Military reference books and manuals (2009-2023, Volume 4)

Procedure for Transportable Compressed Gas Cylinders

Page 5 of 20

4 KEY RESPONSIBILITIES

4.1 SITE MANAGER (SM) / SITE CONTROLLER (SC) / OFFSHORE INSTALLATION MANAGER (OIM)

Site Managers, Site Controllers and Offshore Installation Managers have overall responsibility

for the receipt, safe storage and use of gas cylinders on their site / Installation and shall ensure

that:

 Procedures for procurement, receipt, safe use and storage of gas cylinders are

established and observed on site

 Gas cylinders are procured and stored in accordance with these guidelines

 Receipt, storage and use of gas cylinders are carried out by suitably competent and

qualified personnel

 That no compressed gases, gas hoses or associated equipment is allowed or used on

site unless it has been designed and tested for use and, where necessary, is

accompanied by all relevant certification and in date test certificates

 That, where necessary, adequate records are maintained for all compressed gases, gas

hoses or associated equipment including, certification, examination and test reports.

 That Competent Person’s are appointed to control the issue and inspection of

compressed gases, gas hoses or associated equipment

 That Competent Person’s are appointed to control the use and storage of all compressed

gases, gas hoses and associated equipment

4.2 AREA AUTHORITY (AA)

The Area Authority shall be responsible for ensuring that the requirements of this procedure are

adhered to within his area of responsibility. He shall be responsible for ensuring:

 That the use of gas cylinders have been risk assessed and planned

 That all persons involved in the use of gas cylinders are instructed on the risks or

hazards associated with their work activity

 That regular inspection is performed on all works associated with gas cylinder activities to

confirm that conditions are suitable and sufficient and, that all personnel are in

compliance with this procedure

 That the Performing Authority performs Risk Assessments, and conducts Toolbox Talks

associated with the use of gas cylinders

4.3 PERFORMING AUTHORITY (PA)

Personnel involved in the use of compressed gas cylinders, gas hoses and associated

equipment shall ensure:

 That all equipment is inspected prior to use

 That all equipment is used according to manufacturers and suppliers instructions, best

recognised practice, and with regard to safe working practices, procedures and risk

assessments

 That all equipment in use is placed in safe positions and that all gas hoses are run to

avoid slip and tripping hazards

 That all equipment is inspected after use and returned to appropriate storage locations.

 That all equipment is isolated, disconnected and stored safely and correctly at the end of

each shift

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Procedure for Transportable Compressed Gas Cylinders

Page 6 of 20

4.4 PERSONS RESPONSIBLE FOR INSPECTION AND MAINTENANCE

Personnel responsible for the inspection and maintenance of gas hoses and associated

equipment shall ensure:

 That a record is kept of all equipment on site detailing issue, use, repair, inspection and

maintenance

 That all equipment on site is colour coded for ease of identification and, that details of the

colour code in present use is displayed around the facility and at the point of issue

 That all equipment on site is inspected and maintained to manufactures and suppliers

instructions and recommendations, best practice and, company policy

 That any equipment on site taken out of service is placed in secure quarantine to prevent

use

5 COMPRESSED GAS CYLINDERS

5.1 GAS CYLINDER PROCUREMENT

5.1.1 Design, Manufacture and Testing

Gas cylinders shall be designed, manufactured and tested according to recognised standards.

Generally accepted standards for refillable cylinders are:

 Seamless steel gas cylinders: ISO 9809,

EN 1964

 Welded cylinders for LPG:

ISO 22991, EN 1442

 Welded cylinders:

ISO 4706,

EN 13322

Or to a equivalent standard.

The cylinders shall be subject to initial certification as required by chapter 6.2.1.4 of Annex A to

“The European Agreement concerning the International Carriage of Dangerous Goods by Road

(ADR)” or alternatively according to ADR chapter 6.2.5.6. Cylinders conforming to EC directive

1999/36/EC and bearing the mark of conformity are also acceptable.

Cylinders shall be colour labelled and stamped in accordance with Tables 1a, 1b.

5.1.2 Filling of Cylinders

Gas cylinders shall only be filled by BP approved suppliers according to Procurement Supply

Chain Management (PSCM) practice requirements. Cylinders must only be filled with the type

of gas for which they are intended. In no case shall cylinders be filled in excess of the limit

permitted by ADR chapter 4.1, Packing instructions P200.

During filling, the filling centre shall carry out inspections in accordance with the requirements of

Regulation of

“Structure

(working principles) and Safe Operation of Pressure Vessels”

Moscow 1976 or/and one of the following standards:

 Liquefied gases:

EN 1919

 Compressed gases:

EN 1920

 LPG

EN 1439

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Procedure for Transportable Compressed Gas Cylinders

Page 7 of 20

5.1.3 Periodic Inspection

The cylinders shall be subject to periodic inspection at regular intervals not exceeding the

intervals required by ADR chapter 4.1, Packing instructions P200. The inspection shall be

carried out in accordance with one of the following standards:

 Seamless steel cylinders

EN 1968

 Welded LPG Cylinders

EN 1440

Or a equivalent standard.

The tests shall be carried out by a Testing and Certification body approved by BP.

5.2 RECEIPT OF CYLINDERS ON SITE

5.2.1 Design, Fabrication and Testing of Multiple Cylinder Transport

Gas cylinders shipped to any BP site shall be thoroughly inspected by qualified and competent

personnel before being accepted.

Containers / Frames:

 The owner shall ensure that the transport containers are properly designed and tested

 The design should ensure the security of the bottles as they should not move and stress

the manifold piping during transport

 The structure of the container frame should be properly designed and fabricated to an

approved drawing. The drawings should detail the materials of construction, welding of

the members and coating required

 The lifting lugs shall be designed by a qualified competent person and should include the

details of welding and calculation of the strength of the lugs. There should be approved

drawings and calculations showing this detail

 The fabrication should be carried out to the drawings by a properly qualified and

approved contractor

 The container shall be marked with its unique number, the name of the owner and have

the appropriate Test Plate fitted

 Testing of the container shall be carried out by a properly certified test authority and their

plate shall be fitted to the tested unit

 Regular inspections are to be carried out at period not exceeding 6 months and the

inspection stamp applied to the Test Plate

 Inspected for corrosion, dents, general distortion, scorch marks, defacing, illicit repairs,

modification, or any defect

Manifolds, piping and Valves:

 The manifolds and piping shall be designed, fabricated and tested to an appropriate

international code. The owner should indicate the code used for the fabrication

 Design, fabrication and testing shall be properly documented and these documents held

by the owner

 Normally the design drawings should be appropriately approved by a competent

authority and these must be signed off and issued in a controlled manner

 Valves used in the construction shall be of an approved type and all relevant documents

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Procedure for Transportable Compressed Gas Cylinders

Page 8 of 20

such as, data sheets, material certification, test certification shall be held by the owner.

The threads and connections used should be shown on the drawings and should be to

internationally known standards

 The management of these small bore systems shall be controlled by a regular

maintenance and inspection regime. There is good guidance in documents such as

UKOOA “Guidelines for the management of Small bore Tubing Systems

 Inspected for, dents, general distortion, scorch marks, defacing, illicit repairs,

modification, or any defect

There is guidance to good design in documents such as BCGA Code of Practice CP4

“Industrial Gas Cylinder Manifolds and Gas Distribution Pipework”. It also indicates the codes

and standards used for all aspects of the design.

The requirements of ASME B16.3 “Chemical Plant and Refinery Piping” should be used as

guidance for test pressures and durations, it also gives guidance on design and stress

calculations.

Note: Defective cylinders shall be returned to the supplier / manufacturer.

Cylinders with faulty outlet valve connections, e.g., damaged threads, seized valve spindles,

etc., must be returned immediately to stores with a note stating the cylinder number, the nature

of the fault and whether the cylinder is charged.

Note: Under no circumstances may the user of the cylinder attempt any repair.

5.2.2 Cylinder Identification

Compressed gas cylinders shall be colour coded in accordance with the GOST 949-73 to

properly identify their contents. The required colour coding for Azerbaijan is based on GOST

949-73; for Georgia - EN 1089-3:2004 as listed in Tables 1a and 1b.

Sites within AzSPU shall apply only one Gas Cylinder identification/marking standard in

accordance with their requirements and needs.

Sangachal Terminal - GOST 949-73

Offshore - GOST 949-73

Export

- GOST 949-73

Georgia - BS EN 1089-3:2004

Note 1:

If cylinders cannot be identified in accordance with this colour coding standard,

they shall not be accepted or used on site, but shall be returned to the supplier.

Note 2:

This colour coding system does not apply to Diving Gases which are covered

under separate standards and practices applicable to diving and sub-sea

operations.

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Procedure for Transportable Compressed Gas Cylinders

Page 10 of 20

Table 1a: Compressed Gas Cylinder Identification

ADR Classification

Marking according to GOST-949-73

EN1089-3 ^{1, 2}

Classification

Gas name

Bottle

Label Text

Label

Stripe

Colour on

Number

code

Colour

shoulder

1002

Air

Black

COMPRESSED AIR

White

Bright green

(technical)

1046

Helium

Brown

HELIUM

White

Brown

1049

Hydrogen

Dark

HYDROGEN

Red

green

1072

Medical Oxygen

Blue

MEDICAL OXYGEN

Black

1066

Nitrogen

Black

NITROGEN

Yellow

Brown

Black

1072

Oxygen

Blue

OXYGEN

Black

White

1006

Technical Argon

Black

TECHNICAL ARGON

Dark blue

Dark green

Notes:

1. Note that according to EN 1089-3 2004 colour coding applies to cylinder shoulders. Manufacturers may select the colour for the main cylinder body.

2. Cylinders coded in accordance with EN 1089-3 2004 requirements will be marked with “N” twice on the cylinder shoulders.

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Procedure for Transportable Compressed Gas Cylinders

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Table 1b: Liquefied and Dissolved Gas Cylinder Identification

ADR Classification

Marking according GOST-949-73

EN1089-3 ^{1, 2}

Classification

Gas name

Bottle

Label Text

Label

Stripe

Colour on

Number

code

Colour

shoulder

1001

Acetylene

White

ACETYLENE

Red

Maroon

1005

2TC

Ammonia

Yellow

AMMONIA

Black

Yellow

1011

Butane

Red

BUTANE

White

Red

1013

Carbon dioxide

Black

CARBON DIOXIDE

Yellow

Grey

1017

2TC

Chlorine

Khaki

CHLORINE

Green

Yellow

1965

Hydrocarbon gas

N.A.

mixture, liquefied,

n.o.s.

1053

2TF

Hydrogen Sulfide

White

HYDROGEN SULPHIDE

Red

Yellow

1978

Propane

Red

PROPANE

White

Red

1079

2TC

Sulphur Dioxide

Black

SULPHUR DIOXIDE

White

Yellow

Notes:

1. Note that according to EN 1089-3 2004 colour coding applies to cylinder shoulders. Manufacturers may select the colour for the main cylinder body.

