CPL Handbook 2006

Pipe Line Company

Safety Handbook

2006

Health, Environment & Safety Chevron Pipe Line Company

Safety HandbookRevised September 2006

Emergency Information Immediate Notification Procedure Emergency Hotline Contact Number Ambulance, Police or Fire Department CPL Security Issues http://cpl.chevron.com/ emergencyresponse/ (877) 863-5196 This number is ONLY for CPL internal calls 911 CPL Security Advisor 281-684-4194 Call your supervisor first or the Emergency Hotline For emergency situations and/or injuries call 911 immediately

In Case of a Motor Vehicle Accident

Copyright 2006This handbook contains confidential and proprietary information of Chevron Corp. Any use of this manual without authorization from Chevron and/or its affiliates is prohibited. The Safe Practices Handbook was written by the Chevron Pipe Line Company, Health, Environment, and Safety Team in Houston. It was published by the BRES Global Information Design and Consulting Team in Houston. Publication is available on alternative media at: http://www.chevron.com/pipelinecsm/documents/SafetyHandbook.pdf

Chevron Pipe Line Company

Safe Practices Handbook AcknowledgmentThis Safe Practices Handbook has been prepared with your personal safety and well-being in mind. You are expected to read, understand it and follow these practices as you perform your daily work assignments. If you have any questions about the meaning or intent of any of the practices in this handbook, you may ask your supervisor or contact the CPL HES staff for more information. After you read, understand and agree to follow the practices listed here, please fill out and sign this form, detach this Acknowledgment and return it to your supervisor. This document will be retained. I have read, understood, and agree to abide by the health, environment and safety practices contained herein. Name (Print): ___________________________________ Please check as appropriate: J Employee J Contractor CAI / ID number / Company name: _________________ ______________________________________________ Date: __________________________________________ Signature: ______________________________________Comments: If you have any suggestions for updates or improvements to this handbook, wed like to hear them. Please email your comments to the senior safety specialists or acknowledge understanding of the handbook via Knowledge Planet (CPL Safety Handbook).

Blank

PrefaceIt is the intent of Chevron Pipe Line Company (CPL) to read and use this handbook to comply with our corporate Policy 530, Health, Environment and Safety and to abide by all applicable government laws and regulations, as well as internationally accepted industry best practices. To this end, all levels of the organization are responsible for taking all practical measures to ensure that the design, installation, operation, and maintenance of CPL facilities and equipment, are in accordance with the information contained here. Thats why its important that you read the handbook in its entirety and make these safety practices part of your day-to-day behavior at Chevron Pipe Line Company.

Rebecca B. Roberts President, CPL

Contents1.0 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2.0 General Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.1 Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.1.1 Team Leader . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.1.2 Employee. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2.1.3 Contractor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2.1.4 Short-Service Employees (SSE). . . . . . . . . . . . . 7 2.1.5 Visitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.2 Incident Reporting and Analysis . . . . . . . . . . . . . . . . . 8 2.3 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2.3.1 New Employee Orientation. . . . . . . . . . . . . . . . 8 2.3.2 HES Required Training . . . . . . . . . . . . . . . . . . . 9 2.3.3 Job Safety Analysis (JSA) . . . . . . . . . . . . . . . . . . 9 2.4 Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.5 Food and Beverage . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.6 Smoking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.7 Alcohol and Drugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.8 Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 2.9 Discipline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.0 Personal Protective Equipment (PPE). . . . . . . . . . . . . . . . 14 3.1 Mandatory PPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 3.2 Field Work Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3.3 Protective Clothing General . . . . . . . . . . . . . . . . . . 16 3.4 Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 3.5 Eyes and Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 3.6 Hearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 3.7 Respiratory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 3.8 Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 3.9 Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 3.10 Fall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 4.0 Common Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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4.1 Slip, Trip, and Fall Prevention (walking hazards) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 4.2 Stairways and Elevated Work Surfaces . . . . . . . . . . 26 4.3 Ladders and Scaffolds . . . . . . . . . . . . . . . . . . . . . . . . . 27 4.3.1 Ladders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 4.3.1.1 Portable 4.3.1.2 Positioning a Ladder Straight 4.3.1.3 Positioning Step 4.3.1.4 Permanently Fixed Ladders 4.3.2 Scaffolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 4.4 Worker Safe Guards . . . . . . . . . . . . . . . . . . . . . . . . . . 30 4.5 Grinding Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 4.6 Tools Maintenance and Use . . . . . . . . . . . . . . . . . . . . 31 4.7 Equipment/Machinery in Motion . . . . . . . . . . . . . . . 34 4.7.1 Centrifuge Machines . . . . . . . . . . . . . . . . . . . . 34 4.7.2 Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 4.7.3 Engines/Turbines . . . . . . . . . . . . . . . . . . . . . . . 35 4.7.4 Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 4.8 Pocket Knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 5.0 Safe Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 5.1 Safety Meetings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 5.2 Safety Signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 5.3 Behavior Based Safety Process, Inspections or Audits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 5.4 Permit to Work (PTW) Systems. . . . . . . . . . . . . . . . . 38 5.5 Materials Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 5.5.1 Handling Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . 39 5.5.2 Tractor Loader/Backhoe Unit Operation. . . . 40 5.5.3 Powered Industrial Truck (PIT or Forklift) Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 5.5.4 Cranes and Hoisting, Cables and Slings. . . . . 43 5.5.4.1 Inspection Criteria 5.5.4.2 Capacity Chart 5.6 Hazardous Materials and Substances. . . . . . . . . . . . 49 5.6.1 General Principles . . . . . . . . . . . . . . . . . . . . . . 49

Safe Practices Handbook 2006

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5.7

5.8

5.9

5.10

5.11

5.6.2 Safety Color Coding. . . . . . . . . . . . . . . . . . . . . 50 5.6.3 Storing Flammable Liquids . . . . . . . . . . . . . . . 50 5.6.4 Corrosive Chemicals . . . . . . . . . . . . . . . . . . . . 51 5.6.5 Solvents and Cleaning Agents . . . . . . . . . . . . . 51 5.6.6 Using Tools Around Chemicals and Gases . . 52 Hazards Communication (HAZCOM) . . . . . . . . . . . 53 5.7.1 List of Chemicals . . . . . . . . . . . . . . . . . . . . . . . 53 5.7.2 Material Safety Data Sheet (MSDS) . . . . . . . . 53 5.7.3 Material Labeling . . . . . . . . . . . . . . . . . . . . . . . 54 Excavation, Trenching and Shoring . . . . . . . . . . . . . 57 5.8.1 Soil type and Site Preparation. . . . . . . . . . . . . 57 5.8.2 Worker Protection . . . . . . . . . . . . . . . . . . . . . . 58 5.8.3 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 5.8.4 Permit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Gas Testing and Analysis . . . . . . . . . . . . . . . . . . . . . . 59 5.9.1 Plan the Gas Tests. . . . . . . . . . . . . . . . . . . . . . . 59 5.9.2 Calibrating and Maintaining Gas Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . 59 5.9.3 Verify Instrument Performance Before Gas Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 5.9.4 Review Precautions . . . . . . . . . . . . . . . . . . . . . 60 5.9.5 Conduct Gas Tests . . . . . . . . . . . . . . . . . . . . . . 60 5.9.6 Interpret Gas Test Readings. . . . . . . . . . . . . . . 61 Confined Spaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 5.10.1 Workplace Evaluation . . . . . . . . . . . . . . . . . . . 62 5.10.2 Pre-Entry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 5.10.3 Working in a Non-Permit Required Confined Space. . . . . . . . . . . . . . . . . . . . . . . . . 63 5.10.4 Confined Space Entry Using Forced-Air Ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 5.10.5 Permit-Required Confined Space Entry . . . . 64 Lockout/Tagout (LOTO) . . . . . . . . . . . . . . . . . . . . . . . 64 5.11.1 Energy Sources . . . . . . . . . . . . . . . . . . . . . . . . . 64 5.11.2 Equipment Specific Procedure (ESP) Sheet . 65 5.11.3 Normal Equipment Isolation . . . . . . . . . . . . . 66 5.11.4 Shift Change . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

