Training & DevelopmentJanuary 2012

Module 2.1

State Workshop and Plant Safety Practices

Trainee Handbook

© Copyright Saudi Aramco, 2012.All rights reserved. No portion of this book may be reproduced, by any process

or technique, without the express written consent of Saudi Aramco.

TABLE OF CONTENTS

January 2012

Unit 2: Perform Bench Work

Module 2.1

State Workshop and Plant Safety Practices

TRAINEE HANDBOOK

Information Sheets 1

Exercise A 7

Exercise B 11

Exercise C 19

Glossary 21

INFORMATION SHEET

Module 2.1 January 2012 1

Terminal Objective

Unaided, the trainee will correctly state general workshop and personal safety practices in Saudi Aramco.

Enabling Objectives

2.1.1Unaided, the trainee will correctly state general shop safety rules.

2.1.2Unaided, the trainee will correctly identify restricted areas.

2.1.3Unaided, the trainee will correctly identify personal protective equipment requirements relating to specific hazards.

InTrOducTIOn

In this unit, you are introduced to the training and work environment of Saudi Aramco. This first module introduces you to safety at work. The next six modules cover hand skills needed for Process Control Systems Technicians. You are introduced to measuring, layout and shop tools and you will build practical skills in their use. You will also learn to make wire terminations.

In this module, you will study safety. Safety is very important. You must be aware of, and follow, all safety rules and procedures. This applies wherever you work.

Safety does not stop at work. Safety in the home and on the roads is just as important as safety at work.

INFORMATION SHEET

2 January 2012 Process Control Systems Technician

Working safely is an ongoing process. You must know the safety requirements and procedures for your work area, and for any task you perform.

In this module, you will learn safe work practices. You will study three main topics:

o general workshop safety

o restricted areas

o personal protective equipment

INFORMATION SHEET

Module 2.1 January 2012 3

parT I ObjEcTIvE 2.1.1

General Shop Safety rules

Safety starts with you. That is the first rule of safety. It is your responsibility to know and follow safety rules. During this training program you will spend time in a workshop. There are 10 general safety rules you must follow in the workshop.

1. Wear proper personal safety equipment.

You must always wear safety shoes and safety glasses. Some tasks require extra safety equipment. You must learn when and how to use this extra safety equipment.

2. If you do not know or you need help, ask!

You will use tools and equipment that are new to you. You will also test equipment with power applied to it. Before performing a task, safety rules and procedures will be explained to you. If you are not sure of something, or if you need some help, ask the instructor.

Remove all jewelry and watches before starting work.

"Live" equipment has power applied or connected to it.

Figure 1If You Do Not Know, AskFigure 1If You Do Not Know, AskProcess Control Systems TechnicianCore Program - Module 2.1

INFORMATION SHEET

4 January 2012 Process Control Systems Technician

3. Know and use the correct tool for the job.

You will use new tools and equipment while training. Each tool is designed for a specific task. To protect yourself, there are safety rules and procedures for using each tool. Make sure you know which tool or equipment to use, and how to use it safely.

4. Keep your mind on your work.

Do not distract others or permit them to distract you. If distracted you will make mistakes. In a workshop with live equipment and machinery, making a mistake can be very painful, and sometimes fatal. Keep your mind on your work. Stay safe.

Figure 2Know Your Tools

Figure 3Keep Your Mind on Your Work

5. Report safety hazards and practice good housekeeping.

If you see a safety hazard, report it. If the hazard is small and you can correct it (make it right) safely, do so. For example, a minor hazard you can correct is removing waste material from your work area.

If you cannot correct the hazard, report it to your instructor.

Figure 3Report Safety Hazards

Figure 2Know Your ToolsProcess Control Systems TechnicianCore Program - Module 2.1

Figure 3Keep Your Mind On Your WorkProcess Control Systems TechnicianCore Program - Module 2.1

Figure 4Report Safety HazardsFigure 4Report Safety HazardsProcess Control Systems TechnicianCore Program - Module 2.1

INFORMATION SHEET

Module 2.1 January 2012 5

6. Follow all instructions and only use authorized equipment.

Perform only your assigned (given) tasks. Use only the tools and equipment that you have been trained for, or allowed to use. You must never operate any machine or use any tool unless your instructor tells you to do so.