2. Cylinders coded in accordance with EN 1089-3 2004 requirements shall be marked with “N” twice on the cylinder shoulders.

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Procedure for Transportable Compressed Gas Cylinders

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5.2.3 Cylinder Markings

All cylinders shall be permanently and legibly labelled or stamped in accordance with the

applied standard. The marking shall include, at minimum, the following elements:

 Trade symbol of manufacturer

 Serial number

 Calculated quantity (tare) of empty mass

 Manufacturing date (month, year)

 Marking of inspection body, date of next inspection/test date, adjacent to the previous

inspection date (month, year)

 Service pressure (psi/bar)

 Test pressure (psi/bar)

 Capacity (cubic feet/litres)

All markings shall be stamped on the shoulder of cylinders near valves.

Note: Do not remove or change any numbers or marks stamped on cylinders. Any cylinders

that do not comply with this system or show tampered cylinder markings shall not be

accepted or used on site but shall be returned to the manufacturer/supplier.

5.3 CYLINDER STORAGE

5.3.1 All Cylinders

All cylinders shall be stored in a cool, well ventilated area, preferably in the open air but

sheltered from direct sunlight and at least 3 metres (10 feet) from combustible materials.

Note: Medical services have to look after their compressed gas portable equipment to ensure

the medical gas cylinders as well as other cylinders should not be subjected to extremes of

temperature and/or weather e.g. direct sunlight, rain.

Cylinders shall be chained or otherwise secured, in an upright position with valves shut and

valve caps in place when cylinders are not in use.

Cylinders shall not be stored in enclosed spaces such as workshops, accommodation or

enclosed modules except for where required that breathing air cylinders and medical gases that

are used for immediate response by emergency response teams be stored in the temporary

refuge and clinic these should be limited and subject to regular inspection.

All cylinders shall be stored away from:

 The direct rays of the sun or from radiant heat, e.g., flares

 Locations where the temperature may exceed 45C (113F)

 Locations exposed to adverse weather

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Procedure for Transportable Compressed Gas Cylinders

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Note: Weather protection shall be provided if required

 Possible sources of ignition

 Flammable materials

 Corrosive liquids



Any direct contact with soft or damp ground, or any other location where water can

accumulate, thereby increasing exposure to the possible effects of corrosion

 Locations where cylinders are vulnerable to impact, e.g. fork lift trucks

Cylinders containing different gases must be stored separately and in accordance with

established spacing requirements. Oxygen cylinders shall be separated from the cylinders

containing flammable gas by at least 3 metres or by non-combustible barrier at least 2 metres

high.

Empty cylinders shall be marked with “EMPTY” or “MT”, and stored separately from full

cylinders.

Leaking cylinders or cylinders with leaking valves that cannot be shut off must be removed to a

safe area away from any possible source of ignition and drainage, where they shall be allowed

to vent off slowly until empty. Stores shall be advised of the fault.

Note: Propane and Butane are heavier than air and may therefore accumulate in dips and

hollows.

Note: Regardless of whether or not cylinders have been marked / empty, all cylinders shall

be handled and treated as if they were full.

5.3.2 Oxygen Cylinders

Warning: Oils and greases are spontaneously combustible in the presence of oxygen.

Oxygen cylinders and their fittings, including hoses, must not be stored or used

where they can come into contact with oil or grease. This includes handling the

equipment with oily hands, gloves or rags.

Oxygen cylinders must be stored apart from fuel gas cylinders by a minimum distance of 3

metres (10 feet). Separation by using cylinders of non-flammable gases is acceptable. This

separation must be maintained.

The preferred practice is to store oxygen cylinders vertically, valve end up. However, it is

acceptable to store oxygen cylinders horizontally provided that:

 The stacks shall not exceed a maximum height of three cylinders

 The largest cylinders must be at the bottom

 The row must be securely wedged.

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Procedure for Transportable Compressed Gas Cylinders

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5.3.4 Damaged Cylinders

Cylinders that may have been damaged in any way shall be returned to the supplier.

Leaking cylinders shall immediately be moved to a freely ventilated area away from any source

of ignition or places where leaking gas will become trapped.

5.4 CYLINDERS EXPOSED TO FIRE

In the event of gas cylinders being involved in a fire, they must be kept cool with water spray,

e.g., a fog nozzle, and where possible, removed to a safe area. Such cylinders must be

returned to the manufacturer for checking prior to re-use.

In the case of acetylene cylinders that have been so exposed, prolonged cooling is necessary

for several hours after the incident to prevent exothermic decomposition.

5.5 CYLINDER HANDLING

5.5.1 Transport

The transport shall, at minimum, comply with the national regulations applicable for the relevant

mode of transport. The following shall be observed:

 Gas cylinders shall only be transported in properly ventilated cylinder containers

 Suitable valve protection caps shall be fitted

 Ensure cylinders are securely stowed to prevent moving, e.g. by use of baskets

 Cylinders shall be stowed in the upright position unless instructions for transport

specifically say otherwise

 Do not let gas cylinders project beyond the sides or end of a vehicle

5.5.2 Lifting

If cylinders are lifted by crane, a suitable cradle or similar device should be used.

Trolleys should not be used as lifting cradles unless they have been specifically designed for

that purpose and are certified and checked on a six monthly basis.

Cylinders shall not be lifted using:

 The cylinder valves

 Chain or wire rope slings (these can allow the cylinder to slip during lifting)

 Lifting magnets

5.5.3 Movement of Cylinders on Site

Note: Cylinders shall not be dropped, dragged, rolled, used as supports or for any other

purpose than the storage and transport of gas, and must be protected from damage at all

times.

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Procedure for Transportable Compressed Gas Cylinders

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5.5.3.1 Cylinder Trolleys

Cylinders shall be transferred to, and moved within, the working area on trolleys specifically

designed for that purpose, or in suitable containers providing stable and secure positioning of

the cylinders.

All valves must be closed before a cylinder is moved and, if the correct trolley is not being used,

regulators and hoses should be detached from the cylinders.

5.5.3.2 Electric Cables

Cylinders and gas hoses shall not be allowed to come into contact with current carrying wires.

Therefore:

 Special attention should be paid to the places where electro-welding and gas burning of

metals are carried out simultaneously

 The distance from oxygen or fuel gas cylinders to electro-welding cables shall be not less

that 1 m

When in use, hoses should be protected from damage, and laid out in such a manner as to

avoid being a tripping hazard.

5.6 CYLINDER USE

Many of the specific uses of gases will vary from gas to gas but there are several points that

apply to all of them:

 Do not use a cylinder that appears to be damaged or defective in any way

 Keep the cylinders away from operations that create sparks, heat, fire and electrical

circuits

 Do not use oil or grease on cylinders or handle them with oily hands or gloves. Do not let

oxygen spray on an oily or greasy surface, or on your clothes

 Use cylinders in ventilated areas only

 Keep cylinders secured upright in cylinder racks

 Open valves by hand, not with a wrench or other tool. If they cannot be opened by hand,

notify the supplier/manufacturer

 Do not tamper with safety devices

 Check that the regulator is rated for the correct pressure and service, is in date,

stamped, and does not show signs of damage or temporary repair

(e.g. jointing

compound or tape)

 If a cylinder has a leaky valve or fitting which cannot be stopped by closing the valve, the

cylinder must be taken outdoors away from sources of ignition. Tag the cylinder as in bad

order and promptly notify the supplier. Do not try to fix a leaking cylinder or valve. Dented

cylinders should never be used

 Ensure that all equipment, including hosing

/ tubing, for use in oxygen service is

designed for this purpose and is completely degreased and dust free before each use

 Always open valves slowly. If a valve cannot be opened by hand with the key or hand

wheel provided, the cylinder shall be returned to the supplier / manufacturer. Do not

attempt to force the valve open using wrenches or other hand tools

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Procedure for Transportable Compressed Gas Cylinders

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 Do not empty gas cylinders completely. If appropriate, cylinders should be fitted with

residual pressure valves

(non-return valves) to prevent backflow of air or other

contaminants

6. REFERENCES

This procedure shall, where appropriate, be used in conjunction with this suite of AzSPU

Procedures referenced below.

Document Number

Title of Procedure

AZSPU-HSSE-DOC-00053-2

Procedure for Hot Work Naked Flame

AZSPU-HSSE-DOC-00061-2

Procedure for Personal Protective Equipment

AZSPU-HSSE-DOC-00060-2

Procedure for Permit To Work

AZSPU-HSSE-DOC-00064-2

Procedure for Welding & Cutting

AZSPU-HSSE-DOC-00063-2

Procedure Task Risk Assessment

AZSPU-HSSE-DOC- 00002-2

SSOW Procedure for Control of Work Standards

Further information available:

This document has been updated to include selected international standards referenced by

“The European Agreement Concerning the International Carriage of Dangerous Goods by

Road” (ADR). Azerbaijan became signatory to ADR in September 2000.

In addition to the referenced standards stated here, other requirements of ADR may be useful

as additional detailed guidance on e.g. cylinder securing and transport aspects.

Standard No

Title

GOST-949-73

Steel gas cylinders of small and middle sized volume.

www.centrogas.ru

Transportable gas cylinders - Gas cylinder identification (excluding

EN 1089-3, edition 2, 2004

LPG) - Part 3: Colour coding

Transportable refillable welded steel cylinders for liquefied

EN 1439, edition 1, 1997

petroleum gas (LPG) - Procedure for checking before, during and

after filling

Transportable refillable welded steel cylinders for liquefied

EN 1440, edition 1, 1997

petroleum gas (LPG) - Periodic re-qualification (Corrigendum

AC:1999 incorporated

Transportable refillable welded steel cylinders for liquefied

EN 1442, edition 1, 1999

petroleum gas (LPG) - Design and construction (Corrigendum

AC:1999 incorporated

Transportable gas cylinders - Cylinders for liquefied gases

EN 1919, edition 1, 2000

(excluding acetylene and LPG) - Inspection at time of filling

Transportable gas cylinders - Cylinders for compressed gases

EN 1920, edition 1, 2000

(excluding acetylene) - Inspection at time of filling

Transportable gas cylinders - Specification for the design and

construction of refillable transportable seamless steel gas cylinders

EN 1964-1, edition 1, 1999

of water capacities from 0,5 litre up to and including 150 litres -

Part 1: Cylinders made of seamless steel with an Rm value of less

than 1100 Mpa

Transportable gas cylinders - Specification for the design and

EN 1964-2, edition 1, 2002

construction of refillable transportable seamless steel gas cylinders

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Procedure for Transportable Compressed Gas Cylinders

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of water capacities from 0,5 litre up to and including 150 litres -