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5.12 Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 5.12.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 5.12.2 Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 5.12.3 Extension Cords . . . . . . . . . . . . . . . . . . . . . . . 69 5.12.4 Electrical Power Tools . . . . . . . . . . . . . . . . . . 70 5.12.5 Static Electricity . . . . . . . . . . . . . . . . . . . . . . . 71 5.12.6 Sampling and Gauging . . . . . . . . . . . . . . . . . 72 5.12.7 Electrical Fuses and Circuit Breakers . . . . . 72 5.12.8 Explosion-Proof Electrical Equipment . . . . 73 5.12.9 Batteries and Standby Generators . . . . . . . . 73 5.12.10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 74 5.13 Hot Work Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 5.13.1 Hot Work Permits . . . . . . . . . . . . . . . . . . . . . 74 5.13.2 Area Preparation . . . . . . . . . . . . . . . . . . . . . . 76 5.13.3 Fire Watch . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 5.14 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 5.14.1 General Precautions . . . . . . . . . . . . . . . . . . . 78 5.14.2 Minimizing Electric Shock from Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . 79 5.14.3 Welding in or Near Tanks or on Pipelines That Contained or Have Contained Hydrocarbons . . . . . . . . . . . . . . . . . . . . . . . . 80 5.14.4 Hot Tapping . . . . . . . . . . . . . . . . . . . . . . . . . 82 5.14.5 Compressed Gas Cylinders. . . . . . . . . . . . . . 82 5.14.5.1 Oxygen and Acetylene 5.14.5.2 Compressed Air 5.14.5.3 Natural Gas 6.0 Pipeline Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 6.1 General Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 6.1.1 DOT Pipeline Safety Regulations . . . . . . . . . . 90 6.1.2 Work on Existing Pipelines . . . . . . . . . . . . . . . 90 6.1.3 LOTO (5.11) and Blinding Procedure . . . . . . 92 6.1.4 Valves, Piping and Tubing . . . . . . . . . . . . . . . . 93 6.1.4.1 Block Valves


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6.1.4.2 Check Valves 6.1.4.3 Pressure Relief (Safety) Valves 6.1.4.4 Valve Actuation 6.1.4.5 Pressure Gauges 6.1.5 Scraper Traps . . . . . . . . . . . . . . . . . . . . . . . . . . 95 6.1.6 Engine and Motor Operation . . . . . . . . . . . . . 95 6.2 Tank Gauging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 6.2.1 Ascending and Descending Tanks . . . . . . . . . 96 6.2.2 Tank Top Safety . . . . . . . . . . . . . . . . . . . . . . . . 96 6.2.3 Gauging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 6.2.4 Static Electricity . . . . . . . . . . . . . . . . . . . . . . . . 97 6.2.5 Sampling and Gauging . . . . . . . . . . . . . . . . . . 97 6.2.6 Tank Dike Maintenance. . . . . . . . . . . . . . . . . . 97 6.3 Tank and Vessel Cleaning . . . . . . . . . . . . . . . . . . . . . . 98 6.3.1 General Precautions . . . . . . . . . . . . . . . . . . . . . 98 6.3.2 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 6.3.2.1 Light Inside Tanks 6.3.2.2 Personal Protective Equipment 6.3.2.3 Atmospheric Monitoring Equipment 6.3.2.4 Ventilating Fan or Exhauster 6.3.3 Cleaning Procedures . . . . . . . . . . . . . . . . . . . . 99 6.3.3.1 Prepare the Area 6.3.3.2 Cold Repair Work 6.3.3.3 Hot Repair Work 7.0 Transportation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 7.1 Motor Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 7.1.1 Vehicle Operation. . . . . . . . . . . . . . . . . . . . . . 102 7.1.2 Driver Responsibility . . . . . . . . . . . . . . . . . . . 102 7.1.3 Safe Driving Principles . . . . . . . . . . . . . . . . . 103 7.1.3.1 Inspecting Vehicles 7.1.3.2 Backing 7.1.3.3 Turning 7.1.3.4 Following 7.1.3.5 Parking 7.1.3.6 Loading and Unloadingv Chevron Pipe Line Company

7.1.3.7 Use of Cellular Phones While Driving 7.1.3.8 Transporting Tools and Other Materials 7.1.4 Breakdowns. . . . . . . . . . . . . . . . . . . . . . . . . . . 107 7.1.5 Trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 7.1.6 Commercial Drivers License . . . . . . . . . . . . 110 7.1.7 Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 7.2 Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 7.2.1 Marine Travel (Boat Transportation). . . . . . 110 7.2.2 Personal Flotation Devices . . . . . . . . . . . . . . 112 7.2.3 Swing Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . 113 7.2.4 Personnel Baskets . . . . . . . . . . . . . . . . . . . . . . 115 7.3 Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 7.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 7.3.2 Helicopter Travel . . . . . . . . . . . . . . . . . . . . . . 116 7.3.2.1 Arrival at Departure Points 7.3.2.2 Embarking and Disembarking Aircraft 7.3.2.3 Pilot-in-Command 7.3.2.4 Special Rules for the Sikorsky S-76 7.3.2.5 In Flight 7.3.2.6 Miscellaneous Rules 7.3.3 Fixed Wing Aircraft . . . . . . . . . . . . . . . . . . . . 121 8.0 Ergonomics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 8.1 Musculoskeletal Injuries and Cumulative Trauma Disorders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 8.2 Alternative Work Breaks. . . . . . . . . . . . . . . . . . . . . . 122 8.3 Workstation Design. . . . . . . . . . . . . . . . . . . . . . . . . . 122 8.4 Work Habits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 8.4.1 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 8.4.2 Back Injury Low Back Pain . . . . . . . . . . . . 123 8.5 Exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 9.0 Office Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 9.1 Computer Workstations . . . . . . . . . . . . . . . . . . . . . . 126


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9.2 9.3 9.4 9.5 9.6 9.7

Floors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Aisles and Stairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Office Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . 128 Material Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Fire Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

10.0 Emergency Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 10.1 Work Site Fire Emergencies . . . . . . . . . . . . . . . . . . . 130 10.2 Emergency Response Plans . . . . . . . . . . . . . . . . . . . . 131 10.3 Emergency Drills . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 11.0 First Aid and CPR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 11.1 First Aid Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 133 11.1.1 First Aid Kits . . . . . . . . . . . . . . . . . . . . . . . . 133 11.1.2 Eye Wash and Safety Showers . . . . . . . . . . 133 11.2 Basic First Aid Steps . . . . . . . . . . . . . . . . . . . . . . . . . 134 11.2.1 Artificial Respiration. . . . . . . . . . . . . . . . . . 134 11.2.2 Cardiopulmonary Resuscitation (CPR) . . 135 11.2.3 Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 11.2.3.1 Arterial 11.2.3.2 Venous 11.2.4 Burns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 11.2.4.1 Thermal 11.2.4.2 Chemical 11.2.4.3 Electrical 11.2.5 Thermal Stress . . . . . . . . . . . . . . . . . . . . . . . 138 11.2.5.1 Heat Stroke/Heat Prostration 11.2.5.2 Heat Exhaustion 11.2.5.3 Frostbite 11.2.5.4 Hypothermia 11.2.6 Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 11.2.7 Fractures. . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 11.2.8 Foreign Body in an Eye. . . . . . . . . . . . . . . . 141 11.2.9 Choking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 11.2.10 Snake and Insect Bites. . . . . . . . . . . . . . . . . 142

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12.0 Fire Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 12.1 Fire Triangle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 12.2 Fire Classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 12.3 Fire Suppression Equipment . . . . . . . . . . . . . . . . . . 145 12.3.1 Fire Protection Equipment. . . . . . . . . . . . . 145 12.3.2 Inspection and Maintenance of Fixed Fire Extinguishing Systems . . . . . . . . . . . . . . . . 145 12.3.3 Portable Fire Extinguishers . . . . . . . . . . . . 146 12.3.4 Wheeled Fire Extinguishers . . . . . . . . . . . . 147 12.3.5 Fire Water Systems . . . . . . . . . . . . . . . . . . . 147 13.0 Occupational Health . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 13.1 Work Environment Hazards . . . . . . . . . . . . . . . . . . 149 13.1.1 Chemical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 13.1.2 Physical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 13.1.3 Dusts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 13.2 Monitoring Exposures. . . . . . . . . . . . . . . . . . . . . . . . 158 13.3 Bloodborne Pathogens . . . . . . . . . . . . . . . . . . . . . . . 159 14.0 Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 14.1 Waste Management. . . . . . . . . . . . . . . . . . . . . . . . . . 160 14.1.1 Hazardous . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 14.2 Regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 14.2.1 Clean Air Act . . . . . . . . . . . . . . . . . . . . . . . . . 161 14.2.2 Clean Water Act . . . . . . . . . . . . . . . . . . . . . . 161 14.2.3 Resource Conservation and Recovery Act RCRA . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 14.2.4 Comprehensive Environmental Response, Compensation and Liability Act CERCLA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 14.2.5 Superfund Amendment and Reauthorization Act (SARA Title III) . . . . . . . . . . . . . . . . . . . 161 14.2.6 Occupational Safety and Health Act (OSHA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 14.2.7 Toxic Substances Control Act (TSCA) . . . . 162 14.2.8 Hazardous Materials Transportation Act . . 163 14.2.9 Safe Drinking Water Act. . . . . . . . . . . . . . . . 163Safe Practices Handbook 2006 viii

