Contractor Safety Handbook Hro

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Houston Refinery
Safety, Health and Environmental

Handbook for Contractors
For a copy of the HSE procedures, the contractor may request a copy from the site Point Of
Contact (POC)
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This Handbook Belongs To:
Contractor Name: ________________________

Company: ______________________________
Telephone: ______________________________
I have read the contents of this manual and will comply
with them. I understand this is a guideline and does not
replace plant procedures and policies. Each employee is
expected to correct or stop any unsafe act to prevent
incident or injury.
The Site Leadership personally welcomes you to the

LyondellBasell Houston Refinery. We are committed
to an injury-free facility and know that you are the
backbone to our success.
When you enter this facility, you are a part of an elite

TEAM with excellent Safety and Environmental
standards. It is a condition of employment to uphold
these standards and follow all Refinery policies and
procedures. Our goal is to always work toward the
following.
GoalZERO
starts with me…
WELCOME TO OUR FACILITY!

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TABLE OF CONTENTS PAGE
Rules of Performance 4
Purpose and Scope 5
HSSE Contacts 6
Contractor Responsibilities 7-8
General Plant Requirements 9-26
Emergency Procedures 27- 29
General Safety Rules 30 - 49
Life Critical Procedures & Work Permits 50- 72
Industrial Hygiene 72- 66
Environmental Requirements 78- 81
Incident Reporting & Medical Treatment 81-82
Hand Safety 83
Safety Reminder 84
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Rules of Performance:
------------------------------------
We are committed to preventing all injuries, incidents and
work-related illnesses.
Rule No 1. Working safely is a first and forever expectation.
Rule No 2. Intervene – act to stop anything you think is unsafe.
Rule No 3. Take the necessary time to complete the task

properly.
Rule No 4. Wear proper PPE and follow approved procedures.
Rule No 5. Use equipment correctly – never misuses a dedicated

system or bypass safety devices.
Rule No 6. Produce products and services that meet or exceed

customer expectations.
Rule No 7. Make sure you have the proper skills and knowledge
to do your job.
Rule No 8. Report injuries and incidents promptly.
Rule No 9. When a situation is not understood, move to a safe

condition and get help.
Rule No 10. Take care when making changes; document your

actions and verify safety is not compromised.
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PURPOSE AND SCOPE

This manual is designed to provide contractors a
reference source for basic health, safety,
environmental and security rules, procedures and
precautions to be used while performing work at the
Houston Refinery.
A publication of this size cannot encompass all of

the safety procedures for every situation or
condition, but does provide general guidance to
reduce potential incidents and control losses. This
handbook is not intended to replace a contractor
safety program nor summarize all the safety, health
and environmental regulations governing the
contractor’s operations.
The primary focus of the Refinery safety program is

to prevent incidents and control losses. It is our
intention that EVERY individual goes home in the
same condition as they came to work. Arrive home
safely to your family. Familiarization with this
handbook will help accomplish our goal of an injury-
free facility.
Should situations arise which are not covered in

these guidelines, or if you have a question about a
guideline, contact your supervisor and he/she will
answer it or contact a Refinery representative for
clarification.
Contact (POC)
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REFINERY HSSE CONTACTS

Emergency Number –
In Plant Phone x4444
Emergency Number –
Outside Plant Phone 713-321-4444
SAFETY CONTACT:
HSE Department Contact: 713-321-4677
Environmental Contacts
Solid Waste Coord. 713-321-4969
FE Coord. 713-321-5449
Environmental On-Call: 713-304-7875
ALL HEALTH, SAFETY AND ENVIRONMENTAL

PERSONNEL MONITOR HOUSTON REFINERY
RADIO CHANNEL HSE 1
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CONTRACTOR RESPONSIBILITIES
1. Contractors and their employees shall comply
with all Houston Refinery Health, Safety, Security &
Environmental policies and procedures, the policies
and procedures of their company, as well as all
applicable federal, state and local regulations and
ordinances. Failure to do so will result in removal
from plant property.
2. The Contractor shall supply all safety and

personal protective equipment (PPE) required to
complete the scope of the contracted work (or as
stated in the Contract). Equipment supplied by the
contractor must meet or exceed all Refinery
requirements and the requirements of the
appropriate governmental regulatory agency.
3. The Contractor shall ensure that ANY chemical

brought on site is approved by the Houston Refinery
Industrial Hygiene and has a current SDS in the
system. Contact your Refinery Job Contact if there
is any question.
4. The Contractor must obtain necessary disposal

manifests and approvals before arranging waste
shipments. All waste disposals will be coordinated
through the Environmental group.
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5. Contractors shall provide a competent, well-
trained supervisor at the site at all times during
which their employees are present.
6. The Contractor shall designate an HSE

