Flash Hazards Mitigation gives clear instructions on the controls required to prevent
this type of incident.
Controls:

• LOTO.
• Ground fault circuit interrupter.
• Approach boundaries for live work.
• Qualified individuals wearing PPE to work on electrical equipment.
• Certified electrical equipment.
163
Electrical fire hazards

Common electrical fire hazards, including electrical system short circuits, can generate enough heat or
sparks to ignite nearby combustible materials.
Below is a list common electrical fire hazards.
Hazards:
• Damaged power cords.

• Overloaded extension cords.
• Unsafe space heaters.
• Accumulated trash.
• Poor storage and housekeeping.
164
Electrical fire hazards

Controls:
• Regular inspections.
• UL listed equipment.
• Use of GFCI.
• Fire extinguisher(s).
• Qualified personnel for maintenance.
165
Review questions
166
Summary
In Module 9 you were introduced to fires and explosion hazards.
List common workplace fire and explosion hazards and associated controls, including
• Fire and explosions.
• Cutting, welding and brazing.
• Hot work permit controls.
• Fire watch.
• Electrical fires.
Your instructor will now start Module 10, emergency preparation.
167
Module 10
Emergency
preparations
Enabling objectives
• List common emergency preparation hazards and

168
Emergency preparations | Module 1. 10
Introduction
of the common emergency preparation
and what controls are used to eliminate or
minimize the risks.
169
Emergency preparedness
• Orientations.
• Response plans.
• Reporting and responding to an emergency.
Orientations
Orientations inform you of the site specific hazards, controls, response plans, local area operations
and the actions you will be expected to take during an emergency.
Hazards:
Employees unaware of:
• High risk work areas.

• Local alarm sounds.
• Correct actions on hearing alarms.
• Muster point locations.
Your work may be affected by the work of others.
• Equipment Opening and Line Break permits.

• Hot work.
171
Orientations
The orientation may also include the coordination of work activities.
For example, where to get your work permits, notification and authorization requirements for work
and accessing restricted areas, and the coordination of different work activities (simultaneous
operations).
Controls:
• Orientations for the site and work areas.
• Awareness of local alarm sounds.
• Awareness of response actions required.
• Your attendance in the area is identified and
logged (e.g. visitor log).
• Surrounding jobs that may effect your work have
been communicated to you (SIMOPS).
172
Response plans
An incorrect or delayed response to a real emergency can result in incident escalation and/or
increased damages or casualties.
You should know what is expected of you, whether you are a responder or simply a visitor. The plan
should state what you are expected to do in an emergency.
Hazards:
• Lack of planning.
Generic plans that are not specific to:
• The work or job performed.

• The exact work site.
Workers do not:
• Understand their role and responsibilities.

Workers not:
• Trained in response plan actions.
173
Response plans
If you have a specific role within an Emergency Response Plan (ERP), you must know that role and
complete it safely.
Controls:
Written emergency response and rescue plans for:
• All high risk work and jobs.

• Confined space work, such as inert entry.
Workers are aware of:
• Roles and responsibilities.

• Rescuers trained to carry out the plan.
Contractor plans must fit with existing site rescue plans.
174
Reporting and responding to an

emergency
Hazards:
Worker does not know:
• What is an emergency.
• How to report an emergency.
• Actions to take.
• Evacuation or muster location.
• No ability to report emergencies.
175
Reporting and responding to an

emergency
Controls:
Know how to report an emergency.
• Dial 911.
• Radio call.
Training on:
• What to do in an emergency.
• Response actions required.
• Alternative muster points.
176
Reporting an emergency
The table below lists the seven steps on how to report an emergency.
How to report an emergency

1. say “this is an emergency”.
2. describe the incident location.
3. describe the incident
4. report injuries, if any.
5. give your name and badge number.
6. repeat the above information.
7. stay on the line until further instructed.
177
Review questions
178
Summary
In Module 10 you were introduced to emergency preparation hazards.
List common emergency preparation hazards and associated controls, including

• Orientations.
• Response plans.
• Reporting and responding to an emergency.
Your instructor will now start Module 11, hazard recognition review activities.
179
Module 11
Review activities
Enabling objectives
• Identify common workplace hazards and controls

by completing the hazard recognition activities.
180
Review activities | Module 1.
11
Introduction
In this module you will complete the
hazard recognition activities.
Using the information that you have
learned during this course you will
identify the hazards and control
measures required to eliminate or
minimize the risks.
181
Review activities | Module 1. 11
Hazard recognition activities

In Module 11 you will practice the hazard recognition and controls knowledge that you have studied over the
previous 10 modules:
Hazard recognition activities