Part 2: Cylinders made of seamless steel with an Rm value of 1100

MPa and above

Transportable gas cylinders - Specification for the design and

construction of refillable transportable seamless steel gas cylinders

EN 1964-3, edition 1, 2000

of water capacities from 0,5 litre up to and including 150 litres -

Part 3: Cylinders made of seamless stainless steel with an Rm

value of less than 1100 MPa

Transportable gas cylinders - Periodic inspection and testing of

EN 1968, edition 1, 2002

seamless steel gas cylinders

Transportable gas cylinders - Refillable welded steel gas cylinders -

EN 13322-1, edition 1, 2003

Design and construction - Part 1: Carbon steel

Transportable gas cylinders - Refillable welded steel gas cylinders -

EN 13322-2, edition 1, 2003

Design and construction - Part 2: Stainless steel

ISO 4706:1989, edition 1, 1989

Refillable welded steel gas cylinders

Gas cylinders -- Refillable seamless steel gas cylinders -- Design,

construction and testing -

ISO 9809-1:1999, edition 1, 1999

Part 1: Quenched and tempered steel cylinders with tensile

strength less than 1 100 MPa

Part 2: Quenched and tempered steel cylinders with tensile

ISO 9809-2:2000, edition 1, 2000

strength greater than or equal to 1 100 MPa

ISO 9809-3:2000, edition 1, 2000

Part 3: Normalized steel cylinders

Gas cylinders -- Transportable refillable welded steel cylinders for

ISO 22991:2004, edition 1, 2004

liquefied petroleum gas (LPG) -- Design and construction

REVISION/REVIEW LOG

Revision Date

Authority

Custodian

Revision Details

08 February 2005

Alan McNulty

Esmira Akhundova

Initial Issue as controlled document

(CHSSE Manager)

25 January 2008

Alan McNulty

Abbas Islamov

General:

(AzSPU CH&S

(Central Safety TL)

Throughout the procedure the document

Manager)

numbering for referred procedures has been

changed from UNIF to AzSPU.

Section 1. Introduction:

1.2 Scope; Wording changes. The following are

inclusion to Section 1. They are: 1.3 Legislation &

Standards, 1.4 Company Requirements, 1.5

Stopping Unsafe Work, 1.6 Deviations, 1.7

Document Review, 1.8 SSOW Specific Cross

References (new doc control numbers), 1.9

Language Facilitation, 1.10 Procedure Summary

Section 2. Definitions:

New section

Section 3. Roles & Responsibilities:

3.1 Site Manager; Site Controller and Offshore

Installation Manager added. 4 additional bullet

points added. 3.2 Area Authority; 4 bullet points

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Procedure for Transportable Compressed Gas Cylinders

Page 19 of 20

added. 3.3 Performing Authority; This is an

addition to the procedure. 3.4 Persons

Responsible for Inspection and Maintenance;

This is also an addition to the procedure.

Section 4. Gas Cylinder Procurement:

4.2 Filling of Cylinders; Procurement Supply

Chain Management (PSCM) added to first

paragraph

Section 5. Receipt of Cylinders on Site:

4.1 Cylinder Inspection has been change to

Design, Fabrication and Testing of Multiple

Cylinder Transport

Appendices.

2 new appendices included to the document as

follows:

Appendix A: Procedure Summary

Appendix B: Feedback & Improvement

Suggestions

Authority position/name and custodian name

05 December

Yuliy Zaytsev Safety

Adalet Mamedov

have changed to reflect org changes in HSE&TD

2008

& Compliance

Central Safety TL

as of December 1st 2008

Systems Manager

The next review/revision date is extended to

5 February 2009

Yuliy Zaytsev

Adalet Mamedov

01.05.2009 due to rescheduling

Safety&Compliance

Central Safety TL

Systems Manager

Additional wording in regard to cylinders storage

24 July 2009

Yuliy Zaytsev

Niyaz Mamedov

and breathing air cylinders in the temporary

Safety&Compliance

HSE Systems / CoW

refuge is given to the Paragraph 6.1

Systems Manager

Adviser

25 May 2010

Yuliy Zaytsev

Kamran Aliyev

The document has been reformatted to consider

AzSPU Health &

AzSPU Safety

the requirements of Standardized Document

Safety Manager

Systems / CoW

Control Template.

Offshore

Specialist

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Procedure for Transportable Compressed Gas Cylinders

Page 20 of 20

Paragraph 1.2 Reference to old group

requirements has been removed

Section 3 General Requirements updated with

OMS essentials requirements, Removed

reference with Golden rules

Section 5. Compressed Gas Cylinders has

been modified in order to comply with relevant

local and group standards requirements for color

coding and inspection regimes

Sub-paragraph 5.3.1 Note section has stressed

storage requirements for medical service

purposes used compressed gas cylinders

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Procedure for Welding and Cutting

Page 1 of 21

Procedure for Welding and Cutting

AZSPU-HSSE-DOC-00064-2

This number supersedes UNIF-HSE-PRO-153-C1

Authority:

AzSPU Safety & Compliance

Custodian:

HSE Systems / CoW Advisor / Niyaz Mamedov

Systems Manager / Yuliy

Zaytsev

Scope:

AzSPU

Document

MS Documents Coordinator

Administrator:

Issue Date:

05 October 2004

Issuing Dept:

Safety & Compliance Systems

Revision Date:

10 December 2010

Control Tier:

Next Review

17 March 2011

Date:

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Welding and Cutting Procedure

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TABLE OF CONTENTS

PURPOSE / SCOPE

1.1

PURPOSE

1.2

SCOPE

DEFINITIONS

GENERAL REQUIREMENTS

3.1

LEGISLATION & STANDARDS

3.2

COMPANY REQUIREMENTS

3.3

STOPPING UNSAFE WORK

3.4

DEVIATIONS

KEY RESPONSIBILITIES

4.1

PU & EA

4.2

SITE MANAGER (SM) / SITE CONTROLLER (SC) / OFFSHORE INSTALLATION MANAGER

(OIM) 5

4.3

AREA AUTHORITY

4.4

PERFORMING AUTHORITY

4.5

WELDER

4.6

FIRE WATCHER

WELDING AND CUTTING PROCESS

5.1

GAS WELDING AND CUTTING EQUIPMENT

5.1.1

Identification of Cylinders

5.1.2

Cylinder Storage

5.1.3

Cylinder Handling

5.1.4

Cylinder Fittings

5.2

ELECTRIC ARC WELDING AND CUTTING EQUIPMENT

5.2.1

Welding Sets

5.2.2

Cables and Connections

5.2.3

Electrode Holders

5.2.4

Earthing and Bonding

5.3

WELDING AND CUTTING - HAZARDS AND PRECAUTIONS

5.3.1

Personal Protection Equipment

5.3.2

Fumes and Gas Risk

5.3.3

Hearing Protection

5.3.4

Fire and Explosion Prevention

5.3.5

Confined Spaces

5.3.6

Welding and cutting on Small Containers

KEY DOCUMENTS / TOOLS / REFERENCES

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Welding and Cutting Procedure

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PURPOSE / SCOPE

1.1 PURPOSE

This document provides the information necessary to ensure that welding, cutting

and associated activities are carried out in a safe and efficient manner, without harm

to personnel or damage to equipment and the environment.

1.2 SCOPE

The contents of this procedure are applicable to all BP owned and managed sites /

installations in Azerbaijan and Georgia. Contractors working on BP owned or

managed sites / installations are also responsible for alignment with this procedure.

This document does not replace the procedures prepared and adopted by specialist

contractors. Neither does it supersede any national and local regulatory

requirements.

- Operating Management System OMS Essentials 3.2(3.2.1) and 4.5(4.5.1)

- BP Group Defined Practice for Control of Work GDP 4.5-0001

All guidelines contained shall be regarded as the minimum requirements for BP

owned or managed sites / installations in Azerbaijan and Georgia.

The scope covers defined activities of BP and Contractors at all BP AzSPU sites and

installations.

2 DEFINITIONS

Refer to document AzSPU-HSSE-DOC-00021-2 HSE Definitions for definitions

common to this procedure. Definitions specific to this Procedure are included below.

Hazardous

Plant areas processing highly flammable materials, e.g. gas and

Area

condensate

ALARP

As Low As is Reasonably Practical

A combustible

Any material that will burn, while a flammable material is a gas or

material

liquid that is easily ignited by most low-energy heat sources.

HWNF

Hot Work Naked Flame

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3 GENERAL REQUIREMENTS

3.1 LEGISLATION & STANDARDS

This procedure complies with applicable national law. Applicable national law is

national law as amended by project specific agreements, e.g. the ACG Production

Sharing Agreement (PSA), and relevant International Conventions, if any, in force in

Azerbaijan or Georgia, as applicable.

In the absence of national legislation, or where national legislation is inconsistent

with the requirements of project specific agreements, BP Group Standards or

applicable requirements from UK or US legislation will be complied with.

Where requirements conflict, legal advice has been obtained and a defendable

compliance position adopted.

The standards and practices contained in this procedure are consistent with those

internationally recognized within the petroleum industry.

3.2 COMPANY REQUIREMENTS

It is a company requirement that all tasks are subjected to an assessment of risk to

demonstrate that risks have been reduced to as low a level as reasonably

practicable

(ALARP). This can be achieved by complying with the Company’s

existing standards. Where compliance with Company standards cannot reasonably

be achieved, a formal level 2 Risk Assessment will be undertaken to identify any

additional controls and demonstrate that risks remain as low as reasonably

practicable.

3.3 STOPPING UNSAFE WORK

To stop the continuation of potentially unsafe work at the earliest possible stage, the

Control of Work (CoW) Policy and this procedure for Welding & Cutting make it very

clear that all personnel are obliged and have the authority to “STOP” the work that

they consider to be unsafe.

3.4 DEVIATIONS

This procedure is written in sufficient detail that it should be able to be applied

consistently at all sites / installations. There may still be the requirement for some

local rules covering site / installation specific logistical/administrative arrangements

and local variations in responsibilities to reflect differences in organisational

arrangements. These local rules should not deviate from the core processes within

this document. Any form of deviation from this procedure, including but not limited to

local rules, shall be requested and authorised in accordance with SSOW, Procedure

for Deviations (Doc. No: AZSPU-HSSE-DOC-00011-2).

4 KEY RESPONSIBILITIES

4.1 PU & EA

Provide approval for Hot Work Naked Flame in hazardous area.

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Welding and Cutting Procedure

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4.2 SITE MANAGER (SM) / SITE CONTROLLER (SC) / OFFSHORE INSTALLATION

MANAGER (OIM)

The Site Manager / Site Controller / Offshore Installation Manager shall be

responsible and accountable for the application of this procedure in his area of

responsibility. He shall ensure:

 That adequate numbers of Competent responsible persons are appointed to

manage and maintain the requirements of this procedure

 That this procedure is strictly adhered to for all occasions when it is identified

that welding / cutting hot work is to take place.