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 A. Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 B. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 C. Safe Work Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . 167 D. Excavations Checklist . . . . . . . . . . . . . . . . . . . . . . . . 168 E. Confined Space Checklist . . . . . . . . . . . . . . . . . . . . . 169 F. LOTO Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 G. Hot Work Permit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

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1.0

Introduction

Chevron Pipe Line Company (CPL) is committed to the principles of Chevrons Policy 530, for Health, Environment and Safety. We follow the Operational Excellence (OE) Management System and our conduct is guided by the Tenet Principles. This Handbook has been given to you to: Provide general guidelines and rules for conducting company business in a safe manner. Verify compliance with various Occupational Safety and Health Administration (OSHA) and Department of Transportation (DOT) requirements as well as many other applicable regulations. The information contained here applies to all personnel and visitors, company- or contractor-related, engaged in or on any CPL activity or in any company owned, operated or maintained pipelines or facilities. Remember:

Stop Work AuthorityIt is your Responsibility You have the Authority Zero is AttainableYour ideas and concerns are important. We always comply with the Tenets of Operational Excellence shown on the following page. As an employee or contractor for Chevron, you are responsible and authorized to stop any work that does not comply with these tenets, and there will be no repercussions to you. That is our commitment to you. Chevron Pipe Line Company


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CPL Tenets and PrinciplesWe believe all incidents are preventable. Do it safely or not at all There is always time to do it right When in doubt, find out

Always: 1. Operate within design or environmental limits. 2. Operate in a safe and controlled condition 3. Ensure safety devices are in place and functioning. 4. Follow safe work practices and procedures. 5. Meet or exceed customers' requirements. 6. Maintain integrity of dedicated systems. 7. Comply with all applicable rules and regulations. 8. Address abnormal conditions. 9. Follow written procedures for high risk or unusual situations. 10. Involve the right people in decisions that affect procedures and equipment.

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Safe Performance Self-AssessmentBefore beginning any activity/task/job, after an incident or near miss, any unusual circumstances:

Assess the riskWhat could go wrong? What is the worst thing that could happen if something does go wrong?

Analyze how to reduce the riskDo I have all the necessary training and knowledge to do the job safely? Do I have all the proper tools and personal protective equipment?

Act to ensure safe operationsTake necessary action to make sure the job is done safely! Follow written procedures! Ask for assistance, if needed!

Do not proceed unless everything is safe!For Everyone Every Day All the Time


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2.0

General RulesAccidents can and must be prevented.

Safety is a necessary part of an efficient operation. Compliance shall not be compromised for convenience, production or expediency.

Shutdown Authorization: In cases of imminent danger, personnel are authorized and expected to order work stoppage, shut down facilities, and activate firefighting and life-safety systems as required to prevent injuries or catastrophic loss. Employees shall notify as soon as possible their team leader (and the site supervisor if appropriate) when such action is taken. Electronic equipment may be considered a risk (as a source of ignition) or security threat in certain areas, therefore the use of:Cell phones, photographic or film cameras (digital or not, with flash, light or without it) or similar devices, is restricted and not allowed without a permit.

2.1 ResponsibilitiesEmployees, contractors and/or visitors shall:

Be familiar with and abide by the: Tenet Principles for CPL rules and practices contained in this handbook posted safety regulations in the workplace written and oral company instructions to perform their jobs safely

Comply with all applicable country, federal and state regulations as applicable

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Consult their team leader before proceeding with a job if there is any question regarding job safety or regulatory requirements

2.1.1 Team Leader

Develop operating rules and procedures consistent with our Policy 530 regarding Health, Environment and Safety. Ensure that:

Emergency procedures (e.g., station bills, pre-fire plans, emergency response plans, evacuation routes, etc.) are posted and that personnel are familiar with them. Visitors, contractors, and/or new personnel: are briefed on appropriate emergency procedures on their arrival have an HES initial orientation before starting work contractors who will perform work shall receive a safety handbook returning its acknowledgement.

Provide instruction and guidance to ensure that employees and contractors follow proper work procedures; including any additional assistance to new employees and/or visitors. Communicate with and join employees regarding LPS activities (e.g., LPOs, LI, NLIs and status of an investigation if a loss is occurred, JSAs, etc.). Inspect tools, equipment, and working conditions to determine that there are no obvious or hidden safety hazards, or people performing unsafe acts. Encourage and enforce (if necessary) the rules and regulations that apply to the operation.


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Maintain workplace conditions by: 1. Periodically auditing facilities for potential hazards 2. Eliminating or mitigating hazards that present an unacceptable level of risk 3. Listening to employee feedback regarding workplace conditions

2.1.2 EmployeePeriodically check the equipment, tools and work area for possible safety hazards and inform the team leader of any unsafe conditions. Be prepared for emergency situations, locating safety showers, fire protection equipment, evacuation route, rally point, respiratory equipment and first aid equipment before you begin working, and make sure that the equipment is in good working order. Whenever necessary, participate and support LPS activities, including investigation processes.

2.1.3 ContractorEnsure that personnel assigned to work at Chevron locations are fit for duty and that they are physically capable of performing all aspects of their jobs. Conduct operations in a manner that constitutes no potential hazard to the employees, property, or the environment. Provide and maintain all required PPE, safety equipment, and instrumentation necessary to perform their work effectively, efficiently and safely. Have a designated safety representative at each job site responsible for all safety-related activities. On small or low-risk projects, the person in charge of the job may designate a qualified crewmember to contractors work. In any case, contractor safety

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personnel must periodically make visits to Chevron locations where their personnel are working. Bring any observed, unsafe conditions to the attention of a Chevron representative. Provide the designated Chevron Pipe Line representative with reports of hazards presented by the contractors work or identified during the contractors work. Have written safety programs and procedures, as required or needed. Conduct appropriate industrial hygiene monitoring and, if requested, provide copies of the results to CPL.

2.1.4 Short-Service Employees (SSE):Note: An SSE is an individual who has been employed by contractor or subcontractor for less than six months or has been in a like job by contractor for less than six months. No one-person crew may be staffed by an SSE. Only one SSE is allowed on a two-to-four person crew and on crews of five persons or more. No more than 20 percent may be SSEs. Contractor shall notify team leader and clearly identify any SSEs on its crews. A qualified mentor must be assigned to each SSE to monitor the SSE job performance. Exceptions to the SSE policy may be made only with Companys prior approval.

2.1.5 VisitorSign in when entering, boarding or leaving any CPL-owned site Follow instructions for the facility you are visiting Adhere to the safety practices contained in this handbook Wear your security ID at all times Never be alone on premisesSafe Practices Handbook 2006 7

2.2 Incident Reporting and Analysis

Report to your team leader and/or Chevron representative immediately: all accidents (e.g., on-the-job injury/illness, spill, fire, etc.) near-misses all motor vehicle incidents occurring at or affecting the worksite or its employees, visitors or contractors

Promptly investigate and analyze the reported events with your team to determine the root cause, and formulate immediate corrective and preventive measures. Depending on the nature of the incident, assistance from other departments may be warranted. Data collection and investigation will begin within 24 hours

2.3 Training

Personnel must be trained in the proper use of equipment and safe performance of their jobs. Documentation of past training must be kept at the work location. Any questions or concerns regarding your training shall be expressed to your team leader.

2.3.1 New Employee OrientationThe team leader is responsible for: orientation which will take place the first day on the job enrolling the new employee in the first available session regarding HES procedures

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2.3.2 HES Required TrainingMany of the activities summarized here are not allowed until the employee has taken specific training, such as, but not limited to: confined spaces entrylockout/tagout (LOTO) heavy equipment operation (e.g., forklift, crane operation, etc.) first aid response etc.

2.3.3 Job Safety Analysis (JSA)Every task that is not covered by a procedure or activity must have a JSA before the activity is performed. Employees must be trained and aware of the potential risks involved with the operation. JSA must be documented and available to consult at the work location.

2.4 Housekeeping

Good housekeeping improves safety and efficiency. Keep tools, equipment, facilities and your work area clean and orderly. Before waste accumulates, dispose of it in compliance with local regulations. When not in use, store hand tools in bins or toolboxes with sharp edges facing inward. Return tools and work equipment to the place provided for them. Maintain tools and work equipment in good condition. Store heavy equipment and heavy tools on low shelves. Discard any tools that cannot be maintained in good condition, and request replacements through your team leader.


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Keep access clear to walkways, exits and firefighting equipment. Exits shall be kept free of obstructions. Work areas, walkways, and stairways shall be kept free of slipping/tripping hazards. Keep all company vehicles free of trash, oily rags, and other debris. Clean up spills immediately. Use barricades to secure the area, if necessary.

2.5 Food and Beverage

Food or drink shall not be kept or consumed in areas where possible contamination is present. Use only designated areas.