Figure 5Follow All Instructions

7. Know and follow emergency procedures.

Each workshop has emergency procedures and evacuation plans posted. These procedures are to protect you. Learn what actions you must take in an emergency. Following these procedures correctly can save your life.

Figure 6Learn Emergency Procedures

8. Disconnect equipment before making adjustments.

You must disconnect equipment from its power source before working on it.

Figure 7Discount Equipment!

Figure 5Follow All InstructionsProcess Control Systems TechnicianCore Program - Module 2.1

Figure 6Learn Emergency ProceduresProcess Control Systems TechnicianCore Program - Module 2.1

Figure 7Isolate (Disconnect) EquipmentProcess Control Systems TechnicianCore Program - Module 2.1

INFORMATION SHEET

6 January 2012 Process Control Systems Technician

9. Report all accidents, injuries or near misses.

Reporting a "near-miss" makes others aware of unsafe practices or areas. Being aware of unsafe items can prevent you or someone else from being hurt in the future.

10. Know and follow all safety procedures, directions, and signs.

Most tasks you perform will have safety procedures in addition to the general procedures. Different work areas require different safety procedures. Make sure you know and follow all the safety procedures required for your work, your equipment, and your area.

These are only the basic safety rules. Tools and machines in the workshop have their own specific safety rules and procedures that you must follow.

At this time, complete exercise A.

Figure 8Follow Signs and Directions

If you do not think it's safe, do not do it!

Figure 8Follow Signs and DirectionsProcess Control Systems TechnicianCore Program - Module 2.1

EXIT

INFORMATION SHEET

Module 2.1 January 2012 7

ExErcISE adirections: Your instructor will take you around the workshop. After this, you will have a discussion on shop safety.

INFORMATION SHEET

8 January 2012 Process Control Systems Technician

Summary

Safety procedures are designed to protect people, equipment, and facilities. Review and become familiar with the ten general safety rules for working in the workshop. Never forget rule number 2: If you do not know what to do or need help, ask your supervisor, mentor, or instructor.

INFORMATION SHEET

Module 2.1 January 2012 9

parT II ObjEcTIvE 2.1.2

Identify restricted areas

A restricted area has work being carried out, or has an environment, that makes the area dangerous. To reduce the danger, only certain people are allowed to enter and work in those areas.

You must learn to recognize an area that has safety restrictions. To help you identify these areas, you must examine:

o the paperwork for the job or task

o the work site where you will do the task

o the tools and equipment you need to do the task

dOcumEnTS

In the field, every task comes with supporting documents. These documents includes work orders, maintenance procedures, planning documents, general instructions (GIs), and various work permits. These documents contain information and instructions about the task and its relevant safety rules and procedures.

These documents contain safety information such as area restrictions, the work you can do on different shifts, the type of tools you can use, as well as general task/site safety.

Specific means things that apply exactly. Therefore, specific area safety rules are rules needed for that area.

It is always a good idea to discuss the task with your supervisor or mentor.

INFORMATION SHEET

10 January 2012 Process Control Systems Technician

Make sure you find and understand this type of information. Read all the relevant documents before beginning a task. While reading the documents, you should find out:

o the kind of work so you can plan it out safely.o the kind of work permit required and who is

authorized (allowed) to get it.

Figure 9 shows a work permit.

WOrK SITE

Once you have all the information you can get from these documents, inspect the site carefully. Time spent inspecting your work site is important. The more you know about the site, the easier it is for you to identify possible safety hazards. Remember, conditions in the field change regularly. Make sure you are aware of any changes at the work site. Figure 10 shows workers at a work site.

When at the work site, look for:

o safety warnings, signs or posters–(follow these instructions)

o caustic or flammable liquid containers near your work area, to make sure they do not cause a safety hazard to you or the equipment

o any possible cause of sparks or flames at the work site or from the tools you plan to use

o electrical lines, systems or equipment near your work area

Remember, safety does not just happen–you must work for it. Any work site, no matter how safe it seems, can become an accident site if you forget safety. Accidents don’t just happen, they are caused.

At this time, complete exercise B.

Caustic materials can cause chemical burns.

Flammable materials can catch fire and burn easily.

Remember that safety is your responsibility. Safety starts with you.

Figure 9Work PermitFigure 9Work PermitsPCST 2.1

Figure 10Work SiteFigure 10Work SitePCST 2.1

INFORMATION SHEET

Module 2.1 January 2012 11

ExErcISE bdirections: Write the correct answers in the spaces provided.