 That formal records of all SimOps risk assessments are maintained in

accordance with this procedure

 Use only contractors who employ suitably competent and experienced

personnel in the use of welding and cutting equipment

 Advise all contractors with regard to flammable materials and hazardous

conditions when using welding and cutting equipment

 Establish approved areas for cutting and welding

 Establish approval procedures for cutting and welding.

 To ensure the correct approvals from PUL are in place for HWNF in

Hazardous Area

4.3 AREA AUTHORITY

The Area Authority shall be responsible for ensuring that the requirements of this

procedure are adhered to within his area of responsibility. He shall be responsible for

ensuring:

 That welding

/ cutting hot work activities have been risk assessed and

planned

 That all persons involved in hot work activities are instructed on the

requirements of risk assessment, permit to work conditions, and any risks or

hazards associated with the work activity

 Ensure that welding and cutting activities are carried out under the

appropriate supervision.

 Ensure that welding and cutting equipment is maintained in satisfactory

operating condition and in good repair

 That regular inspection is performed on all hot work activities to confirm that

conditions are suitable and sufficient and, that all personnel are in compliance

with this procedure, and that good housekeeping practices are being

implemented to limit or eliminate the potential for fire.

That the Performing Authority performs Risk Assessments, and conducts Toolbox

Talks associated with hot work activities.

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Welding and Cutting Procedure

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4.4 PERFORMING AUTHORITY

The Performing authority shall ensure:



That a risk assessment has been performed and a toolbox talk conducted



That all personnel are informed of, and understand, the risks associated with

the task they are performing, and any associated works that may affect their

work activity



That the safe use of the cutting or welding equipment is in place



That the determining the nature and quantity of combustible materials and

hazardous areas present at the work site



That work activities have been reviewed and pertinent information exchanged

with all other affected parties



That fire protection and extinguishing equipment are properly located at the

site and that equipment us within inspection / test dates



That welding/cutting hot work activity is halted if an unsafe situation occurs.



That fire watches are available and remain at the site when welding and

cutting activities are being carried out



That making a final check of the work site 30 minutes after the completion of

cutting or welding operations is carried out



That good housekeeping practices are implemented at all work areas and

combustibles are safe from ignition by:

 moving the work to a location free from dangerous combustibles

or,

 having the combustibles moved to a safe location

or,

 having the combustibles properly shielded against ignition.

4.5 WELDER

The Cutter and / or Welder shall:

 have approval by the Performing Authority before starting to cut or weld

 carry out daily pre use visual inspection of welding and cutting equipment

 cut or weld only where conditions are safe

 stop working if conditions change from those under which the Permit to

Work was granted

 after finishing work, ensure nothing is burning or smouldering near the

work site.

For habitats requirements, if any, refer to the Appendix B of the Procedure for Hot

Work Naked Flame AZSPU-HSSE-DOC-00053-2.

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Welding and Cutting Procedure

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4.6 FIRE WATCHER

A fire watch shall be maintained for at least 30 minutes after the completion of

cutting or welding operations, in order to detect and extinguish smouldering fires.

Fire Watchers shall:

 have fire extinguishing equipment readily available and be trained in its

use (including practice on test fires), ref. to AZSPU-HSSE-DOC-00088-2,

Control of Work Training Policy.

 be familiar with the facilities and procedures for sounding an alarm in the

event of a fire

 watch for fires in all exposed areas, and shall:

 sound the alarm immediately

and...

 try to extinguish them (only when obviously within the capacity

of the equipment available).

5 WELDING AND CUTTING PROCESS

5.1 GAS WELDING AND CUTTING EQUIPMENT

5.1.1 Identification of Cylinders

5.1.1.1 Cylinder Markings

All cylinders shall be permanently and legibly labeled or stamped with the following:

 trade symbol of manufacturer

 serial number

 calculated quantity (tare) of empty mass

 manufacturing date (month, year)

 next inspection/test date, adjacent to the previous one (month, year)

 service pressure (psi/bar)

 test pressure (psi/bar)

 capacity (cubic feet/litres).

All markings shall be stamped on the shoulder of cylinders near valves.

Note: Do not remove or change any numbers or marks stamped on cylinders.

Note: For additional information refer to Procedure for Transportable

Compressed Gas Cylinders AZSPU-HSSE-DOC-00014-2

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Welding and Cutting Procedure

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5.1.1.2 Cylinder Color Coding

For detailed information please refer to Paragraph

5.2 of the Procedure for

Transportable Compressed Gas Cylinders AZSPU-HSSE-DOC-00014-2.

5.1.2 Cylinder Storage

5.1.2.1 All Cylinders

All cylinders shall be stored in a cool, well ventilated area preferably in the open air.

They shall be chained or otherwise secured and valve caps should be kept in place

when cylinders are not in use.

Cylinders shall not be stored in enclosed spaces such as workshops,

accommodation or enclosed modules on offshore installations.

All cylinders shall be stored away from:

 the direct rays of the sun or from radiant heat, e.g., flares

 locations where the temperature may exceed 45C (113F)

 locations exposed to adverse weather

Note: Weather protection shall be provided if required

 possible sources of ignition

 flammable materials

 corrosive liquids

 any direct contact with soft or damp ground, or any other location where

water can accumulate, thereby increasing exposure to the possible effects

of corrosion.

Empty cylinders shall be marked with “EMPTY” or “MT”, and stored separately from

full cylinders.

Note: Regardless of whether or not cylinders have been marked, all cylinders shall

be handled and treated as if they were full.

5.1.2.2 Oxygen Cylinders

Warning: Oils and greases are spontaneously combustible in the presence of oxygen.

Oxygen cylinders and their fittings, including hoses, must not be stored or

used where they can come into contact with oil or grease. This includes

handling the equipment with oily hands, gloves or rags.

Oxygen cylinders must be stored apart from fuel gas cylinders by a minimum

distance of 3 metres (10 feet). Separation by using cylinders of non-flammable

gases is acceptable. This separation must be maintained.

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Welding and Cutting Procedure

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The preferred practice is to store oxygen cylinders vertically, valve end up. However,

it is acceptable to store oxygen cylinders horizontally provided that:

 the stacks shall not exceed a maximum height of three cylinders

 the largest cylinders must be at the bottom

 the row must be securely wedged.

5.1.2.3 Acetylene and Propane Cylinders

Warning: Acetylene cylinders must not be stored or used in a horizontal position.

All acetylene cylinders, full or empty, shall be stored and used in the

vertical, valve end up position.

5.1.2.4 Damaged Cylinders

Cylinders that may have been damaged in any way shall be returned to the supplier.

Leaking cylinders shall immediately be moved to a freely ventilated area away from

any source of ignition or places where leaking gas will become trapped.

5.1.2.5 Cylinders Exposed to Fire

In the event of gas cylinders being involved in a fire, they must be kept cool with

water spray, e.g., a fog nozzle, and where possible, removed to a safe area. Such

cylinders must be returned to the manufacturer for checking prior to re-use.

In the case of acetylene cylinders that have been so exposed, prolonged cooling is

necessary for several hours after the incident to prevent exothermic decomposition.

5.1.3 Cylinder Handling

Note: For any additional information that may be required but not covered

within this procedure please refer to Procedure for Transportable Compressed

Gas Cylinders AZSPU-HSSE-DOC-00014-2

5.1.3.1 Lifting

If cylinders are lifted by crane, a suitable cradle or similar device should be used. If a

trolley is used as a cradle during lifting, care should be taken to ensure that its base

is strong enough to take the weight of the cylinders.

Cylinders shall not be lifted using:

 the cylinder valves

 chain or wire rope slings (these can allow the cylinder to slip during lifting).

5.1.3.2 Movement of Cylinders on Site

Note: Cylinders shall not be dropped, dragged, rolled, or used as supports.

In addition, the cylinder valves must be protected from damage at all times.

Cylinders should be transferred to, and moved within, the working area on trolleys

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Welding and Cutting Procedure

Page 10 of 21

specifically designed for that purpose, or in suitable containers providing stable and

secure positioning of the cylinders.

All valves must be closed before a cylinder is moved and, if the correct trolley is not

being used, regulators and hoses should be detached from the cylinders.

5.1.3.3 Electric Cables

Cylinders and gas hoses shall not be allowed to come into contact with current

carrying wires. Therefore:

 special attention should be paid to the places where electro-welding and

gas cutting of metals are carried out simultaneously

 the distance from oxygen or fuel gas cylinders to electro-welding cables

shall be not less that 1 m.

5.1.4 Cylinder Fittings

5.1.4.1 Acetylene Fittings

Warning: Wherever copper comes into direct contact with acetylene, the explosive

compound Copper Acetylide may be formed.

Only approved alloys of less than 70% copper shall be used for

acetylene fittings.

Where approved fittings are silver soldered, the solder should contain no

more than 40% silver and 20% copper.

5.1.4.2 Regulators

Only automatic pressure regulators and pressure gauges as recommended by the

gas cylinder supplier shall be fitted to oxygen and fuel gas cylinders. These pressure

regulators provide the following safety features:

 provision of a filtered supply of gas at a constant delivery pressure

 safety diaphragms that burst before the bonnet is blown off

 pressure gauges with safety backs that deflect the venting gas.

Note: The adjustable screw on the regulator must always be released before the

cylinder is opened.

5.1.4.3 Valves

To avoid leaks and possible dangerous gas build-up, valves and fittings shall be kept

scrupulously clean, and care taken to ensure that no grit or foreign matter is allowed

to remain on them.

Note: The use of any kind of packing in the valve joints is strictly forbidden.

Packing, particularly lead or copper, can easily be forced into the orifice,

causing a blockage.

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5.1.4.4 Valve Keys

Only standard valve keys shall be used, and cylinder valves shall always be opened

slowly by gently tapping the key.

Keys with long leverage should never be employed to force a valve shut.

5.1.4.5 Blowpipes

Only high pressure blowpipes may be used with high pressure equipment.

All blowpipes shall be dismantled and cleaned internally at regular intervals. During

use, accumulated slag should be frequently removed from the blowpipe tip during

operation. To avoid severe blockage, care should be taken to avoid dipping the

blowpipe tip into molten metal.

Only the manufacturer’s recommended tip cleaners should be used for cleaning or

altering the blowpipe tip.

Note: Hard metal reamers shall not be used to clear the blowpipe tip.

5.1.4.6 Hoses

Unnecessarily long lengths of hose should be avoided. Oxygen and fuel gas hoses

should be the same length.

Only good quality hoses fitted with check valves (to prevent gas flowing back from

the blowpipe) are acceptable for use. Faulty or damaged hoses must not be used.

Hoses are supplied with connections suitable for standard regulators and blowpipes.

If required, hose lengths should be joined by the use of crimped connecting fittings,

not hose clips.

In order to identify and / or prevent possible blockage, hoses should be blown

through with air before being connected to regulators and blowpipes.