Representative who is knowledgeable about the
facility and regulatory Health, Safety, Security and
Environmental policies and procedures. This
individual shall be the Contractor’s primary contact
for any HSE issues while at the Houston Refinery.
Contractors during a Turnaround will provide Safety
Supervisors on days and nights that will attend
meetings and perform safety audits.
7. The contractor shall report ALL injuries, illnesses

and incidents (including near misses) to their
supervisor who will contact their Refinery Contractor
Coordinator (x5241).
8. Contractors shall actively participate in all

Refinery HSSE practices as directed by Refinery
management including but not limited to the
following:
 Job Observations ● Gate Pass &Visits
 Toolbox Meetings ● HSSE Audits
 Morning Stretch ● Total Incident Reporting
 JSA System ● Daily Walkabout
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Failure to actively participate in HSSE practices
will represent a significant deviation to Refinery
HSSE policies.
The contractor’s employees must be familiar with
the contents of this handbook and will be held
accountable for complying with the provisions stated
herein.
GENERAL REFINERY REQUIREMENTS
Refinery Training and Orientation
 Attend and pass Safety Awareness 5 (19SA5),

available only at Houston Area Safety Council
(HASC)
 Or, attend and pass Basic Orientation Plus/Basic
Orientation Plus Refresher from a safety council
that is a member of the Association of Reciprocal
Safety Councils, Inc. (ARSC) such as HASC
 Attend and pass the HRO Site Specific Orientation
LyondellBasell Houston Refinery Site Specific
delivered at the Houston Area Safety Council
(HASC) or other ARSC members. Check with the
appropriate council for availability
 Contractor’s employees must attend orientation/
training prior to initial work at LyondellBasell sites
and orientation/ training must be repeated
annually. Any Contractor employee entering
LyondellBasell sites must have a government
issued ID badge (TWIC) for identification in
addition to proof of completing the approved
safety orientation program before an access
(TWIC) will be issued.
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 Visitors who do not perform any “hands on work”
can receive the Visitor’s Safety Orientation at the
main gate. A Refinery authorized person must
approve their entry to the Refinery.
General Safety
Personal Protective Equipment (PPE)

Your employer is responsible for ensuring you are
equipped with approved personal protective
equipment. Minimum requirements include:
 Hard Hat (Z-89.1) hard hats are to be worn with
bill protection facing forward for general work
practice. Allowances are acceptable for specific
tasks such as welding and grinding, provided the
manufacturer approves the use with the
suspension reversed. There must be a valid need
for a hard hat to be worn in any other way other
than as designed.
 No hat must be worn under the hard hats (unless
welders with welder caps or cold weather liners
designed for this purpose).
 Nothing must be stored between the hard hat
suspension system and the hat shell that would
affect the performance of the hard hat.
 Chemical goggles on hard hat at all times
and worn in locations designated as chemical
goggle required areas, where required by
specific tasks and during periods of high wind
to prevent airborne particles/dust from
entering the eyes. Goggles should be donned
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carefully so as to protect against any debris
or dust that may have collected on the top of
the goggles).
 Safety glasses with hard side shields.

Wearing sunglasses is prohibited between
sundown and sunup, during a confined space
entry, and while working inside buildings.
Ultraviolet eye protection worn during open
flame operations is exempt.
 Safety-Toe footwear (impact resistant)(Z-41) is
recommended.
 Hearing Protection
 H2S Personal Monitor must be worn within one
square foot of breathing zone.
 Fire Retardant Clothing (FRC). If wearing FRC
shirt and pants, the shirt must be tucked in.
 Additional PPE will be required for certain tasks
and shall be noted on the permits issued to the
contractor performing the work. Always wear the
PPE listed on the permit for the work you are
performing.
Hand Protection
 In an effort to minimize the number and severity of
hand injuries, protective gloves are required to be
on your person and must be worn by anyone
conducting any manual work on site. Activities
requiring protective gloves include climbing
ladders, entering and climbing inside vessels, and
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handling hoses. Also see HRO’s ten cardinal
rules on page 82.
Hearing Protection
 Hearing protection is required while at the Refinery
in process areas and adjacent roads.
 Dual-hearing protection (ear plugs and earmuffs)
may be required if certain activities exceed
101dBA. Contact site IH Personnel for a noise
survey as needed.
Physical Readiness
 Contract personnel should know their physical
limitations regarding lifting, climbing, kneeling,
crawling, pushing & pulling prior to beginning a
task.
 Begin your day with some easy stretching
techniques to help warm up your body prior to any
physical activities.
Back Injury Prevention