Look at the following images, identify any common hazards that you can see and think about suitable control
measures that may be required to minimize or eliminate the risks.
But first a reminder of safety hazards and health hazards.
Safety Health
hazards Examples Examples
hazards
power lines, transformers, static charge, animals, bacteria, viruses, insects, blood borne
Electrical lightning, energized equipment, wiring and Biological pathogens, improperly handled food,
batteries. contaminated water.
dust, fumes, gases, mists, vapors, liquids,

crane lifting operations, excavations, falling Chemical
Gravity hydrocarbons, solvents, lead.
objects, collapsing roof, a body tripping of falling.
lighting issues, welding arcs, solar rays,
Radiation
Mechanical rotating shafts, belts, pulleys, saw blades. microwaves, lasers, x-rays, NORM scale
vehicles, marine vessels, equipment movement, equipment noise, impact noise, vibration, high
Noise and
Motion flowing water, wind, body positioning when lifting, pressure release, impact of noise on
vibration
straining or bending. communication.
pressure piping, compressed cylinders, control open flame, sparks, hot or cold surfaces, liquids,
Pressure lines, vessels, tanks, hoses, pneumatic and Temperature gases, steam, friction, general environmental and
hydraulic equipment. weather conditions.
183
Image 1
184
Image 1
Motion: repetitive movement of arms while
using the cutting torch and grinder. Strain from
using heavy tools.
Mechanical: mechanical energy from spinning

disc on grinder.
Pressure: pressure contained within the two

gas cylinders and hoses.
Electrical: electrical energy hazards from the

electric grinder and the control box for the
winch supporting the pipe.
Gravity: gravity acting on the pipe, if the

supports fail the pipe will fall.
Gravity hazard to the worker falling off the
edge of the raised working platform.
185
Image 2
186
Image 2
Biological: biological hazard from bacteria in the
open water.
Temperature: worker in an open location, heat or

cold hazards depending on specific location.
Radiation: from the welding arc (UV light), potential

for UV burns to skin and eyes.
Chemical: toxic fumes from the welding.
Noise/sound: high levels of noise (above 85db) from

the pile driver/hammer.
187
Image 3
188
Image 3
Pressure: hazards from the high pressure
hydraulic system and operating rams on the back-
ho arm/bucket
Motion: movement of the back-ho arm and bucket

close to workers.
worker walking/standing on the top of an
unsecured pipe.
Gravity: risk of excavation collapse from gravity

pulling on the unsupported sand/soil sidewalls.
189
Image 4
190
Image 4
Motion: movement and operation of the
truck lifting arm.
Electrical: high voltage overhead power

lines.
191
Summary
In Module 11 you applied the knowledge that you have learnt over the previous 10 modules.
You should now be able to recognize common hazards that you may see at your workplace and describe
their associated controls and precautions.
Identifying hazards and precautions are part of how you will manage your site safety risks so that you and
your co-workers can work safely.
Safe completion of your work can only be done by:
• Proper preparation and supervision.

• Agreeing to the minimum safety precautions
192
Developed by: Health, Safety, Environment Curriculum Development and Evaluation Group.
© Copyright Saudi Aramco, 2016. All rights reserved.
No portion of this book may be reproduced, by any process or technique, without the express written consent of
Saudi Aramco.

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Hazard

2020 LTP classroom edition

• Identify practices, hazards and conditions that can

Stop Work Authority (SWA)

Stop Work Authority

• SMS Manual, Element 6, Safe Operations.

• Safety Handbook Rules 1 and 4.

SWA 5 step process

2. Notify affected personnel and supervision.

3. Investigate the cause for intervention and correct the hazard.

SWA 5 step process

Identify hazards and conditions that lead to incidents

Some jobs will always have one or more hazardous components

Is it possible to do something 100% safely?

Programs and processes

Programs, processes, procedures and standards Examples

Safety standards Employee evaluation.

• Safety courses, hazard recognition, gas testing etc.

• Job safety analysis.

Observation processes • Joint site inspection.

• Hazard analysis checklist.

Reporting processes Injury reporting, incident reporting

Unsafe conditions and acts

Incidents are caused by:

Unsafe act examples Unsafe condition examples

Operating equipment without proper training or Inadequate guards or safety devices.

Failure to secure (LOTO, fall protection).

Improper use of equipment.

• Operating equipment without authority or certification.

• Know your safety responsibilities

• Knocking on a valve with a wrench to open it is an example

• Performing a job without the required certification, or not

• Taking shortcuts, trying to accomplish work in a hurry or to

• Human nature to want to complete a task as quickly as possible.

• They are in a rush to get the job done.

• Nearly 3,000.000 non-fatal and 4,000 fatal workplace injuries.

There are usually two types of barriers:

You should now be able to:

Describe the Stop Work Authority program.

• List the methods to recognize and control hazards.

Methods to recognize & control hazards

• Common causes of incidents.

How to recognize and control

Remember, the purpose of hazard recognition…

Common causes of incidents

Hazards not recognized or controlled.

Equipment is not properly isolated, powered off or depressurized.

Gas testing not performed or monitored.

No effective joint site inspection.

Improper responses when conditions change.

Safety hazards Examples

Mechanical rotating shafts, belts, pulleys, saw blades.

Health hazards Examples

Recognize and control hazards

• Joint site inspection.

• Work permit system and forms.

• Hazard analysis checklist.

Recognize and control hazards

• Section 2, hazard identification and control.