Warning: Under no circumstances shall oxygen be used for ventilation or to blow

through acetylene hoses. Explosions can occur when acetylene gas is

present in air in any proportion between 2.5% and 80% by volume.

When in use, hoses should be protected from damage, and laid out in such a

manner as to avoid being a tripping hazard.

5.1.4.7 Flashback Arrestors

Flashback arrestors, which quench flashback flames and cut off the gas flow

automatically, must be incorporated in all oxygen lines and fuel gas lines.

5.1.4.8 Damaged / Faulty Cylinders and Fittings

Cylinders with faulty outlet valve connections, e.g., damaged threads, seized valve

spindles, etc., must be returned immediately to stores with a note stating the cylinder

number, the nature of the fault and whether the cylinder is charged.

Note: Under no circumstances may the user of the cylinder attempt any repair

whatsoever.

Cylinders with leaking valves that cannot be shut off must be removed to a safe area

away from any possible source of ignition and drainage, where they shall be allowed

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to vent off slowly until empty. Stores shall be advised of the fault.

Note: Propane and Butane are heavier than air and may accumulate in dips and

hollows.

5.2 ELECTRIC ARC WELDING AND CUTTING EQUIPMENT

5.2.1 Welding Sets

All welding sets must be maintained in good condition, and be of adequate capacity.

Where stationary transformers or generator sets are used, a suitable switch must be

mounted adjacent to the equipment to provide isolation from the supply main.

Diesel driven welding sets shall not be used except with the formal agreement of the

Site Manager for each occasion of use. If used, the sets must be approved for the

area in which they are sited.

Note: The engine must not be refuelled whilst in operation.

In order to protect the trailing leads and the equipment, portable transformers or

generator sets with trailing leads, must be provided with interlocked fused switch

sockets and plugs.

Under no circumstances shall the welder:

 connect and disconnect the welding device from the electricity supply network

when the connection is anything other than a plug and socket

 repair electro-welding machines (such repairs shall be carried out by a

competent electrician only).

5.2.2 Cables and Connections

All cables, connectors and terminators must be maintained in good condition, and be

of adequate capacity. To avoid long lengths of power cables the machine must be

sited as close as possible to the workplace.

All supplies for welding equipment must be made of approved cables and

connections, and must be controlled from a circuit which includes protection sensitive

to earth fault currents.

Welding leads and returns shall comprise flexible, tough rubber covered cables,

using approved cable couplers where necessary. Leads shall be properly terminated

and cable couplers and terminations must be of adequate carrying capacity.

Welding leads must be inspected daily for any damage. In the case of worn or torn

cable sheaths, or flattened or kinked cables, the affected part should be removed /

replaced.

Welding return leads must always be used to prevent uncontrolled welding currents

passing back from the work-site to the generator through the structure and/or plant

items. This could give rise to sparks or cause damage to bearings in machines, etc.

Particular attention should be paid to welding returns when welding on pedestal

crane booms, so that currents cannot pass through main slew bearings.

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Welding and Cutting Procedure

Page 13 of 21

Note: It is prohibited for the welder to commence or continue welding operations

with faulty cables, starting devices or electrode holders.

5.2.3 Electrode Holders

Electrode holders shall be provided with a handle of tough, insulating non-ignitable

material with a guard disc of similar material between the hand of the operator and

the projecting line portion.

A fully insulated holder or hook should be provided for the live electrode holder when

not in use. Laying live electrode holders on gloves, face screens or handing them up

by the electric cable where it could come in contact with other equipment etc., is

discouraged.

Warning:

Electrode holders under voltage must not be left unattended.

5.2.4 Earthing and Bonding

For all AC welding transformers, the transformer low voltage winding must not be

earthed but the transformer case must be effectively bonded to an earthing system

adjacent to the equipment.

The DC welding output of all AC driven DC welding generators must not be

grounded. The machine frame must be effectively bonded to ground.

For engine driven DC welding generators, no earth connection must be applied to

the generator output terminals.

The work piece must be bonded to earth by means of a heavy section conductor

having suitable clamped or bolted connections.

Under no circumstances shall pipelines or structures be used for grounding

purposes. The ground connection shall be directly into the work piece.

5.3 WELDING AND CUTTING - HAZARDS AND PRECAUTIONS

5.3.1 Personal Protection Equipment

Personnel engaged in, or working in close proximity to, welding, cutting, chipping

and grinding operations must use the appropriate protective clothing/equipment,

e.g., goggles, face shields, welding helmets, welding screens, gloves, leather

aprons, etc.

The necessity for protective clothing against sparks and pieces of hot metal,

depends upon the position of the arc in reference to the welder’s body.

For some classes of welding, e.g., where the welder is standing at a bench, the head

screen and gauntlets may well provide sufficient protection.

A thick apron of leather or other suitable material may be needed if the welder is

sitting at his work position, where molten metal may fall upon his thighs and legs.

If the arc is above the level of his shoulders or overhead, complete protection for the

head, arms and upper part of the body is necessary.

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Welding and Cutting Procedure

Page 14 of 21

5.3.1.1 Welding Helmets, Welding Shields and Flip-Front Goggles

The specifications for welding helmets, welding shields and flip-front goggles shall

comply with:

 EN 169 “Specification for filters for PPE used in welding”

 EN 175 “PPE for eye and face during welding”

 EN 166 “Eye protection”.

5.3.1.2 Wide Vision Welding Goggles

The lenses of wide-vision welding goggles shall conform to BS 679 and their frames

to BS 1542.

5.3.1.3 Coveralls

Flame retardant welders coveralls shall be approved to:

 BSEN 470

 BSEN 531.

5.3.1.4 Gauntlets

Note: For gauntlets used for electric arc welding, see Additional Protection for

Electric Arc Welding below.

Gauntlets used for welding, brazing and cutting shall conform to:

 BSEN 407

 BSEN 388 (Mechanical Risk)

 BSEN 420 (General Requirements).

5.3.1.5 Additional Protection for Electric Arc Welding

Gloves or gauntlets made of non-ignitable material are required for shielding the

hands and arms from sparks and heat radiation of the welding arc. Leather gloves

and gauntlets give no protection against electrical hazards. In particular, for electric

arc welding, oiled or greased clothes and gloves shall not be worn.

As well as normal protective clothing, while performing electric arc-welding in

hazardous conditions (welding of wet structures) electric welders shall use:

 dielectric gloves (BSEN 388)

 overshoes (BSEN 345)

 rubber mats.

5.3.2 Fumes and Gas Risk

Welding, cutting, and brazing operations, etc., can produce toxic fumes and gases,

the composition of which depends on welding temperature, arc intensity, electrode

material and the gas mixture being used. Therefore, it must be ensured that:

 any organic coatings are removed prior to any welding and cutting

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Welding and Cutting Procedure

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 gases/fumes are removed either by natural ventilation or forced

mechanical ventilation

 a suitable respiratory system should be available as a back up if the

ventilation system is inadequate.

Warning: Respiratory protection must be worn where the welding or cutting of

cadmium alloys or a cadmium-coated material takes place.

5.3.3 Hearing Protection

Most of welding and cutting activities generate high noise. Where noise level

exceeds 80dB use of adequate hearing protection is mandatory.

5.3.4 Fire and Explosion Prevention

Note: Welders and helpers must always be alert to the danger of fire and explosion.

5.3.4.1

Restrictions on Welding and Cutting

Cutting or welding is only permitted in areas that are fire safe.

Note: Cutting or welding is not permitted:

 in areas not authorised by the Area Authority

 in enclosed spaces / areas where sprinkler systems have been inhibited

 in buildings where sprinkler systems have been inhibited

 in the presence of explosive atmospheres, e.g., mixtures of flammable

gases, vapours, liquids, or dusts with air

 on pipelines where mechanical seal plugs are to be used, or where “hot

tapping” procedures are to be employed on live lines, without written

authorisation from the Site Manager.

Welding or cutting shall not take place in restricted areas without a Hot Work (Naked

Flame) Permit. In addition, the conditions laid down on that permit must be strictly

observed.

5.3.4.2 Approved Welding and Cutting Areas

Within the confines of an operating plant or building, the cutting and welding work

area shall be either:

 a specific area designed or approved for such work, i.e., a maintenance

shop

or...

 a detached outside location of non-combustible or fire-resistive

construction, essentially free of combustible and flammable contents, and

suitably segregated from adjacent areas.

Where work cannot be moved practically, as in most construction work, the area

shall be made fire safe by removing combustibles or protecting combustibles from

ignition sources.

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Welding and Cutting Procedure

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5.3.4.3 Area Preparation

Fully charged and operable fire extinguishers, appropriate for the type of possible

fire, shall be available at the work area. Where hose lines are available, they shall be

connected and ready for service.

Work must be screened to prevent sparks from flying outside the immediate welding

area and all combustible material must be removed or covered with fire resistant

material. Combustible materials such as paper clippings, wood shaving, or textile

fibres on the floor shall be swept clean.

If welding is to be carried out on a metal wall, partition, ceiling, or roof, precautions

shall be taken to prevent ignition of combustibles on the other side due to conduction

or radiation. The preferred precaution is to relocate combustibles. However, where it

is not possible for the combustibles to be relocated, a fire watch on the opposite side

from the work shall be provided.

Any drains in the area must be plugged, gullies cleaned and if possible water filled

and finally covered with fire blanket.

Openings or cracks in walls, floors, or ducts within 11m of the site shall be tightly

covered to prevent the passage of sparks to adjacent areas.

Conveyor systems that might carry sparks to distant combustibles shall be protected.

Combustible floors shall be kept wet, covered with damp sand, or protected by fire-

resistant shields.

Warning: Do not wet down floors where electric arc welding or cutting equipment is

to be used.

5.3.4.4 Removal of Slag

Slag shall not be cleaned from newly welded joints until it has had time to cool.

Safety goggles must be used for slag removal.

5.3.4.5 Welding on Tanks and Vessels

Note: Before welding on tanks and vessels may take place, inspection by the Area

Authority will be necessary to decide on the precautions to be taken.

All tanks, vessels and equipment on which welding, cutting, brazing and soldering

work is carried out, must be either free from flammable gases and vapours and

cleaned of all traces of liquid, wax or solid hydrocarbons, or provision made for

excluding oxygen, e.g., filled with nitrogen, high expansion foam or similar product.

The space between double plates or wear plates, where flammable material may be

found, must be considered. Work on a main deck forming the roof of an in-deck tank

must be given special consideration.

Before cutting the bottom plates of any tank, test holes must be drilled and a gas test

taken, to ensure that conditions are safe under the tank floor.

5.3.4.6 Unattended Welding Equipment

Blowpipes and hoses, if not in use, must not be left in vessels or enclosed spaces. If

blowpipes and hoses cannot be removed from the space, the connections must be

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Welding and Cutting Procedure

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disconnected at the cylinders.