1. Why do some areas have restricted access?

2. What three things help you identify work site safety restrictions?

3. List three examples of the safety information you can get from task documents?

4. Why should you spend time getting to know your work site?

5. Why must you keep alert?

INFORMATION SHEET

12 January 2012 Process Control Systems Technician

Summary

You must be constantly aware of hazards and know the safety and emergency procedures. Different work areas have different safety requirements. You must be aware of the safety aspects of the areas you work in and every task you do. Plan your work safely. Check your work area and check that your tools and equipment are safe, both for the task and work site. Only by doing these things will you be safe.

Never assume something’s safe. Check it! In the field ask your supervisor to tell you about site safety and emergency procedures. Make sure you know what your responsibilities are. Never assume that the safe work site you left an hour ago will still be safe when you return.

INFORMATION SHEET

Module 2.1 January 2012 13

parT III ObjEcTIvE 2.1.3

Identify personal protective Equipment Requirements Relating to Specific Hazards

During training you will learn that some tasks require the use of protective equipment. To work safely in the field, you must increase your knowledge of protective equipment. You must learn:

o what parts of your body need most protection

o what to protect your body from

o what protective equipment you can use

WHat muSt you pRotect? WHy? and WHat to uSe?

Many people are injured at work because they were not working safely. They did not follow rules, regulations, and procedures. They were not aware of the dangers. To avoid getting injured learn how to protect yourself. Learn the different types of protective equipment available and how to use them to protect you.

protection for your Head

The hard hat, shown in figure 11, provides protection for your head. Always wear a hard hat when in a “hard hat area”.

Make sure the hard hat fits properly. Keep the hat clean and in good condition. Never paint or modify the hat.

The items listed here are in addition to the general workshop safety items you must always wear.

note: Personal protective equipment will only protect you if you use it correctly and work safely.

Figure 11Hard ProtectionFigure 11Hard ProtectionPCST 2.1

INFORMATION SHEET

14 January 2012 Process Control Systems Technician

protection for your Eyes and Face

Protect your eyes and face with face shields, goggles and hoods. These are shown in figure 12. Your eyes and face are easily injured by metal particles, chemicals, and heat. Make sure you use a face shield or goggles when the task requires it.

The following is a general guide for using different types of eye/face protection.

o Safety glasses protect your eyes from flying objects. They must be worn whenever you are in a workshop or a restricted area. If you normally wear prescription glasses or contact lenses, do not wear them at the work site. Wear only prescription safety glasses.

o Safety goggles protect your eyes from light, dirt, dust, and sand, depending on the type of goggles. For example, welders, tint, and clear. Most safety goggles are designed to fit over safety glasses.

o Face shields protect your face and eyes from flying particles, hot sparks, and chemical splashes. For added protection, wear safety glasses when you use a face shield.

Make sure you know the specific protection you need for each task.

Don't assume–check!

Make su re you know the location of the nearest eye

bath. If you get chemicals in your eyes, wash them immediately, then seek medical attention.

Figure 12Eye and Face ProtectionFigure 12Face ProtectionPCST 2.1

Welder’s Mask

Face Shleld

Safety Glasses

Multi-Purpose Safety Goggles

INFORMATION SHEET

Module 2.1 January 2012 15

o Protective hoods protect your entire head, including your face and eyes. Some hoods have their own air supply to give you added protection. Protective hoods are shown in figure 13.

protection for your Hearing

Earplugs and earmuffs (sometimes called ear defenders) protect your hearing. These are shown in figure 14.

Loud noises, high and low frequency sounds can permanently damage your hearing. Earplugs give the best protection from high frequency noise.

Earmuffs are best for low frequency and background noise. For maximum protection you should wear both earplugs and earmuffs. You should keep your ear protection with you. Use them whenever there is a need.

protection for your Lungs

Filter and respirator masks are used to protect your lungs. Work sites have many hazards that can damage your lungs. Oil and gas plants produce many toxic (poisonous) gasses and fumes. There are processes that remove oxygen from the air. Toxic dust and particles can also severely damage your lungs. These dangers mean you must use protective measures. The type of protective equipment you use depends on the task and the work area. Figure 15 shows lungs protection equipment.