2.6 Smoking

Smoke in designated smoking areas only. When in doubt, please ask! Safety matches are the only type of matches permitted on a CPL work site. Carrying strike-anywhere or lighters on company premises is prohibited. Disposable butane lighters are not permitted at any field locations. Any lighter carried on company premises must have enclosed flint, steel, and operating mechanisms to prevent accidental lighting and sparking.

2.7 Alcohol and Drugs

Employees shall notify their supervisors when they are taking medication, (prescription or nonprescription), that might affect job performance.

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Prescription drugs brought onto Chevron facilities must be in the container in which they were originally dispensed and must be prescribed for that employee. The employee's team leader must be notified of the presence or use of any prescription drugs that may impair an employee's judgment or performance. The illegal use, possession, distribution, purchase, or sale of any controlled substance by any person while on CPL premises, engaged in CPL business, or while operating equipment is prohibited. Personnel assigned to a position which is deemed safety-sensitive are required to maintain a blood alcohol concentration (BAC) of 0.00 percent at all times while on duty or driving a company-owned or rented vehicle. CPL reserves the right to conduct or require an alcohol or controlled substance screening test on any person who is on premises or operating CPL equipment, engaging in CPL business, or applying for employment. Prior consent must be obtained from any person who is to be screened. Mandatory screening will occur when: alcohol or drugs are suspected to be a contributory cause to an incident an individuals behavior is such that excessive alcohol or drug influence is suspected a driver is involved in a motor vehicle crash or the drivers vehicle was hit by another vehicle

DOT Drug Testing Regulations All personnel who perform operations, maintenance or emergency response functions


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required by DOT regulations have been deemed by the DOT to be safety sensitive. All safety sensitive employees are subject to part 199 of the DOT drug testing regulations, which includes random drug testing Random and for cause drug testing may be requested in accordance with DOT regulations, the CPL Anti-Drug Plan, and Chevron Corporation drug-abuse prevention policies

2.8 Security

If the security staff is unavailable to conduct a search, the supervisor must have another supervisor present to witness the search. In all cases, the supervisor must inform the department manager before a search is conducted. Without prior announcement, company-authorized representatives may search any person, vehicle, and personal items of anyone entering, working at, or exiting from any controlled company work area. When appropriate, items discovered through an inspection may be taken into custody and turned over to the appropriate local law enforcement agency. Failure to comply with any of the above shall result in disciplinary actions, which may include dismissal.

2.9 DisciplineDisciplinary action, including discharge, will be taken for disregard or violation of safety instructions or practices as follows:

any violations will result in disciplinary action up to and including termination

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failure to maintain fitness for duty will result in disciplinary action up to and including termination to deviate from safety instructions will be cause for disciplinary action up to and including termination


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3.0

Personal Protective Equipment (PPE)

PPE is an essential element in protecting employees from work place hazards and on-the-job injuries. All PPE shall meet standards established by recognized governmental and/or industry groups.

3.1 Mandatory PPE

All employees, contractors, and visitors must wear the following protective equipment when working in areas other than offices, parking areas or change rooms unless wearing the PPE causes an additional risk, which will have to be validated by the team leader: fire-resistant clothing hard hats steel-toed footwear safety glasses Additional protection may be required depending on the hazards (as indicated by the team leader, signs or procedures); this equipment includes, but is not limited to the following: safety glasses hard hats respirators goggles (grinding, chemical, brazing, or cutting) face shields (splash and welding), gloves, welders jacket, pants, arm protectors as appropriate, life jackets, full body harness, etc.

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PPE shall be furnished by the employer (Chevron or contractor) as required and at no charge to the employee or visitor. It is the employee's responsibility to maintain it in a safe and sanitary condition, as well as follow the manufacturers' recommended instructions or applicable procedures for cleaning, maintenance, use and replacement.

3.2 Field Work Clothing

Employees are encouraged to wear natural or nonmelting fibers such as cotton or wool as general clothing or under their Fire Resistant Clothing (FRC). Kermel, Kevlar (PBI Gold or equivalent), and Nomex III are all acceptable materials for protection against flash fires. For other fire resistant clothing materials check with your safety specialists. If clothing (including shoes) becomes contaminated with a potentially hazardous (flammable or toxic) material it should be: immediately removed to prevent skin irritation and/or possible ignition changed in a well-ventilated area, and the person should take a shower if necessary not worn again until it has been properly cleaned

FRC shall be worn by all persons working in or around any of CPL-owned or operated facilities and/or pipelines, which contain hydrocarbons or electrical equipment, but not limited to: any of the operations units and fenced in areas pump stations and valve locations maintenance areas, truck racks, and tank farms electrical switchgear areas rectifier checks, and valve manifold areas

Personnel may travel between designated facility entrances/parking areas and their work locations


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without wearing FRC, provided they use the roadways on the most direct path to their work locations. FRC is not required in offices and machine shops.

FRC shall be worn in the appropriate manner to maximize protection: must cover the entire body from the neck to the ankles should be worn as an outer garment, unless a Tyvek suit is required for the operation (you may also wear layered clothing underneath as needed for personal warmth) may not be modified, such as, long sleeves rolled up, zippers left down or shirts/jackets unbuttoned

3.3 Protective Clothing - General

The wearing of loose or ragged clothing must be avoided when working around moving machinery because it can get caught in machinery, moving belts, etc. Long shirt tails must be tucked in trousers. Clothing (including shoes) that becomes contaminated with a potentially hazardous (flammable or toxic) material should be removed immediately to prevent skin irritation and possible ignition. Change such clothing in a well ventilated area and take a shower if necessary. Do not wear the clothing again until it has been properly cleaned. Hair long enough to be potentially hazardous while working around moving machinery or rotating tools and equipment shall be secured. Hair styles that make it impossible to wear a hard hat properly are not permitted. Except in office jobs, rings and other jewelry (except watches) should be removed while at work.

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3.4 Head

Hard hats shall be worn by all personnel V-Guard at all work locations and along the rightShock Guard of-way, except in offices or when an employee is riding in an enclosed vehicle. Hard hats must be nonmetallic (non-conductive or dielectric) and meet ANSI Z89.1, Class A and B requirements. Electricians and other employees who could be exposed to electrical hazards should use dielectric or nonmetallic accessories (such as liners and chin straps) only. For situations during welding operations where the welder must work in a head-down position, and where there are no overhead hazards, the team leader shall have discretion to allow an exception to the hard hat requirement. These situations occur mainly in welding on the underside of pipelines when the welders attempts to keep the hard hat on can create a hazard. All other welding operations require a hard hat to be worn in combination with a welding shield. Do not alter hard hats in anyway that could reduce its dielectric or impact qualities. This includes drilling of any hole, carving, etching, painting, etc. Do not place objects between the liner and the shell while wearing the hat. Employees should replace liners periodically and replace the hat when it becomes damaged or brittle. It is recommended that liners be replaced at least every six months, and hats at least every two years.


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3.5 Eyes and Face

All safety glasses or face shields must meet ANSI Z87.1 standards, and its primary intention is to protect where a potential eye hazard exists. For prescription safety glasses, the company will pay 100 percent of the cost of frames and lenses. When an employee requires prescription lenses, the employee must furnish an up-to-date prescription (within one year). The employee pays for the examination and fitting. The company will provide up to two pairs of safety glasses per year, one clear and one tinted. The tinted lenses may only be gray, green or rose depending on the employees preference. Contact lenses provide no protection to the eye and should be worn with other eye protection. They should not be worn in high-dust conditions or in the presence of irritating vapors or smoke. Advise your team leader if you routinely wear any type of contact lenses. This information may be needed during a medical emergency. Also advise your team leader if you wear contact lenses due to surgical removal of your natural lenses. Carry some form of medical alert identification at all times. Wear chemical goggles over implanted contact lenses in areas where eye protection is required. Do not wear hard contact lenses when you are working in a contaminated atmosphere with a supplied air respirator unless they are gas-permeable lenses (OSHA 1910.134) (e) (5ii). Air passing over non-gaspermeable lenses may severely dry the eyes and cause severe pain. Soft contact lenses are permitted.