Note: Closing the cylinder valves is not classified as a disconnection.

Whenever equipment is to be left unattended, gas cylinder valves shall be shut,

hoses de-pressurised and disconnected.

Electrical power supply for welding machines shall be switched off and disconnected.

Any diesel driven welding sets shall be shut down.

5.3.4.7 Work Using Scaffolding

Gas cutting or welding operations involving the use of scaffolding is allowed only

after taking measures to prevent the scaffold boards from ignition and molten metal

falling on people below.

Maximum height of gas cutting point

above lower located tier (metres)

Radius of sparks scattering (metres)

5.3.4.8 Fire Watchers

An active fire watch shall comprise at least one nominated person, whose sole duty

consists of fire watching. This person shall be provided with suitable portable fire

extinguishing equipment. In addition fire blankets and a pressurised fire hose may be

provided depending on location/site conditions.

The fire watch shall ensure that the areas are left in a safe condition by inspecting

the work area and any adjacent areas that may be affected 30 minutes after welding

or cutting work ceases.

Trained and competent personnel to act as fire watch shall be required by the Area

Authority whenever cutting or welding is performed in locations where:

 fire and gas detection systems have been inhibited to permit cutting or

welding to take place

 appreciable combustible material in building construction or contents is

closer than 11 metres to the point of operation

 appreciable combustible materials are more than 11 metres away but are

easily ignited by sparks

 wall or floor openings are within an 11 metre radius and give access to

combustible material in adjacent areas, including concealed spaces in

walls or floors

 combustible materials are adjacent to the opposite side of metal partitions,

walls, ceiling, or roofs and are likely to be ignited by conduction or

radiation.

5.3.5 Confined Spaces

All personnel involved in welding and cutting operations in confined spaces must

comply with the requirements of this procedure and the requirements defined in:

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Welding and Cutting Procedure

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 Permit to Work AZSPU-HSSE-DOC-00060-2

 Confined Space Entry AZSPU-HSSE-DOC-00013-2

In particular, when welding or CUTTING in a confined space:

 forced ventilation shall be maintained in the space at all times

 organic coatings shall be removed prior to any welding and cutting

 gas cylinders shall not be taken into the space at any time; they shall be

sited outside the space with the hoses laid through suitable transits and

protected from damage

 welding transformers shall not be placed inside the space; they shall be

sited outside the space with the cables laid through suitable transits and

protected from damage

 where work in confined spaces takes place over several days, welding

hoses and equipment shall be removed from the space overnight in case

of gas build-up due to leakage

 lighting inside the confined space during welding operations shall be

provided by mobile light fixtures with a voltage of no more than 25V. Lights

shall be fitted with wire protection cages

 entry point for hoses or cables must not impede safe entry or exit for

personnel working in the confined space

5.3.6 Welding and cutting on Small Containers

Before any hot work is carried out on any container that may have been used to

store petroleum products or other flammable or combustible materials the following

guidelines must be followed, and the Safety Adviser must certify the container free of

gas and chemicals.

1. Drain the container of all contents.

2. Steam out the container thoroughly or submerge the container in boiling

water for at least one hour.

Note: Compressed air purging or washing out with hot / cold water may

not sufficiently clean the vessel of flammable materials and

therefore shall not be used as methods of preparation for repair

purposes.

3. Blow through the container with compressed air until the container is dry.

During repairs, air (not oxygen) must be blown through the vessel to prevent the

build-up of unburned gases.

6 KEY DOCUMENTS / TOOLS / REFERENCES

This procedure shall, where appropriate, be used in conjunction with this suite of

AzSPU Procedures referenced below.

Document Number

Title of Procedure

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Welding and Cutting Procedure

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AZSPU-HSSE-DOC-00011-2

Procedure for Deviations

AZSPU-HSSE-DOC-00060-2

Procedure for Permit To Work

AZSPU-HSSE-DOC-00053-2

Procedure for Hot Work Naked Flame

AZSPU-HSSE-DOC-00063-2

Procedure for Task Risk Assessment

AZSPU-HSSE-DOC-00053-2

Procedure for Hot Work

AZSPU-HSSE-DOC-00048-2

Procedure for Energy Isolations-Electrical

AZSPU-HSSE-DOC-00049-2

Procedure for Energy Isolations-Process

AZSPU-HSSE-DOC-00013-2

Procedure for Confined Space Entry

AZSPU-HSSE-DOC-00051-2

Procedure for Fire Prevention, Detection and

Response

AZSPU-HSSE-DOC-00014-2

Procedure for Gas Cylinders

AZSPU-HSSE-DOC- 00002-2

Procedure for Control of Work

Note: Welding, cutting, grinding or any other operation that generates heat or

sparks, e.g., abrasive cutting, shall be carried out under the control of the

Permit to Work System and other SSOW related requirements.

Any hot work on a live site shall be carried out only in a strict accordance with

SSOW Hot Works requirements stated in the Procedure for Hot Work Naked

Flame AZSPU-HSSE-DOC-00053-2.

Non-live construction sites may deviate from this requirement at the discretion

of site management.

Revision/Review Log

Revision Date

Authority

Custodian

Revision Details

05 October 2004

Alan McNulty

Esmira Akhundova

Initial Issue

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Welding and Cutting Procedure

Page 20 of 21

30 September 2008

Alan McNulty

Abbas Islamov

General:

AzSPU CH&S Manager

Central Safety TL

Throughout the procedure the

document numbering for referred

procedures has been changed from

UNIF to AzSPU.

Section 1. Introduction:

Wording changes. The following are

inclusion to Section 1. They are:

1.2 Scope, 1.3 Legislation &

Standards, 1.4 Company

Requirements, 1.5 Stopping Unsafe

Work, 1.6 Deviations, 1.7 Document

Review, 1.8 Language Facilitation ,

1.9 SSOW Specific Cross References

Throughout the procedure the term

‘burning’ was changed to ‘cutting’.

Minor changes were made to Section

2. Roles & Responsibilities; to

paragraphs 2.1 & 2.3 accordingly.

Additional wording were added to

Paragraph 5.4 regarding entry point

for hoses and cables.

Appendix A: Feedback &

Improvement Suggestions is added to

the procedure.

5 December 2008

Yuliy Zaytsev

Adalat Mamedov

Authority

position/name

and

Safety & Compliance

Central Safety TL

custodian name have changed to

Systems Manager

reflect org changes in HSE&TD.

17 September 2009

Yuliy Zaytsev

Niyaz Mamedov

The numbering of the whole

Safety & Compliance

HSE Systems / CoW

procedure is changed in accordance

Systems Manager

Adviser

with requirements of Standardized

Document Control Procedure

Template (AzSPU-HSSE-DOC-

00026-2);

Section 4, Key Responsibilities, was

brought in compliance with relevant

responsibilities described in Hot

Work Naked Flame Procedure.

Additional point was added to the

paragraph 4.5, regarding Welder’s

responsibilities;

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Welding and Cutting Procedure

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Additional reference to Procedure for

Hot Work Naked Flame was made in

paragraph 4.5, Welder, in context of

habitats requirements;

Reference to Control of Work

Training Policy was added to

paragraph 4.6, Fire Watcher;

The new paragraph regarding Hearing

Protection (5.3.3) was added;

Additional point is added to the Note

in sub-paragraph 5.3.4.1, Restrictions

to Welding & Cutting;

Two additional documents were

referenced in Paragraph 6, Key

Documents/Tools/References:

Procedure for Hot Work Naked

Flame and Procedure for Gas

Cylinders;

Addition was made to the Note of

Paragraph 6, Key

Documents/Tools/References

regarding the non-live operational

sites.

10 December 2010

Yuliy Zaytsev

Elman Shikhkerimov

Section 1 Purpose and Scope

Offshore Health & Safety

CoW/Safety Systems

Removed reference to Getting

Manager

Lead

HSE right, Golden rules and

replaced with OMS, Group

requirements

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Working at Heights Procedure

Page 1 of 35

Procedure for Working at Heights

AZSPU-HSSE-DOC-00065-2

Authority:

AzSPU Safety & Compliance

Custodian:

Safety Systems / CoW Specialist

Systems Manager

Scope:

AzSPU

Document

Administrator:

MS Document Coordinator

Issue Date:

05 October 2004

Issuing Dept:

Safety & Compliance Systems

Revision Date:

26 April 2010

Control Tier:

Next Review

16 September 2011

Date:

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Working at Heights Procedure

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TABLE OF CONTENTS

PURPOSE / SCOPE

DEFINITIONS

GENERAL REQUIREMENTS

3.1

LEGISLATION & STANDARDS

3.2

REQUIREMENTS FOR WORK ACTIVITIES INVOLVING WORKING AT HEIGHTS

3.3

COMPANY REQUIREMENTS

3.4

STOPPING UNSAFE WORK

3.5

DEVIATIONS

RESPONSIBILITIES

4.1

SITE MANAGER (SM) / SITE CONTROLLER (SC) / OFFSHORE INSTALLATION MANAGER

(OIM) ………………………………………………………………………………………………...5

4.2

AREA AUTHORITY (AA)

4.3

PERFORMING AUTHORITY (PA)

4.4

EMPLOYEES

4.5

WORKING AT HEIGHT EQUIPMENT CONTROLLER

WORKING AT HEIGHTS

5.1

REQUIREMENTS TO WORK AT HEIGHT

5.1.1

Definition of work at Height

5.1.2

Principles of Working at Heights and Hierarchy of Risk

5.1.3

Risk Assessment and Planning

5.1.4

Fragile Surfaces

5.2

WORK EQUIPMENT

5.2.1

Means of Access or Egress at Height

5.2.2

Requirements for Working Platforms

5.2.3

Requirements for Collective Safeguards for Arresting Falls

5.2.4

Requirements for Mobile Elevated Work Platforms

5.2.5

Requirements for Scaffolds

5.2.6

Requirements for Ladders

5.2.7

Personal Fall Protection Systems

5.3

COMPONENTS OF FALL ARREST SYSTEMS

5.3.1

Lanyards and Energy Absorbers

5.3.2

Inertia Reels

5.3.3

Harnesses

5.3.4

Helmets

5.3.5

Anchor Points

5.3.6

Anchorage Slings / Strops

5.3.7

Ropes

5.3.8

Man Riding Winches

5.4

SIGNS AND BARRIERS

5.5

RESCUE

5.6

COMPETENCE AND TRAINING

5.7

INSPECTION AND MAINTENANCE OF EQUIPMENT

5.7.1

Maintenance

5.7.2

Mobile Elevated Work Platforms

5.7.3

Ladders

5.8

CONTROL AND ISSUE OF EQUIPMENT

5.9

TOOLBOX TALKS

5.10

HOUSEKEEPING

KEY DOCUMENTS / TOOLS / REFERENCES

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Working at Heights Procedure

Page 3 of 35

APPENDICES

7.1

APPENDIX A: WORK AT HEIGHT AUDIT CHECKLIST

7.2

APPENDIX B: BARRICADE NOTIFICATION SIGN

7.3

APPENDIX C: REFERENCES

7.4

APPENDIX D: LINKS TO DROPPED CONSEQUENCE OBJECTS CALCULATOR FACILITY

7.5

APPENDIX E: FEEDBACK & IMPROVEMENT SUGGESTIONS

1 PURPOSE / SCOPE

The purpose of this document is to describe the procedures and precautions which

shall be implemented, to ensure that hazards and risks associated with all work

activities at height are either eliminated or mitigated, to ensure safe operations and

safety of personnel, plant and equipment

The contents of this procedure are applicable to all BP owned and managed sites /

installations in Azerbaijan and Georgia. Contractors working on BP owned or

managed sites / installations are also responsible for alignment with this procedure.