 The Refinery encourages contractors to have a
back injury program in place, which includes
medical history and screening new hires.
 Always be aware of body position.
 We encourage warming up and stretching before
starting a task.
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Heat Stress
 Implement Heat Stress Prevention Plan
 Work/ rest regime (i.e. 75% work and 25% Rest)
 Rest in shade or air conditioning
 Confined spaces can not be entered until the
temperature (dry bulb per thermometer) is less
than 100 degrees Fahrenheit.
 Notification will be given to employees and
contractors that the atmospheric temperature and
relative humidity may be conducive for heat related
conditions. >100º F.
 Once a job is identified as having a high heat
stress potential, steps should be taken to control or
eliminate the condition. Examples include using an
air mover, shading from sunlight, working hot jobs
during nights or mornings, use of air conditioning
and personal cooling devices, etc.
 During high heat, it is recommended that one cup
of water be consumed every 20 minutes. Do not
drink coffee, sodas, energy drinks or tea for fluid
replenishment. These products have caffeine and
are diuretics, which will extract additional water
from the body.
 Observe others for potential signs of heat stress.
Use the “Buddy System.” Watch out for each other.
 Factors other than weather could generate a
potential heat stress condition. Cooling towers, fin
fans, fire heaters (furnaces), PPE (Chemical
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Protective Clothing (CPC)), etc, could create
additional potential heat stress issues. Employees
need to be continuously aware of the signs and
symptoms and take precautionary measures.
Chemical Contact
 Always be aware of the nearest safety shower and
eyewash station. Operations will point them out
when issuing permits.
 Try the safety shower and eyewash station prior to
beginning task.
 If you are splashed with a chemical, proceed to the
nearest safety shower and wash the affected area
for a minimum of 15 minutes. Report this incident
to your Refinery representative.
Job Safety Analysis (JSA)

 A JSA will be filled out before each task is started.
Contractors may use their JSA or the Refinery
JSA.
 Each employee must analyze the assigned task for
hazards and fill out a JSA before commencing
work. The complexity of the job determines the
extent of the JSA. Complex tasks may require
detailed explanations for the necessary safety
measures, with additional emphasis placed on the
most potentially hazardous tasks. Other tasks may
only require brief and easily described
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explanations. The employee should ensure that
any hazards present are explained and understood
by each co-worker involved in the task.
Furthermore, employees should ensure that the
preventative measures are fully understood as
well. Each co-worker should demonstrate a
thorough understanding of every safety instruction
given on each job they are to perform. They should
encourage co-workers participation and solicit their
input in the JSA process. Each employee should
assure that the needed safety equipment is
provided. Each different craft employee must
initiate their own JSA since each task will have
different hazards associated with the task.
 Each task or change in job scope requires a JSA.
 Any new team members are required to review the
task with the others and the JSA before starting.
Working Hours
 Contractor work hours may vary based on
assignment, check with your Refinery job
representatives for specifics.
 For example work hours could include:
 7AM to 3:30PM, M-F and 7AM to 5:30PM M-Th
with 30 minutes for lunch.
 Special Projects or Turnaround schedules may
consist of two ten hour shifts per day, six or seven
days per week. As an example the work may be
7AM to 5:30PM and 7PM to 5:30AM with 30
minutes for lunch.
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Fatigue Policy:
The purpose of this policy is to minimize the
occurrence of incidents in which the potential
underlying cause (or significant contributing factor)
is fatigue of employees. This policy
communicates the Houston Refining extended
work schedule requirements related to fatigue and
the policy for implementing them; and applies to
Houston Refining and contract personnel.
Fatigue Day Schedule