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Safety glasses are not safety goggles. Use goggles to protect against hazards that may enter your eye from the sides. Do not depend on safety glasses for this protection. There are two primary types of goggles, impact and chemical. Impact-type goggles shall be worn during activities involving flying or falling objects or particles such as: chipping, cutting, or breaking stone, brick and concrete using hammers, chisels or other steel hand tools scraping paint or scale from wood or metal surfaces using a wire brush to clean threads, fittings or metal and wood surfaces grinding on abrasive wheels (even when a glass or plastic guard is provided) using compressed air for cleaning purposes to clean or blow out debris

Splash-proof chemical goggles and face shields shall be worn when handling potentially hazardous chemical liquids and solids or in any other operation where the eyes may be exposed to potentially hazardous chemicals. Never wear face shields alone as eye protection. Use face shields in addition to eye protection to protect the face and neck from flying particles, sprays of chemicals, splashes of molten metal and from hot solutions. Welding, brazing, soldering or cutting operations require the use of shaded lenses. Use the following table to select the proper shaded lens for welding:


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Welding Operation

Minimum Shade Number

Shield metal-arc welding, up to 5/32" electrodes.............. 10 Shield metal-arc welding, 3/16 to 1/4" electrodes............. 12 Shield metal-arc welding, over 1/4" electrodes..................14 Gas metal-arc welding (nonferrous)..................................11 Gas metal-arc welding (ferrous)........................................ 12 Gas tungsten-arc welding................................................... 12 Atomic hydrogen welding.................................................. 12 Carbon arc welding............................................................ 14 Torch soldering..................................................................... 2 Torch blazing................................................................. 3 or 4 Light cutting, up to 1"................................................... 3 or 4 Medium cutting, 1 to 6"................................................ 4 or 5 Heavy cutting, over 6"................................................... 5 or 6 Gas welding (light), up to 1/8"..................................... 4 or 5 Gas welding (medium), 1/8 to 1/2".............................. 5 or 6 Gas welding (heavy), over 1/2"..................................... 6 or 8

Abrasive blasting and sandblasting require a hood designed specifically for this purpose. The hood should have appropriate eye and face protection: forced-air ventilation for the operator, and appropriate airpurifying respirators for others who may be exposed.

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3.6 Hearing

Hearing protection shall be worn by all workers exposed to 8-hour, time-weighted average (TWA) noise levels of 85 dB or above to prevent hearing loss. This may require wearing a combination of hearing protection devices (for example, earplugs and ear muffs). CPL shall identify high noise areas and post appropriate warning signs so appropriate actions can be taken. Employees should report suspected highnoise areas to their safety specialist. The warning signs will be posted at entrances indicating that hearing protection is required. Also, use hearing protection whenever you're exposed to mobile noise sources such as power tools and equipment or during venting operations.

3.7 Respiratory

Respiratory equipment is required in any situation with at least one of the following conditions: whenever the job needs to be performed in an oxygen-deficient area in an area that contains hazardous concentrations of toxic contaminants

Prior to being approved for the use of respiratory equipment, employees shall: have medical clearance from the company physician


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receive the required training (selection, use, care, maintenance and limitations of the equipment) be fit-tested as appropriate for the respirator model he/she will be wearing

The type of respiratory protection equipment used will depend on the type of respiratory hazard, such as dust, chemical, vapor or paint respirators for protection during exposures to specified concentrations of these contaminants. Use self-contained breathing apparatus or supplied air respirators when the atmosphere is immediately hazardous to life or health (for example, excessive concentrations of C02 or H2S). Breathing air shall meet at least the requirements of the specification for Grade D breathing air. All respirators shall be examined prior to use. Employees shall clean, disinfect, and properly store respirators after each use, unless this responsibility is assigned to others. Additionally, respiratory protective equipment must be inspected monthly and prior to each use. Maintain a written inspection record with each piece of equipment. Employees and contractors who may be required to wear respiratory protection, either in their normal duties or under emergency conditions, shall not be permitted to have beards, mustaches or sideburns in the facial area contacted by the mask. A tight face-tomask seal is required for the safe use of all types of respiratory protective equipment. Employees who must wear prescription glasses, and whose normal duties require them to wear full-facepiece respiratory protection, will be provided with units designed for use with glasses.

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Employees who wear prescription glasses and who are required to wear full-face-piece respiratory protection should remove their glasses only in emergencies if they can see well enough to function without them; if not, positive-pressure units designed for use with glasses will be made available to them.

3.8 Hand

Employees shall wear appropriate hand protection when performing operations that expose the fingers and hands to cuts, scrapes, bruises, burns, and chemicals. Examples of appropriate hand protection include: insulated or heat-resistant gloves when handling steam hose, or when performing other duties in which regular work gloves do not afford burn protection leather or leather-palmed gloves when handling wire rope cloth gloves when handling pipe, and rubber gloves approved for electrical work chemical-resistant gloves when handling acids, caustics, caustic soda, etc. hydrocarbon resistant gloves when using hydrocarbon-based solvents, cleaning agents, or chemicals The company will supply proper gloves, taking into account the type of work being performed and the types of chemicals that may be involved. Use extra caution when wearing gloves where there is a possibility of catching them in moving equipment; ask your supervisor, it may be better not to wear them.


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3.9 Foot

Foot protection is required whenever risk of falling objects is present. Field personnel are required to wear steel-toed footwear when working in areas outside of the office setting. Acceptable footwear must comply with the following: steel-toed provide ankle coverage have a notched heel that prevents slippage when climbing ladders oil-resistant soles

Visitors (non-company personnel) to the field may not need to comply with CPL steel-toed footwear policy provided that they are accompanied by a CPL employee and do not participate in work activities that could result in a foot injury.

3.10Fall

Fall protection shall be used in certain situations. These include, but are not limited to: open-sided floors, floor openings, catwalks, or platforms elevated six (6) feet or higher where handrails or barricades are not provided working over water when personal flotation devices (PFDs) are not used.

Personal fall arrest systems consist of anchor points, connectors, and a full-body harness. They may also include a shock absorbing lanyard, deceleration device, lifeline, or suitable combination of these.

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Employees shall use fall protection devices where they are installed. Fall protection rescue equipment and personnel trained in its use will also have to be available at the job site.


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4.0

Common Hazards

On many occasions, accidents occur in places or during operations and activities that we take for granted. This section includes a few of those that are more frequent.

4.1 Slip, Trip, and Fall Prevention (Walking Hazards)

Watch your step while walking about the job to avoid tripping, stumbling, slipping and similar hazards. Be aware that weather conditions such as ice, water, or mud can create or aggravate existing hazardous situations. Use the walks, stile and stairs provided. Remove or repair tripping or slipping hazards as they are found. Avoid jumping from elevated places. Do not take shortcuts, such as walking up or down earthen banks or berms if stiles and walkways have been installed for your use.

4.2 Stairways and Elevated Work Surfaces

Employees shall use available stairways, walkways and handrails. Employees shall not climb onto vessels, tank roofs, etc. without safeguards (planking, scaffolds, etc.). Working from any surface more than six feet above adjacent floor or ground requires guard rails or the use of fall protection. Stairways having four or more risers shall have handrails.

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Where guard rails are installed, toe-boards shall be provided if a person can pass beneath the open sides or where falling materials can create a hazard. Openings in floors into which a person can accidentally step or fall shall be covered, continuously attended, or protected by barricades or standard hand railings. Employees shall avoid carrying loads that extend above eye level or otherwise obstruct vision when on stairways or elevated work surfaces.

4.3 Ladders and Scaffolds

Shall be examined for defects before each use. Defective equipment shall be removed from service and reported to the appropriate supervisor. Wooden ladders shall not be painted. Paint hides cracks and other damage. Always face a ladder when ascending or descending it. Both hands should be free to grip the ladder firmly. Tools should be carried in a belt or should be raised and lowered by rope. (Make sure no one is standing below the tools as they're being transported). Fiberglass ladders shall be used for electric equipment installations, repair or maintenance work.

4.3.1 Ladders4.3.1.1 Portable

Employees shall only use portable ladders that have labels showing that the ladders conform to appropriate ANSI standards. Metal ladders shall not be used for electrical equipment installations, repair or maintenance work where they may contact electrical conductors. Special non-conductive ladders (approved wooden, fiberglass, etc.) may be used. A ladder shall not be used in a horizontal position as a walkway or scaffold.


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Portable ladders shall be equipped with safety feet to prevent slippage. Not more than one person shall be on the ladder. Employees shall not lean from a ladder to reach work, the ladder shall be repositioned. Employees shall not stand or sit on the top two steps of a stepladder. When two people are carrying a ladder, grasp it near both ends. Exercise caution when approaching doorways and corners. A folding step ladder shall not be used in a straight closed position. Set the portable ladder base at the correct angle. A rule of thumb: The distance from the foot of the ladder to the object it will lean against should be one-fourth the required height.

4.3.1.2 Positioning a Ladder Straight3 1/2 foot minimum lashed, clamped, or otherwise secured to structure ladder

1/4 height In other words, the feet of (working length) of ladder a 12-foot-long ladder should be placed about 2-1/8 feet away from the base of the object (12 ft ladder - 3-1/2 = 8.5 = working length = 8.5/4 = 2-1/8).

Straight and extension ladders shall extend 3-1/2 feet beyond the top resting point when used for climbing onto a platform. If this is not possible, a helper should hold the base of the ladder in position during use. Whenever possible, securely fasten the ladder at the top to prevent slipping.