This document does not replace the procedures prepared and adopted by specialist

contractors. Neither does it supersede any national and local regulatory

requirements.

All guidelines contained shall be regarded as the minimum requirements for BP

owned or managed sites / installations in Azerbaijan and Georgia.

The scope covers defined activities of BP and Contractors at all BP AzSPU sites and

installations.

2 DEFINITIONS

Refer to document AzSPU-HSSE-DOC-00021-2 HSE Definitions for definitions

common to this Procedure. Definitions specific to the Procedure are included below.

Site Manager

Site Controller

OIM

Offshore Installation Manager

Area Authority

Performing Authority

ALARP

As Low as Reasonably Practicable

CoW

Control of Work

L2RA

Level 2 Risk Assessment

PTW

Permit to Work

SSOW

Safe System of Work

TRA

Task Risk Assessment

TBT

Toolbox Talk

AzSPU

Azerbaijan Strategic Performance Unit

PSA

Production Sharing Agreement

MEWP

Mobile Elevated Work Platform

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Working at Heights Procedure

Page 4 of 35

IRATA

Industrial Rope Access Trade Association

3 GENERAL REQUIREMENTS

- Operating Management System OMS Essentials 3.2.1 and 4.5.1

- BP Group Defined Practice for Control of Work GDP 4.5-0001(Appendix 1)

3.1

LEGISLATION & STANDARDS

This procedure complies with applicable national law. Applicable national law is

national law as amended by project specific agreements, e.g. the ACG Production

Sharing Agreement (PSA), and relevant International Conventions, if any, in force in

Azerbaijan or Georgia, as applicable.

In the absence of national legislation, or where national legislation is inconsistent with

the requirements of project specific agreements, BP Group Standards or applicable

requirements from UK or US legislation will be complied with.

Where requirements conflict, legal advice has been obtained and a defendable

compliance position adopted.

The standards and practices contained in this procedure are consistent with those

internationally recognized within the petroleum industry.

3.2

REQUIREMENTS FOR WORK ACTIVITIES INVOLVING WORKING AT HEIGHTS

The controls associated with Control of Work are listed below and shall be applied

whenever the work activity is carried.

Working at heights of 2 metres (6 feet) or higher above the ground shall not proceed

unless:

 a fixed platform is used with guard or hand rails, verified by a competent

person, or…

 fall arrest equipment is used that has

o a proper anchor, mounted preferably overhead

o full body harness using double lanyard, double latch self locking snap

hooks at each connection

o synthetic fibre lanyards

o shock absorber

 fall arrest equipment will limit free fall to 2 metres (6 feet) or less

 a visual inspection of the fall arrest equipment and system is completed and

 any equipment that is damaged or has been activated is taken out of service

Control Tier:

<<2>>

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Working at Heights Procedure

Page 5 of 35

 person(s) are competent to perform the work

3.3

COMPANY REQUIREMENTS

It is a company requirement that all tasks are subjected to an assessment of risk to

demonstrate that risks have been reduced to as low a level as reasonably practicable

(ALARP). This can be achieved by complying with the Company‟s existing standards.

Where compliance with Company standards cannot reasonably be achieved, a

formal level 2 Risk Assessment will be undertaken to identify any additional controls

and demonstrate that risks remain as low as reasonably practicable.

3.4

STOPPING UNSAFE WORK

To stop the continuation of potentially unsafe work at the earliest possible stage, the

Control of Work (CoW) Policy and this procedure for Working at Heights make it very

clear that all personnel are obliged and have the authority to “STOP” the work that

they consider to be unsafe.

3.5

DEVIATIONS

This procedure is written in sufficient detail that it should be able to be applied

consistently at all sites / installations. There may still be the requirement for some

local rules covering site / installation specific logistical/administrative arrangements

and local variations in responsibilities to reflect differences in organisational

arrangements. These local rules should not deviate from the core processes within

this document. Any form of deviation from this procedure, including but not limited to

local rules, shall be requested and authorised in accordance with SSOW, Deviations

from Regulations and Procedures (Doc. No: AZSPU-HSSE-DOC-00011-2).

4 RESPONSIBILITIES

4.1 SITE MANAGER (SM) / SITE CONTROLLER (SC) / OFFSHORE INSTALLATION

MANAGER (OIM)

BP and its Site Management Teams have a duty to ensure that everyone engaged in

any work at height activity, including any specialist contractor, is competent to do so

(or, if being trained, are supervised by a Competent Person). They shall ensure that:

¾ The necessary systems and procedures are in place to manage and control

work at height operations onsite including audit of the process

¾ Where third-party procedures and guidelines require to be used, that they

have been deemed appropriate

¾ Roles and responsibilities for all personnel associated with these regimes are

clear and understood

4.2

AREA AUTHORITY (AA)

Area Authorities shall familiarise themselves with the procedures and other

arrangements in place to mitigate the risks involved in work at height. They are

responsible for:

¾ Ensuring that the appropriate hazards and controls have been identified for

planned tasks

Control Tier:

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¾ Ensuring that the appropriate level of risk assessment has been carried out,

and they liaise closely with Performing Authorities to ensure all appropriate

hazards and controls have been identified for the task

¾ Liaising with the person with working at height expertise

(i.e. Scaffold

Foreman, Services Team Leader and Equipment Controller) to ensure that all

personnel involved with working at height activity have the necessary

qualifications/training to implement the type of work being performed

¾ Ensuring that work activities are planned in such a way that they do not

conflict with or have an adverse affect on other activities in the vicinity of the

work area

¾ Ensuring worksite inspections are carried out before any activities are

performed at height.

4.3

PERFORMING AUTHORITY (PA)

Performing Authorities are responsible for:

¾ Identifying the hazards and control measures for the planned task

required

e of the

work and the hazards and controls for the job

¾ Ensuring adequate handovers take place at shift and at crew change

periods

with the oncoming Performing Authority

4.4

EMPLOYEES

All employees, whether working at height or exposed to other activities being

performed at height, are responsible for ensuring they are sufficiently competent for

the work they are performing, for adhering to safe working procedures, and for

ensuring the safety of themselves and others. Employers must be notified of any

medical conditions which may affect working at height safely.

4.5

WORKING AT HEIGHT EQUIPMENT CONTROLLER

Work restraint, work positioning and fall arrest equipment needs to be controlled by a

competent person.

This person shall be named by the site controller and is normally also responsible for

the issue and control of lifting equipment.

He / she will be responsible for:

¾ Inspecting and maintaining all work restraint, work positioning or fall arrest

equipment

¾ Maintaining a register of and issuing all work restraint, work positioning or fall

arrest equipment to competent personnel.

The Working at Height Equipment Controller is “not” normally responsible for the

control issue and maintenance of rope access equipment unless they have been

deemed competent by the specialist contractor.

5 WORKING AT HEIGHTS

5.1

REQUIREMENTS TO WORK AT HEIGHT

Control Tier:

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The guidelines in this document only reduce the risks involved with working at height

to a point where they are as low as reasonably practicable. They do not remove the

risks entirely. For this reason, wherever possible, every effort shall be made to

minimise the need for personnel to work at elevated positions.

In addition, all personnel have an obligation to “STOP” any activity that they believe

to be unsafe.

5.1.1 Definition of work at Height

Work at height should no longer be considered as an activity over 2m.

Personnel are advised that, work at height now means any place from which -

if preventive measures were not taken

- a person could fall and injure

themselves, including a place at or below ground level or in the course of

gaining access or egress from any place, except by a staircase in a permanent

workplace.

This procedure requires personnel to take a risk-based approach to working at

height.

When considering acceptability of exposure, a hierarchy of risk must be adopted

whereby work at height should be avoided so far as is reasonably practicable; if work

at height must proceed, precautions should be taken that so far as reasonably

practicable, prevent anyone from falling a distance liable to cause personal injury.

The BP Golden Rule covering work at height currently still defines work at

height as 2m or higher above the ground. This procedure is not intended to

replace this golden rule.

5.1.2 Principles of Working at Heights and Hierarchy of Risk

Work at height is generally an activity with well-established procedures of good

practice that can be followed to carry out work safely. If work must be carried out at

height, then risk assessments are required to ensure suitable and sufficient

measures can be taken to prevent any person falling, or otherwise causing personal

injury:

¾ Avoid the risk, where it is reasonably practicable to carry out the work safely

other than at a height

¾ Prevent falls, where there is no safe alternative to work at height.

¾ Mitigate the consequences of a fall where the risk of people or objects still

remains. Risk assessments must define measures to minimise the distance

and consequences of such falls

(i.e. the selection and use of work

equipment).

¾ Collective measures (guardrails, nets, mats and inflated devices) should be

preferred over personal protective measures (e.g. fall arrest equipment).

Local arrangements and support for emergency response and rescue may also need

to be evaluated.

The phrase „hierarchy of risk‟ is often used when discussing fall protection. This can

be considered as a scale of preference, based on risk and practicality, where certain

measures to prevent workers falling are deemed less risky and therefore more

desirable than others.

Control Tier:

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Page 8 of 35

The top of the hierarchy of risk is the installation of permanent fixed access

such as walkways and gantries. This is appropriate where a site must be accessed

on a regular basis for routine maintenance. Once measures have been taken to

avoid a fall (e.g. by providing a properly constructed scaffold with guardrails) there is

no need to take further action, i.e. by providing nets. However, if a guardrail has been

temporarily removed or if the area is being inspected for initial use (i.e. walkways

onboard a normally unmanned platform), this would need to be addressed. Restraint

devices or other suitable Personal Protective Equipment

(PPE), and additional

supervision, may also be required.

Second in the hierarchy is the installation of temporary working platforms,

including scaffolding (which has its own risk implications in the construction phase),

cradles or mobile platforms. Factors such as the duration and nature of the task must

be considered when accessing the practicality and cost effectiveness of a major

temporary structure. For some tasks, e.g. installation of steelwork, the access

method may actually interfere with the smooth running of the job.