At times business needs require employees to work
extended hours in the work day and/or additional
days in the
Work week(s). During such periods the following
policy will be adhered to. Work schedules will be
assigned to meet business needs. This may include
extended hours in the day and 7-days per week.
 Each employee and Responsible Supervisor
will dialog to create a schedule that mitigates
fatigue issues for the employee.
 Employees will not be scheduled to work more
than 16 consecutive hours.
 No more than 2 consecutive 16 hour days will
be scheduled or worked.
 After 2 consecutive 16 hour workdays,
employees will take at least 16 hours off prior
to working another 16 hour shift.
 If the turnaround/project/extended work
schedule is anticipated to last for more than
13 days the scheduling of fatigue days shall
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be planned from the beginning of the work
schedule or as soon as feasible.
 Days off will be scheduled in advance to
minimize disruption to the business and
maximize potential to reduce fatigue.
 No more than 13 consecutive days can be
worked without a day off.
 For additional information reference:
HOUSTON REFINING FATIGUE DAY
POLICY through your Refinery job
representative
Parking and Traffic

 All contractors will park in designated parking
areas. Check with your Refinery job representative
for specifics. Signs and roads are clearly marked
identifying the parking areas. Use caution and be
courteous when entering and exiting the parking
area. Follow Security officer’s direction entering
and leaving the facility.
 Vehicles parked in unauthorized areas in the unit
and parking areas will be towed.
 All vehicles entering the Refinery are subject to
search up to and including all toolboxes and
compartments.
 Contractor Vehicle entering the refinery must have
a valid gate pass and a contractor inventory list.
 Parking inside the Refinery will be in designated
areas only.
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 Do not park in roadways or block access to any
fire monitor or emergency equipment.
 Keys must be left in the ignition of ALL parked
vehicles within the gates of the Refinery, except
when parking in designated parking lots outside of
the unit areas.
 Security cameras survey the parking areas and
security officers will make routine rounds in parking
areas.
 Explosives, firearms/ammunition, matches and
lighters, drugs, narcotics or alcoholic beverages of
any kind are prohibited in the parking areas. All
posted speed limit and warning signs will be
followed.
 These listed rules will be strictly enforced.
 Temporary Facilities, Offices and Storage
 Contractor temporary facilities (i.e. offices, lay-
down yards, fabrication shops, equipment yards,
etc.) areas will be predetermined. Your Refinery
job representative must approve any and all
facilities.
Smoking, Matches, and Lighters