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Based on the nominal length of the extension ladder, each section of a multi-section ladder shall overlap the adjacent section by at least the number of feet stated below:Nominal Length of Overlap Ladder (Feet) (Feet) Less than or equal to 36 3 37-48 4 49-60 5

4.3.1.3 Positioning Step

4.3.1.4 Permanently Fixed 4.3.1.4 Ladders

May vary from vertical to 75 degrees from horizontal and shall have a toe clearance of at least seven inches between the ladder and the surface behind the ladder. Shall be securely fastened at the top, bottom, and intermediate points, as required. Shall not be climbed longer than 20 feet unless it is equipped with a cage or the employee uses a fall protection device.

4.3.2 Scaffolds

Construct scaffolds with provided handrails, midrails, toe boards, and all other items specified in the Chevron Safety in Design Manual.


overlap

Set a portable ladder on a firm base. Fully extend the legs and lock the cross braces into place. Have someone help steady the ladder. Do not use the ladder if all its feet are not firmly contacting the ground.

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A few safety tips while using a scaffold, do not: walk under it while people are on it. work off it during a strong wind. place it in front of a door without locking/blocking the door closed or posting a guard. leave tools or materials on it.

4.4 Worker Safeguards

Do not get inside guardrails or barriers while the equipment is in operation. Guardrails around operating equipment are placed there for your protection. Follow all appropriate requirements regarding excavations to prevent someone or something from falling into one. Provide barricades as required. Install temporary guards whenever portions of handrails have been removed to facilitate the handling of material. Reinstall permanent handrails immediately after the need for the opening has ended. Make sure machine guards, such as those over belts and chains, are in place whenever equipment is readied for operation. Keep long hair, sleeves and shirt tails away from running equipment. High-temperature surfaces (those that will cause burns if contacted) shall be clearly identified, insulated and/or guarded. Apply lockout/tagout (LOTO) procedures on any setup or maintenance work.

4.5 Grinding Wheels

When using or working near a grinding wheel, wear goggles or safety glasses and a full-face shield.

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Do not operate the grinder unless it has a safety guard and is properly adjusted. Grinders are considered an ignition source. Obtain a hot-work permit before operating grinders in a restricted area (i.e., an electrically-classified area). Do not use the side of a grinding wheel to grind unless the wheel is designed for that purpose. Use an appropriate wheel when grinding aluminum, rather than wheels designed for ferrous metals. Inspect safety guards frequently to ensure that proper distances are maintained. The work rest for a grinder shall be no more than 1/4 inch from the wheel and the tongue guard no more than 1/8 inch from the wheel. Do not attempt to adjust the guards while the wheel is in motion. Make sure it is unplugged (with plug within reach) before making any adjustments or repairs. Inspect the grinding wheel before each use for signs of possible cracking or other damage. Replace all defective wheels immediately. Grinding wheels should never be used on Asbestos Containing Materials (ACM) unless retrofitted to an approved HEPA vacuum system.

4.6 Tools Maintenance and Use

Inspect all tools before using them to determine if they are the proper size and in good condition. If they are not in good condition, let your team leader know. Do not use defective or damaged tools.


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Keep tool surfaces and handles clean and free of excess oil to prevent slipping and glancing. Tools shall be used only for the purpose for which they are designed. Use the right tool for the job. Keep tools in a safe place and not in overhead areas or on ladders. Do not carry screwdrivers or other sharp objects in a pants pocket, use an approved tool pouch or equivalent to carry tools. Upon completion of a job, clean tools and return them to the tool box or storage area. Make sure wrenches have a good bite before applying pressure. An employee shall ensure they are in a safe and stable position before applying pressure to a tool handle, to avoid losing balance or falling if the tool should slip. Brace yourself and place your body in the proper position so that you will not fall in case the tool slips. Also provide sufficient clearance for your hands and fingers in case the tool slips. Keep chisels, axes and similar tools sharp for safety and efficiency. Frequently inspect driving faces of hammers, chisels, bars, and similar tools for mushroom heads, broken faces and other defects. Discard defective tools. Use a tool holder when using driving tools, striking chisels, punches, rods, stakes, etc., to prevent hand injuries. Eye protection shall be worn when striking tools are used.

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Mushroomed or expanded heads of impact tools such as chisels and sledge hammers shall be dressed (filed off) as needed. Ball peen hammers and sledge hammers shall be used in conjunction with striking tools (e.g., chisels, punches, rods, stakes, etc.). The use of claw hammers is prohibited. A hammer shall not be struck against another hammer. Files shall be equipped with handles. Wrenches shall be pulled instead of pushed when possible. Adjustable crescent wrenches shall not be used if a box or open-end wrench of the correct size is available. Jaws on adjustable crescent wrenches shall be tightened around fitting/nut and the force applied on the side with the stationary jaw. Local regulations may restrict or prohibit the use of wrench extensions or cheaters. (e.g., CA-OSHA regulations state: When a pipe wrench extension is used, the maximum length of the extension shall be two times the length of the pipe wrench handle. The extension shall be constructed of steel pipe of such a diameter to snugly fit the pipe wrench handle, and cover the full length of the pipe wrench handle. The force exerted on the wrench shall not exceed the manufacturer's rated breaking strength of the wrench.) Tools not bolted, tied or secured in some manner shall be removed from locations where they could fall on employees below. Handles of sledges, hammers, mauls and the like shall be securely wedged into the heads. Wooden handlesSafe Practices Handbook 2006 33

shall not be painted because paint causes handles to be slick and hides cracks and other defects. Cracked or split handles shall be replaced; they shall not be taped.

4.7 Equipment / Machinery in Motion

The following safety precautions shall be observed when working around rotating machinery: follow proper LOTO procedures for any type of equipment do not wipe any moving part while it is in motion keep rags away from moving machinery; don't let them protrude from your pockets rotating machinery consists primarily of compressors, engines, turbines and pumps. Rotating machinery is dangerous because of the high speeds and pressures used in its operation. Repairs shall not be initiated until the fuel supply is shut off and the starting circuits disconnected, locked out, and tagged

4.7.1 Centrifuge MachinesCentrifuge machines shall be equipped with guards Centrifuge machines shall be operated with the tops closed. Pneumatically operated machines shall be operated at manufacturer's recommended pressures.

4.7.2 CompressorsBefore starting repairs, the suction and discharge valves shall be closed and the pressure bled off. Compressor alarms and shutdowns shall be tested periodically.

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4.7.3 Engines and TurbinesPressurized lines shall be bled off. When turbines are shut down for maintenance or service, air or gas supply to the auxiliary lube oil pump shall be shut off to prevent accidental operation (where applicable). Engines shall be located in well ventilated areas and as far away as practical from headers, separators, and oil storage tanks. Air starters shall be used instead of gas starters where practical; however, if gas starters are used, exhaust piping shall be securely anchored and vented to a safe location. Means shall be provided to vent unused gas or liquid accumulation trapped between the starter and the starter valve after it is closed. Before activating the gas starter, the integrity of the vent line shall be checked. Portable internal combustion engines with engine mounted fuel tanks shall be shut down and allowed to cool before refueling. Exceptions shall be approved by local supervision. When cranking engines using a rope starter, employees shall not wrap the rope around their hands or wrist. The starting rope shall be equipped with a pull handle.

4.7.4 PumpsPrior to initiating repairs or maintenance, the pump shall be shut down, isolated, and the internal pressure bled down. Main electrical disconnects and valves shall be locked out and tagged prior to initiating work. A pressure relief valve shall be part of the discharge manifold on every power-driven pump, with the exception of centrifugal pumps. It shall be placed ahead of the first valve on the discharge line. Relief valve


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outlets shall be vented to a safe location or discharged back into the pump suction. When discharge extensions (vents) are necessary, they shall be securely anchored. If it is necessary to tighten packing glands while pumps are in operation, use extreme caution.

4.8 Pocket Knives

Personnel are allowed to carry pocket knives; however, they are not allowed to use them while working. USE THE APPROPRIATE TOOLS FOR THE JOB. POCKET KNIVES ARE NOT APPROPRIATE TOOLS.

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5.0

Safe Practices

5.1 Safety MeetingsPre-job or pre-startup meetings shall be conducted to review all safety procedures, restrictions, guidelines, permits, JSAs and concerns before starting with the activity.

5.2 Safety Signs

Safety signs are usually posted where dangers arepresent. Heed all warning signs (such as those regarding PPE, Danger, Road Closed, Keep Out, etc.) and safety guards.

Never remove, move or change warning signs, safety guards or equipment without company authorization. Warning signs, safety guards or equipment are provided for your protection - don't ignore them!

5.3 Behavior Based Safety Process, Inspections or AuditsAll personnel are expected to participate in a behavior based safety process which shall include training to observe co-workers for safe and at risk performance and provide feedback after completion of the observation.