Where neither of the above options is practical, then the use of personal

suspension equipment and work positioning techniques may be adopted.

Where neither are practical use work restraints. The main consideration is the

practicality of carrying out the required task from suspension equipment.

The least desirable in the hierarchy of risk is the use of fall arrest equipment to

catch a falling worker. It is often difficult to accurately predict the level of risk to the

worker during the operation, but it is important to remember that PPE always „fails to

danger‟. The implications of a fall are very much dependent on the location of the fall,

obstructions that may be hit during a fall, and the capabilities of other workers to

rescue a fallen and injured worker.

5.1.3 Risk Assessment and Planning

The majority of falls from height result from failures of organisation or

planning, e.g. selecting inappropriate and poorly maintained work equipment.

In order to be practical adopt a risk based approach to ensure that the measures

taken are proportionate to the risk involved. Within this framework, the employer

must:

¾ Assess the risks to identify and address hazards before the work

commences.

¾ Follow the hierarchy for safe work at heights - avoid, prevent, mitigate - and

give priority to collective measures over personal protection measures.

¾ Make use of appropriate work equipment, taking account of the following:

o The working conditions and the risks to the safety of persons at the place

where the work equipment is to be used

o In the case of work equipment for access and egress, the distance to be

negotiated

o The distance and consequences of a potential fall.

o The duration and frequency of use.

o The need for easy and timely evacuation and rescue in an emergency.

o Any additional risk posed by the use, installation or removal of that work

equipment or by evacuation and rescue from it.

Control Tier:

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Working at Heights Procedure

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¾ Plan and organise work properly taking account of weather conditions and the

possibility of emergencies.

¾ Make sure those working at height are competent.

¾ Manage the risks from working on or around fragile surfaces and from falling

objects

¾ Inspect and maintain the work equipment to be used and inspect the place

where the work will be carried out.

It must be ensured that any surface from which work at height is to be carried out is

sufficiently strong and stable to support foreseeable loads. Risk assessments need to

consider that, while the surface may support a person‟s weight, it may prove fragile

once the weight of the load or any additional falling force is taken into account. If the

work requires regular or occasional access where there is a fragile surface, then

permanent fencing, guards or other measures to prevent falls should be in place.

All work at height will be risk assessed prior to any work commencing as per the

flowchart, and equipment shall be selected as appropriate.

Necessary actions identified in the risk assessment to control risks should be

proportionate to the risk of harm and reflect what is reasonably practicable.

All SIMOPs are to be carried out under appropriately coordinating control of

Permit to Work. Persons involved in such SIMOPs shall be duly informed about

the activities and strongly keep prioritization of actions according to the

accepted Tasks Risk Assessment. Barriers and entry controls shall be clearly

established and only relevant persons permitted.

5.1.4 Fragile Surfaces

Fragile roofing materials include asbestos, glass, plastic, cement sheets and other

similar brittle surfaces. Roof cladding which has the appearance of being substantial

could be dangerously corroded. Surface coatings or dirt may conceal the fragile

nature of the material, thereby giving a false appearance of solidity to glass, plastic,

asbestos, etc.

No person at work should pass across or near a fragile surface. Nor should they

work on, from or near a fragile surface where it is reasonably practicable to carry out

work safely by another means. If it is not practicable, the following precautions must

be taken:

 When working on, or passing across, fragile roofing materials, crawling

boards must be used so that the person‟s weight is on the board, never on

the fragile roof sheeting. At least two crawling boards should be used, one to

support the person whilst the other is moved to a new position. Asbestos and

various plastic materials are particularly brittle and will shatter without

warning.

 The practice of trying to „walk the line of the bolts‟ is very dangerous and

compares with walking a tightrope. Where walkways are not provided, a safe

system of work such as that described above must be employed.

Control Tier:

<<2>>

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Document Number: << AZSPU-HSSE-DOC-00065-2>>

Print Date: 2/1/2011

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Working at Heights Procedure

Page 10 of 35

 Work involving the handling of sheeting and cladding requires extra care in

windy conditions, when a sheet may act like a „sail‟ causing the person

holding it to lose their balance.

 Walkways near fragile materials (in valleys, parapets, gutters or channels)

must be provided with suitable guard-rails, or the fragile material should be

suitably covered to prevent any possibility of anyone falling through.

 Warning notices must be fixed at all approaches to roofs constructed with

fragile materials to comply with the Health and Safety (Signs and Signals)

Regulations 1996.

IF YOU ARE WORKING ABOVE GROUND LEVEL, OR CLOSE TO AN EXPOSED EDGE

OVER WHICH YOU COULD FALL, THEN YOU WILL NEED TO MAKE THE FOLLOWING

ASSESSMENT:

Control Tier:

<<2>>

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Working at Heights Procedure

Page 11 of 35

IS THERE A RISK

OF A PERSON FALLING A

DISTANCE LIABLE TO

CAUSE PERSONAL INJURY?

YES

PERFORM THE TASK

IN A SAFE MANNER

IS IT REASONABLY

PRACTICABLE TO

SAFELY CARRY OUT

THE WORK , OTHER

THAN AT HEIGHT?

YES

CAN PLATFORMS,

PERFORM THE TASK

NETS ETC BE

IN A SAFE MANNER FROM

USED?

YES

THE GROUND

CAN YOU

PREVENT THE

FALL?

EMPLOY PERSONAL

Rescue /

PROTECTIVE EQUIPMENT

Recovery Plan

TO SET UP A FALL ARREST

YES

SYSTEM

(Perform the task in a safe manner)

PERFORM TASK

EMPLOY PERSONAL

FROM SAFE WORKING

PROTECTIVE EQUIPMENT

PLATFORMS WITH GUARDRAILS

TO SET UP RESTRAINT

USE A COLLECTIVE FALL

ASSESS THE

PROTECTION

RISK OF BEING

SYSTEM

SUSPENDED IN

e.g. air bags, netting etc

A HARNESS

REMEMBER IF YOU USE A WORK

RESTRAINT OR GUARDRAILS, YOU WILL

HAVE:

• NO FALLS

Inertia reel?

Lanyard & shock

• NO SUSPENSION ISSUES

absorber?

• NO RESCUE ISSUES

Control Tier:

<<2>>

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Working at Heights Procedure

Page 12 of 35

5.2

WORK EQUIPMENT

5.2.1 Means of Access or Egress at Height

To determine if a place of work at height is safe, the criteria listed below must be

checked. If it meets these criteria, work may be carried out from the platform without

the need to use work equipment to make it safe:

intended to be or is being used

¾ Resting on a stable, sufficiently strong surface

¾ Of sufficient dimensions to permit the safe passage of persons and the safe

use of any equipment or materials requiring to be used, and to provide a safe

working area with regard to the work to be carried out there

¾ Provided with suitable and sufficient edge protection to prevent risk to others

¾ Devoid of openings through which any people, material or object could fall

and injure a person or through which a person could fall

¾ Constructed, used and inspected, and maintained to prevent, so far as

reasonably practicable, the risk of slipping or tripping, or any person being

caught between it and any adjacent structure

¾ Prevented by appropriate devices, where it has moving parts, from moving

inadvertently during work at height

¾ Fitted with suitable guardrail of sufficient height to prevent person falling,

where 1m. height and maximum gap kept of 0.5m. between guardrails

¾ If these criteria‟s cannot be met, then further precautions will be required to

protect personnel.

5.2.2 Requirements for Working Platforms

Working platforms are defined as „any platform used in a place of work or as a

means of access to or egress from a place of work‟. It includes any scaffold,

suspended scaffold, cradle, mobile platform, trestle, gangway, gantry and stairway.

All working platforms should:

¾ Rest on a stable surface of suitable composition and strength to support the

structure and any loads intended to be placed upon it

¾ In the case of a wheeled structure, any supporting structure must be

prevented by appropriate devices from inadvertently moving during work at a

height

¾ In other cases, any supporting structure must be prevented from slipping by

secure attachment to the bearing surface or to another structure

¾ When erecting, modifying, dismantling a „working‟ platform and its supporting

structure it should be done in such a way as to ensure it remains stable and

avoids accidental displacement.

¾ A working platform and its supporting structure must never be loaded in a way

to give rise to a risk of collapse and its SWL (safely working load) must never

be exceeded.

5.2.3 Requirements for Collective Safeguards for Arresting Falls

Collective safeguards for arresting falls include nets, mats and inflated devices that

are designed to catch a falling person. When using this equipment, follow the

manufacturer‟s instructions. A safeguard shall only be used if:

Control Tier:

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¾ A risk assessment has demonstrated that the work activity can so far as

reasonably practicable be performed safely while using it and without

affecting its effectiveness

¾ The use of other, safer work equipment is not reasonably practicable

¾ Sufficient number of persons have received adequate training specific to the

safeguard, including rescue procedures

¾ A safeguard shall be suitable and of sufficient strength to arrest safely the fall

of any person who is liable to fall.

A safeguard shall:

¾ In the case of a safeguard which is designed to be attached, be securely

attached to all the required anchors, and the anchors and the means off

attachment thereto shall be suitable and of sufficient strength and stability for

the purposes of safely supporting the foreseeable loading in arresting any fall

and during the subsequent rescue

afford sufficient clearance.

When applying any safeguard, steps should be taken to ensure, so far as reasonably

practicable, that in the event of a fall, the safeguard itself does not cause injury.

When an external power source is required (such as a pump for an airbag) or

restraints

(such as brickwork enclosing bags) to make it effective, these power

sources or restraints must be sufficient to maintain the effectiveness of the

equipment in the event of a fall and rescue.

5.2.4 Requirements for Mobile Elevated Work Platforms

Mobile Elevated Work Platforms (MEWP‟s) can provide a safe place of working at

height, but precautions need to be taken to minimise the risks of users falling from or

being thrown from the basket or impact with other equipment.

The precautions for safe work from a MEWP include:

¾ A guard rail, with mid rail and toe-boards round the edge of the basket

¾ A slip resistant floor

¾ Dead-man controls

¾ Stability device, e.g. outriggers that are interlocked such that the MEWP will

not operate unless they are fully extended

¾ Locking-out controls to prevent inadvertent operation

¾ Suitable anchor point to allow personnel to attach a backup system

¾ Personnel anchored to the base of the basket via a full body harness and

short lanyard that creates an effective work restraint

Access to work at height can also be achieved by the use of working platforms fitted

to counter-balanced forklift trucks etc. There are two types of these working

platforms, including:

Occasional working platform: a platform and an enclosure fitted to the forks of a

counter-balanced forklift truck

Integrated working platform: containing controls within the platform that are

integrated into the controls of the truck

Control Tier:

<<2>>

Revision Date: 26 April 2010

Document Number: << AZSPU-HSSE-DOC-00065-2>>

Print Date: 2/1/2011

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Military reference books and manuals (2009-2023, Volume 4) - page 45