 Smoking will ONLY be allowed in the designated
areas and ONLY before work, at lunch, natural
breaks and after work.
 Smoking in non-approved areas in the Refinery,
including all temporary and permanent buildings is
strictly prohibited. Smoking is only permitted in
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approved smoking areas (bull pens) that are
clearly marked with signs reading “SMOKING
PERMITTED HERE.” Smoke pens must be
equipped with a smokeless butt can, a trash can
and at a minimum a 10# ABC fire extinguisher.
Safety matches and lighters with caps covering the
striking mechanism are recommended. The use of
strike-anywhere matches (wooden or kitchen
matches) and butane lighters are prohibited.
 Temporary smoking areas may be approved for
some construction projects. All smoking areas are
approved jointly by the department responsible for
the area and the Area HSSE Representative.
Toilets
 The Refinery will supply and service sanitary
facilities for all contract personnel. Special Projects
or Turnaround contractors shall use the Portable
Chemical Toilets furnished. Do not use the sanitary
facilities located in the Refinery Control Buildings
and shops without permission from the refinery
personnel.
 Some portable facilities may be designated for
female use only.
 Keep the area clean and be respectful of the next
person who will use these facilities.
 Contact your Refinery job representative if facilities
are in need of service.
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 Any vandalism of portable toilets including
carving, graffiti, or defacing in any way will lead to
disciplinary action.
Lunch
 Each contractor working at the Refinery will be
assigned a lunch area through your Refinery job
representative. You must eat at your assigned
area. These areas must be kept clean.
 Food and drinks are not allowed outside of
designated lunch areas.
 Do not place hard hats, gloves or any PPE on table
tops.
 Water coolers will be located at designated
locations throughout the plant. They must stay
taped closed. Do not add anything to the drinking
water or break the seal for any reason.
Facial Hair
 All personnel that enter PPE required areas of the
refinery shall maintain their face free of facial hair
that interferes with or has the potential to interfere
with the sealing surface of the respirator and/or the
respirator exhalation valve.
 Facial hair growth includes: any beard (including
goatee), mustache and /or sideburns extending to
the respirator seal area. Mustaches may extend
past the corners of the mouth so long as they do
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not go past the crease in the chin. Any facial hair
below the lower lip must be properly trimmed so it
will not interfere with the sealing surface of the
respirator and/or exhalation valve.
Contractor Conduct
 Plant Policy prohibits weapons, theft, falsification of
records, fighting, intoxication and the possession or
use of alcohol and controlled substances.
 Prescription medication is acceptable only when its
use will not affect job performance in the opinion of
the prescribing physician and must be approved
through your company.
 No gambling or soliciting of any material is allowed.
 These rules are strictly enforced
Refinery Access
 The LyondellBasell Houston Refinery is regulated
by the Maritime Transportation Security Act and
33 CFR Part 105. Any violation of refinery access
control measures specified in this handbook is
possibly a violation of federal law. Unauthorized
access to the refinery is considered a security
breach and must be reported to federal
authorities.
 Refinery access is by electronic card readers at the
entrance to the gates using your TWIC.
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 “Piggy backing” to allow multiple entries with one
badge or using someone else’s badge to gain entry
is prohibited and violators will be removed from the
property.
 All personnel traveling in vehicles with Refinery
access passes must swipe their TWIC at the gates
when entering and leaving the refinery. The
vehicle driver must ensure all personnel riding in
the vehicle swipe their TWIC at the gate before
driving into or leaving the Refinery.
 All contract vehicles entering the Refinery are
subject to inspection. Lunch kits, bags, etc. may be
checked entering and leaving the facility.
 Theft of any company property and/or having any
contraband will be reported to law enforcement
officials.
 In order to reduce traffic congestion, only
Contractor work vehicles with a legitimate business
need and meeting insurance requirements are
allowed access in the Refinery.
Vehicle Operation
 Vehicles must have the appropriate logo or name
displayed on the door before entering the refinery.
Posted speed limits, other traffic signs and state
and local laws must be adhered to the vehicle at all
time (i.e. seatbelts and inspection). Vehicle parking
and traffic should be minimized around unit and
turnaround areas at all times.
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 Passengers may be transported in the back of
pickup trucks as long as they stay seated in the
bed and are not seated on the sides or the fender
wells of the truck. Proper PPE is required while
riding in the back of the pickup truck. This includes
fire retardant clothing (FRC), safety glasses with
side shields, approved footwear, hard hat with
attached chemical goggles on hard hat, hearing
protection and gloves on person and H2S personal
monitor.
 Contractor personnel must go through their
Refinery Contact Person before requesting a
decal. Decals can be obtained at the Security
Office above the Main Gate. Check with the Main
Gate for specific times in which decals are issued.
Proof of vehicle insurance, drivers license and
vehicle license plate number must be provide to
security personnel be fore the decal will be issued.
 Contractors are required to have an Inventory List
for equipment and tools are their vehicle. The job
representative or designee must complete the
inventory list prior to entering the facility and must
remain with the vehicle at all times. The same
Inventory List will be required when exiting the
facility. Ask your Refinery job representative for a
copy of the refinery Gate Pass Procedure.
 Use of mobile phones (i.e. calls, text messages,
etc) while driving is prohibited, including hands free
devices.
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NOTE: “Carts and bicycles will not be allowed
inside the battery limits during turnaround activities”.
 All road closures must be approved at least 24