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Contractor companies may have their own program. Any employee or visitor may approach the work area to perform a safety observation, inspection or audit. The job will continue as scheduled and everybody is encouraged to participate if allowed by the operation and requested by the observer. The team will be expecting feedback from the observations as soon as practical, in order to improve the overall safety of the process.

5.4 Permit to Work (PTW) SystemsCPL has instituted permit systems to authorize and approve, in writing, various types of work activities. The permit specifies the location and type of work to be performed and also certifies that hazards have been evaluated by a qualified person and that all necessary protective measures have been specified and implemented. Please review and follow the Safe Work Permit checklists in the Appendix section. Safe Work Permits are required for:

High-risk operations: hot work confined space entry lockout/tagout excavations

Non-routine maintenance work: pipeline repair or replacement tank or vessel maintenance and/or repair (except inspections) hot taps overhauling of equipment (pumps, compressors) site remediation projects any other work that is hazardous or unusual, such as:

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working from heights where personal fall protection is required overhead activities involving rigging in a congested area or over piping or equipment in service work activities requiring respiratory protective equipment unbolting, disconnecting, opening or removal of any line, process piping, equipment or system that has been in service unflanging or removal of heads, isolating blinds, blind flanges, man ways, process piping or equipment that has been in service working on electrical equipment over 600 V removal of process valves and relief valves any maintenance work done by contractors construction work (includes the installation of new equipment and the modification of existing equipment)

5.5 Materials Handling5.5.1 Handling PipeDesignate a leader if working in a team of two or more persons. Team will follow his/her directions. Wear gloves and other appropriate PPE when handling pipe. Make sure stops to hold pipe from rolling are in place before moving pipe on a rack. Roll pipe away from, rather than toward you, to reduce the possibility of it rolling on your toes. Use a tether for loads above your head to help control pipe. The person in charge is responsible to determine if pipe contains Asbestos Containing Material (ACM) and ensure proper handling.


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Do not hold pipe on the end with your fingers inside, if the end comes in contact with another object your fingers could be injured.

5.5.2 Tractor Loader/Backhoe Unit OperationInspect the backhoe equipment before operating it. Give special consideration to: Installing step plates or other devices that provide suitable footing for the operator when moving between the backhoe and tractor seats. Installing an engine kill switch in an explosionproof housing near the backhoe controls to provide a fast means of killing the engine in an emergency. Modifying the exhaust system to minimize the possibility of igniting petroleum vapors or dry vegetation. The backhoe should be equipped with: lights on the front and back of the tractor suitable for use with the backhoe an easily accessible dry-chemical fire extinguisher on the tractor a rollover protection device. a noise device that beeps when the vehicle is backing. Inspect the trailer used to haul the backhoe to make certain it complies with prevailing motor vehicle codes. In addition, install the following: expanded metal or other suitable material to provide a non-skid surface on the trailer bed for tractor wheels side rails to aid in preventing the unit from slipping off the trailer during loading or unloading40 Chevron Pipe Line Company

a hydraulic control, or other device, to control the rate of tilting during loading or unloading (if applicable) adequate loading ramps, if required Maintain the tractor unit in a safe operating condition. Be thoroughly familiar with the manufacturer's instructions regarding maintenance, operation and safety precautions. Take the following precautions during the operation of this equipment: Only the operator is allowed on the equipment. Do not make mechanical adjustments while the unit is in motion. Do not repair hydraulic hoses while they are under pressure (e.g., loader bucket raised, backhoe raised, or engine running). Rest loader and backhoe buckets on the ground and set the brakes when the unit is left temporarily. If the unit is left unattended for a longer period, turn off the engine; place the transmission in park, and remove the key from the ignition. Have the operator check for clearance before moving the unit. Keep co-workers and bystanders clear of the unit while it is in operation and while loading or unloading on the trailer. Drive at a speed that allows you to maintain control of the vehicle and ensure the safety of yourself and others.

5.5.3 Powered Industrial Truck (PIT or Forklift) OperationsNo employee who is currently unqualified may operate a forklift truck. Each forklift truck operator must re-qualify at least every two years.


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Before a forklift truck may be operated the first time during a shift, the forklift operator must complete an inspection checklist. Keep a copy of the checklist for three years. To prevent unexpected movement of the vehicle, do not unload any truck or cargo trailer that is not secured. As a minimum, set the brake and place chocks under the wheels of the vehicle. Any employee who is working near a forklift truck must notify the operator of his/her activities. Each employee must be careful to avoid entering the path of a moving forklift truck. Guidelines for safe forklift operation: use seat belts report any damage or problems that occur to a forklift during a shift dont jump from an overturning forklift. Stay with the truck. Hold on firmly. Lean in the opposite direction of the overturn use extreme caution on grades and ramps on grades, tilt the load back and raise it only as far as needed to clear the road surface dont raise or lower the forks while the forklift is moving dont handle loads that are heavier than the weight capacity of the forklift operate the forklift at a speed that will permit it to be stopped safely slow down and sound the horn at locations where vision is obstructed look toward the travel path and keep a clear view of it

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dont allow passengers to ride on forklift trucks unless a seat is provided when dismounting from forklifts, set the parking brake, lower the forks or mast, and neutralize the controls dont drive up to anyone standing in front of a bench or other fixed object dont use a forklift to elevate workers who are standing on the forks elevate a worker on a platform only when the vehicle is directly below the work area whenever a truck is used to elevate personnel, secure the elevating platform to the mast or forks of the forklift use a restraining means such as rails, chains, or a full-body harness with a lanyard or deceleration device for the worker(s) on the platform dont drive to another location with the work platform elevated or with people on it

5.5.4 Cranes and Hoisting, Cables and SlingsCranes are machines used to lift, swing, and lower heavy objects or loads. Cranes shall be properly operated and maintained in accordance with manufacturer's guidelines and applicable regulations. Only qualified (certified and carry the certification on their person) personnel who are familiar with the equipment shall operate cranes and hoisting equipment. Only qualified (certified and carry the certification on their person) rigger who are familiar rigging shall rig load for hoisting.Safe Practices Handbook 2006 43

Check that the capacity of the equipment can support the weight of the material to be lifted. Operators must ensure that safe working capacities are posted on cranes, and that these capacities are not exceeded. Cranes shall be certified annually. Crane components (booms, cables, rigging, slings, shackles, fittings, fastenings, foundation mountings, control cables, etc.) and safety devices, shall be examined and determined to be functioning properly by the crane operator each day before starting operations. All cranes shall have a pre-operation checklist performed by the operator prior to use. The checklist can be a manufacturer or vendor check list. The examination shall include, but not be limited to, a visual examination for: cracked welds cable defects bent braces sheave condition deformed or broken hooks load indicators stops evidence of overloading excessive wear sharp bends knots equipment damage or any other defects In addition to these before-use inspections, Maintenance-related inspections shall be made on cranes and their cables and any other lifting devices. Records of these periodic inspections shall be maintained.

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The crane operator shall not operate the crane until persons involved have been instructed as to the work to be performed. Employees shall be clear of a load before it is picked up or landed and must remain clear at all times. Employees shall not stand/pass under suspended loads. Cranes shall not be operated in adverse weather conditions (lightning storm, high winds, rain, etc.). The operator of a truck-mounted crane shall check truck positioning and anchoring prior to use. The wheels shall be chocked to prevent the truck from moving. If the truck is so equipped, maxi brakes shall be set. Outriggers shall be properly used and positioned when available. Outriggers shall not be used in the place of wheel chocks. Wire rope and wire rope slings shall be lubricated to protect against wear and corrosion. Slings must be inspected before each use. Chain and fabric slings shall have an identifier indicating manufacturer, load rating, and date placed in service. This identifier shall not be removed. Slings must be inspected before each use. Lifting accessories (chains, slings, etc) should be stored away from direct contact with adverse weather and conditions when not in use. Slings must be inspected before each use. Boom angle indicators shall be permanently attached to the boom to show the operating radius. The rated load capacity/boom angle of the crane shall not be exceeded. The crane operator shall check the load chart, confirm boom length with chart, and establish load weight and maximum operating radius or corresponding minimum boom angle.


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Practice extreme care when operating or working around equipment such as portable cranes, power shovels, and forklifts. Do not ride on equipment except in seats provided for that purpose. If you are operating equipment and cannot see the load from your position, you must have the assistance of a co-worker and use the appropriate crane hand signals. For cranes with a lifting capacity of three tons or greater, a properly trained signalman shall work with the crane operator. Standard signals shall be used. Normally, all signals shall be given by the signalman, but the operator shall obey any emergency stop signal given by anyone.CRANE SIGNALSHOIST LOWER STOP

EMERGENCY

STOP

SWING

TRAVEL

RAISE BOOM

LOWER BOOMMOVE SLOWLY

TELESCOPING BOOMSEXTEND BOOM RETRACT BOOM

DOC EVERYTHING

Taglines shall be used when it is necessary to control the load. During operation, at least three wraps of cable shall be maintained on the drum at all times. During operation, at least three wraps of cable shall be maintained on the drum at all times. Never stand at, near, or in line with a rope or cable that is under strain or within a loop that could tighten.