Figure 13Protective HodsPCST 2.1

Figure 13Protective Hood

Figure 14Hearing ProtectionFigure 14Hearing ProtectionPCST 2.1

INFORMATION SHEET

16 January 2012 Process Control Systems Technician

o Filter masks are used at most plants for general work. A simple paper, cloth, or foam filter fits over your mouth and nose. These filters protect you from airborne dust and dirt particles.

o Respirator masks protect you from poisonous gases and most toxic fumes. These masks have complex filters that clean the air as you breathe. Though some of these masks cover the whole head or face, most cover only your nose and mouth.

o Fresh air or oxygen pack respirators have their own clean air supply. You use them when there is heavy smoke or toxic fumes. These masks cover your whole face. Some cover your head and shoulders. There are courses on how to use air packs.

Always follow plant smoking restrictions. Many times smoking is not allowed because of the danger of flammable gases. Smoke in designated areas only.

protection for your Hands and Lower arms

Wear gloves to protect your hands and lower arms. These are shown in figure 16. As a technician, you use your hands for many things. You can injure your hands and lower arms if they are not protected. As with other protective equipment, different tasks need different safety equipment.

o Leather gloves protect you from minor cuts and bruises. Use them for general work. Make sure your arms are also covered correctly.

N e v e r u s e a resp i ra tor mask while fire fighting. Respirator masks

do not protect you from smoke. Nor do they protect you in low-oxygen conditions.

Figure 15Lung ProtectionFigure 15Lung ProtectionPCST 2.1

INFORMATION SHEET

Module 2.1 January 2012 17

o Rubber gloves protect you when working with chemicals and electrical equipment. Make sure they are long enough to protect your arms from acid or solvent spills.

At this time your instructor will demonstrate how to test rubber gloves.

Protection for Your Feet and Ankles

You must always wear safety shoes at work. Safety shoes are shown in figure 17. Safety shoes help protect your feet if something falls on them. Only safety shoes can do this because they have a steel toe cap. Make sure your safety shoes fit correctly and are in good condition. Without the correct safety measures, it is very easy to injure your feet and ankles.

A l w a y s t e s t rubber g loves before you use them.

Figure 16Protecting Hands and Lower ArmsFigure 16Protecting Hands and Lower ArmsPCST 2.1

Rubber

Cloth & Leather

Leather

Figure 17Safety ShoesFigure 17Safety ShoesPCST 2.1

Steel Cap

INFORMATION SHEET

18 January 2012 Process Control Systems Technician

protection for your Trunk (body)

Depending on the task, you may have to use a cloth or leather apron, non-flammable cloth coveralls, and safety belts to protect your trunk (body). Figure 18 shows a leather apron.

remember: No safety equipment can protect you if you have unsafe work habits.

At this time, complete exercise C.

Figure 18Leather ApronPCST 2.1

Figure 18Leather Apron

INFORMATION SHEET

Module 2.1 January 2012 19

ExErcISE cdirections: Your instructor will show you some examples of specialized protective equipment. You must identify what part of your body the equipment protects and what it protects you from.

INFORMATION SHEET

20 January 2012 Process Control Systems Technician

Summary

In this module, you learned the basics of general workshop safety, restricted areas, and personal protective equipment. You need to protect yourself from the many hazards at the work site. Always check to see if any specific protective equipment is needed for your task.

Always be aware of all personal protective equipment needed for the task to work safely at any work site. Practice safety when you work.

GLOSSARY

Module 2.1 January 2012 21

Demonstrate (to)Show how to do something.

FlammableCapable of burning.

ParticlesSmall pieces.

ProcedureAn established or correct method of doing something.

HANDOUT

Module 2.1 January 2012 Handout 2.1-1

GENERAL WORKSHOP SAFETY RULES

1. Wear proper work clothing and personal safety equipment.

2. If you don’t know or need help, ask.

3. Know and use the correct tool for the job.

4. Keep your mind on the task, no horseplay.

5. Report safety hazards and practice good housekeeping.

6. Follow all instructions and use authorized equipment ONLY.

7. Follow emergency procedures.

8. Disconnect or unplug equipment before making any adjustments.

9. Report all accidents, injuries and near misses.

10. Follow all work safety rules, procedures, directions, and signs.

Safety Starts With YOU !

Remember, if you don’t think it’s safe, DON’T DO IT!