hours prior to the road closure. Road Closure
Permits may be obtained at the Refinery’s Main
Gate and must be approved by the Refinery
Emergency Management and Security Supervisor
or designee (i.e. main gate).
Bicycle Safety
 Bicycles shall be equipped with front and back
reflectors or red striped reflection tape.
 Bicycles equipped with baskets shall have basket
liners.
 Bicycles may not be ridden over railroad tracks.
Bicycles shall be walked over the tracks.
 Minimum appropriate PPE must be worn to match
the local area requirements if riding in a PPE
designated area
 Bicycles riders shall stop at stop signs
 Bicyclists shall not ride against normal traffic flow
Railroad Safety
Railroad traffic at HRO is a 24/7 operation that
includes from 4 to 7 active rail lines that travel
from east to west across the refinery parallel to
Louisiana Ave. Additionally, a rail spur runs
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parallel to El Paso Street and travels north and
south.
 It is imperative that all vehicle and pedestrian
traffic obey the Stop Signs and the train horn.
 Do not cross the rail line when the train is near
the crossing and sounding its horn.
 Pedestrians must not cross the tracks near
moving trains and they must not move
 in between rail cars.
 Do not cross the tracks anytime the cross
arms are down at the roadways.
 Personnel must cross the tracks at authorized
crossings only. For personnel working near the
Coker complex a pedestrian bridge is located on
the east side of the 736 Coker that crosses
Louisiana and the rail tracks. There are other
hazards with crossing the tracks besides the train;
uneven tracks, rocks, and possible damaged rail
ties.
 Rail tracks that are Blue Flagged may indicate
no rail car movement allowed. It is imperative
to still Stop, Look both ways, Listen and Look
again before moving across the tracks.
 Remember one rail line may not be active but
another may have moving rail cars. Please, Stop,
Look both ways, Listen and Look again before
moving across the tracks. Never stop your
vehicle on the tracks, if your vehicle stalls on the
tracks get out and away from the tracks and get
help to move your vehicle. Call your supervisor or
Security at 713-321-4211 for assistance.
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Cameras
 Cameras are not allowed in the Refinery or Dock
facilities without a pass.
 A Camera Permit Badge must be obtained by the
photographer from the Main Gate Dispatcher.
 Camera permit must be worn on the outermost
clothing at all times while photographing in the
facility.
 A unit sign in and gas check (LEL) are required
when using a camera inside process areas of the
Refinery.
 A Refinery employee/contact person must
accompany the photographer (if the photographer
is not LyondellBasell employee) while in the
facility.
 Pictures or film removed from the Refinery must
be approved.
Refinery Buildings
Contractors are prohibited from entering any
refinery building, shop, laboratory, etc. unless there
is a specific permitted work requirement or you are
instructed so by your Refinery representative.
Cellular Phone Usage

 Cellular phones are not allowed in the operating
areas of the complex and are permitted in only
limited areas of the refinery unless it’s intrinsically
safe.
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 Camera phones are not allowed to take pictures
in the refinery.
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EMERGENCY PROCEDURES
Reporting Emergencies
Report all emergencies by dialing 4444 from any in-
plant phone. From an outside plant phone dial 713-
321-4444. Give your name, location, type of
emergency you have. Wait for the information to be
repeated back to you and confirmed before hanging
up unless it is unsafe to do so. You may also report
an emergency to any LyondellBasell personnel.
Emergency Alarm System

When the refinery alarm sounds it will be followed
by an announcement over the radio PA system.
Additional electronic announcements will be made
via the site computer network.
Contractor Response and Rally Points
Non-Essential Personnel Evacuation of a Unit /

Area
 Contract personnel that are working in the
impacted unit should leave the unit (sign out
of the unit if possible)
 Go to your assigned Rally Point and report to
your Accountability Coordinator
 If you cannot travel safely to your Rally Point,
report to an alternate safe Rally Point or
Evacuation Point and contact your
Accountability Coordinator
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 Only those working in the impacted area need

to stop work and leave the unit. All other
personnel can continue with their normal
activities
Non-Essential Personnel Evacuation Plant-Wide

 All contract personnel in the refinery should
stop all work and go to your assigned Rally
Point (sign out of the unit you are working in if
possible)
 Badge in on a Rally Point Reader
 Alternately, go to the gate from which you
entered the facility and badge out of the
refinery
All Personnel Evacuate a Unit

stop all work and go to your assigned Rally
Point (sign out of the unit you are working in if
possible)
 Badge in on a Rally Point Reader
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refinery
All Personnel Evacuate Plant-Wide

stop work and go to an Evacuation Point
 Badge in on a Rally point Reader at the
Evacuation Point
refinery
Returning to Work after an Emergency

 When the all clear sounds, proceed back to your
work site.
 Work may not commence until operations has re-
issued your permit or updated and initialed the old
one.
Personnel must be aware of the location of the

nearest Rally Point and On-Site Evacuation Point
at all times. The location of the nearest Rally/On-
Site Evacuation Point shall be identified prior to
work assignment.
Do not operate vehicles during any emergency.