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Employees shall wear gloves and appropriate PPE when handling wire rope slings. Boom stops shall be provided on crane booms to prevent the possibility of overtopping the boom. Platforms, walkways, steps, handholds, guardrails, and toe boards shall be provided on cranes where necessary. Crane hooks shall not be used without safety bolts or latches. The crane boom shall be kept in the cradle when not in use. The operator shall properly secure the crane and boom before going off duty or when shutting down operations. Minimum required clearances from overhead highvoltage lines shall be maintained in all directions:Line Voltage Minimum Required (Phase to Phase) Clearance (Feet) < 50k 50k - 75k 75k - 125k 125k - 175k 175k - 250k 250k - 370k 370k - 550k 550k - 1000k 10 11 13 15 17 21 27 42

Except where electrical distribution and transmission lines have been de-energized and visibly grounded on both sides of the work area, or where insulating barriers not a part of or an attachment to the crane have been erected to prevent physical contact with the lines.

In transit with no load and boom lowered, the following minimum clearances shall be maintained:Line Voltage Minimum Required (Phase to Phase) Clearance (Feet) < 50k 50k - 345k 345k - 750k 4 10 16

When working in areas with power lines: the area of the work and paths of equipment travel shall be surveyed to identify locations of all overhead power lines


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a person shall be assigned to observe the operation of the equipment and power lines high voltage proximity alarms should be mounted on the crane boom5.5.4.1 Inspection Criteria

Lifting equipment presenting any of the following conditions shall be immediately removed from working area and replaced as needed.Acid Damage

Examples of Wire Rope Sling Abuse

Heat Damage

Broken Wires

Cuts

Worn WiresCuts & Tensile Damage

Corroded

Abrasion Damage

Bird CagingFace Cuts

Punctures & Snags

Tensile Breaks

Kinked and Crushed

Worn and Deformed AttachmentsIllegible or Missing Tag

Taken from the World Wide Web http://www.lift-all.com/PDF/WebSlings/WebSlingGeneral.pdf

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5.5.4.2 Capacity ChartHOW ANGLES EFFECT SLING STRESS1. Divide the total load to be lifted by the number of legs to be used. (This provides the load per leg if the lift wher being made with all the legs lifting vertically.) 2. Determine the angle between the legs of the sling and the verticle. 3. Then, MULTIPLY the load per leg by the LOAD FACTOR for the leg angle being used (from the table at right) to compute the ACTUAL LOAD on each leg for this lift and angle. NOTE: THE ACTUAL LOAD MUST NOT EXCEED THE RATED SLING CAPACITY. LEG ANGLE (Degrees) 0 5 10 15 20 25 30 35 40 45 50 55 60 LOAD FACTOR 1.000 1.003 1.015 1.035 1.064 1.103 1.154 1.220 1.305 1.414 1.555 1.743 2.000

5.6 Hazardous Materials and Substances5.6.1 General PrinciplesBe certain of the properties of every substance you handle and take every precaution as directed. Know the protective equipment you need to wear. Consult your team leader and the Material Safety Data Sheet (MSDS) if you're ever in doubt. Employees should be aware of how chemicals and substances can contact the body and how that contact can be prevented. Handle all chemicals with caution. Avoid contact with the skin or eyes, and never put them in or near your mouth. Be sure to wash carefully after working with petroleum or chemicals. Many of these materials will not cause immediate burns but will irritate your skin if they are contacted repeatedly and not washed off thoroughly. Don't wear clothing or shoes contaminated with petroleum or chemicals; take a shower and put on clean clothing. If you find evidence of chemical spills - such as a visible fume or vapor cloud or a strong odor or eye irritation notify your team leader. If you suspect that you or a


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co-worker are reacting to a chemical exposure and have any symptoms - such as dizziness, headache, irritated nose, throat or eyes, coughing or nausea seek medical help and notify your team leader as soon as possible.

5.6.2 Safety Color CodingColor-coding provides a uniform system of identifying corrosive and toxic chemicals, hazardous equipment or conditions, and emergency safety equipment.

5.6.3 Storing Flammable LiquidsUse only safetyrated metal containers for flammable liquids as required by DOT regulations.Automatic Closing Flame Arrestor Vent Cap

Spout Small Storage Container Large Storage Container Large Dispensing Container

Store flammable liquids in designated cabinets and areas only; away from heat sources, electrical apparatus and other sources of ignition. Label all containers. Samples or other liquids with flash points less than 100 degrees Fahrenheit should not be stored inside of laboratories. Store them in a separate building in flammable materials storage cabinets provided for that purpose. Do not carry gasoline or other flammable liquids in the trunk of company vehicles. Flammable liquids may be transported in the bed of company trucks if they are in proper containers that are securely fastened to the bed. Gasoline or other flammable material shall be transported only in approved DOT (metal) safety containers.50 Chevron Pipe Line Company

Bonding and grounding procedures shall be followed during the transfer/collection of flammable liquids into portable containers to prevent ignition from static electricity. Plastic buckets do not conduct or dissipate static electrical charges and therefore shall not be used to collect flammable liquids, e.g., condensate samples, oil samples, etc.

5.6.4 Corrosive ChemicalsBefore using corrosive chemicals, note the location of emergency showers and eye wash facilities, as well as other nearby water sources. Take every precaution to avoid direct contact with corrosive chemicals. These chemicals may cause severe burns or poisoning. If you do come into contact with corrosive chemicals, immediately remove any contaminated clothing and flush the affected parts with running water. Eyes should be washed for at least 15 minutes; skin may need to be washed for 30 minutes to remove all traces of the chemical. After washing, consult a physician to see if further medical treatment is needed.

5.6.5 Solvents and Cleaning AgentsGasoline, distillate, condensate or any other similar flammable materials shall not be used for cleaning purposes (skin, clothing or machinery). It is a fire hazard and could cause flesh burns. The following may be approved by local management for use as cleaning agents if proper PPE is used: diesel fuel kerosene stoddard solvent or equivalent cold water cleaners (solvents or detergent base)


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Carbon disulfide, carbon tetrachloride, benzene, and halogenated solvents shall not be used as degreasers or cleaning agents. Stoddard solvent or equivalent, kerosene, or cutting agents shall be used for the purpose of shakeouts (cuts). Cleaning agents shall not be heated or used on hot surfaces or near flames. Rags that have been used with cleaning agents shall be placed in designated covered metal containers until they can be properly cleaned or disposed of. Skin contact with solvent liquids or inhalation of vapors shall be avoided. Nitrile, neoprene, or other suitable gloves shall be used to protect hands when using petroleum based solvents and cleaning agents. If a cleaning agent or solvent comes in contact with the skin, the affected area shall be cleaned with soap and water and a lotion applied to replace the natural body oils. Areas where cleaning solvents are used shall be well ventilated. Employees shall review cleaning agent container labels to determine if contents are acceptable for the intended use. Acceptable solvents shall be those listed in this section. Non-petroleum based products should be substituted where practical in parts washers. Fusible links on parts washers shall not be bypassed, disabled, or altered.

5.6.6 Using Tools Around Chemicals and GasesHandle tools with caution when working around acid, caustic substances or other hazardous chemicals. Be careful not to drop tools where they may cause chemicals to splash.

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Thoroughly clean all tools after working with hazardous chemicals. If the tools become heavily contaminated while working, wash them at once. Avoid using rope slings or lines near corrosive chemicals. If you must use a rope sling or line in this environment, carefully check it for wear after you're done and tag it identifying the hazard before returning it to the tool storage area.

5.7 Hazardous Communication (HAZCOM)5.7.1 List of ChemicalsThe company maintains an inventory or index of all chemicals used at each facility. This index, the Chemical Inventory, is available at each facility and from your team leader.

5.7.2 Material Safety Data Sheet (MSDS)The MSDS must be made available to each employee for review prior to handling hazardous chemicals. It contains precautions for handling, requirements for protective clothing, and a 24hour emergency number to reach the manufacturer who can tell you what to do in an emergency. Each facility must have its set of MSDSs for the chemicals normally used at that location. Contact your local safety specialist before bringing any new chemicals onto company property. An MSDS must accompany each chemical brought onto the work site regardless of how long it will be used there. The MSDS must be obtained from the manufacturer and reviewed for possible health hazards and handling concerns.Safe Practices Handbook 2006 53

Chemicals that will be used or stored routinely at the location must be added to the chemical inventory for that location.

5.7.3 Material LabelingAny container containing chemicals must be labeled with the name of the substance and any hazards associated with it, regardless of the size of the container. There are three main systems of hazard warnin

CPL Handbook 2006

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