Move the vehicle to the side of the roadway, shut
it off and leave the keys in the ignition and
proceed on foot to a Rally Point.
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GENERAL SAFETY RULES
Housekeeping
 It is the responsibility of all Contractors at the
Refinery to keep their work areas free of debris and
orderly.
 Daily walkthroughs will audit for housekeeping and
Toolbox Safety Meetings will review any issues.
 Keep materials out of aisles and walkways.
 When using electrical cords, air, water, or nitrogen
hoses, place them so they do not pose a tripping
hazard.
 Dispose of all used material in the proper trash
containers. If the container is full, make
arrangements to empty.
 Remove all trash and surplus materials from pipe
racks or platforms before coming down.
 Decontaminate, clean and return all safety
equipment to the proper location after each use.
 Do not discard used PPE without decontaminating.
 Remember that a clean area is a safe area. Unless
your work area is clean, Operations will not issue a
Work Permit and will not sign off as completed.
Scaffolding
 All scaffolding shall be constructed in accordance
with OSHA regulations (29 CFR 1910.28 and
1926.451). A trained competent person will
supervise all scaffold building and scaffold
alterations. Fall protection is required when
erecting or dismantling scaffolds.
 Scaffold Inspection – Construction Scaffolds
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o A construction scaffold is required to be
inspected and tagged by a competent person
before each shift of use. (i.e. turnaround, short
outages)
 Scaffold Inspection – Maintenance Scaffold
o A maintenance scaffold is required to be
inspected and tagged by a competent person
every 24hrs. (i.e. routine Operations or
Maintenance activities). And after any
occurrence which could affect a scaffold’s
structural integrity.
 Inspection tags affixed to the scaffold must be
updated to show proof of inspection.
 Scaffold builder's "Competent Person" who
performs the inspection must attach a tag holder
to the scaffold, approximately 5 feet from the base
of the access ladder, not attached to the ladder
rungs
 Tags must be completed and legible at all times.
Only one approved scaffold tag is to be attached
on the scaffold.
NOTE: Scaffolds shall not obstruct block valves, fire

extinguishers, and safety showers. Minimize
scaffolds that are built in main walkways.
 Trained scaffold users must verify proof of

inspection by reading the scaffold inspection tag,
review the hazards listed on the scaffold inspection
tag and visually check for any obvious hazards
prior to accessing any scaffold, including the need
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for fall protection. Any problems will be reported
to their supervisor.
 Any scaffold under construction or left unattended
prior to inspection must have a DO NOT USE
SCAFFOLD TAG or a scaffold tag holder with
the wording DO NOT USE SCAFFOLD affixed to
the scaffold.
 Completed scaffolds will be affixed with a scaffold
inspection tag shall include the following
information:
 Date erected
 Location
 Name of inspector
 Loading schedule (light, medium, or heavy duty)
 Hazards (missing hand rail, toe board, uneven
deck, etc.)
 Inspection date
Scaffold Tags:
 Green Tag – Denotes a completed scaffold
 Red Tag – Denotes an uncompleted scaffold that
must not be used
 Yellow Tag – Denotes a scaffold that can be
accessed, but requires special precautions or PPE
(wear fall protection, overhead obstacles etc.). The
tag shall indicate the hazard.
Ladder Safety
 The Refinery requires a full body harness and tie
off whenever employees are over 6’ or more above
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34
the working surface and the platform is not
protected by handrails. This is a minimum
requirement.
 Inspect all ladders before each use.
 Remove and tag-out any ladder that is unsafe for
service.
 All ladders brought into the Refinery must comply
with Refinery site procedures (Procedure 9:
Working at Heights).
 Position ladders so that the horizontal distance
from the base to the vertical plane of the support is
approximately one-fourth the ladder length
between the ladder and the support. (For example,
place a 12-foot ladder so that the bottom is three
feet away from the object against which the top is
leaning.)
 Do not position ladders in front of doors that open
toward the ladder unless the doors are secured to
prevent opening.
 Tie-off ladders before performing any type of work

from the ladder. Have a second person hold the
ladder in position at the bottom while it is being
securely fastened at the top level. A safety harness
is required when working from a ladder above six
feet.
 Ladders must extend at least three feet above exit
point, when exiting onto roofs or work platforms.
 Ladders must not be positioned against or near
(within reach) of unprotected electrical power lines.
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 Do not climb higher than the third rung from the
top of the ladder.
 Always face the ladder when ascending or
descending or working from the ladder.
 Set ladder on a solid level and secure surface.
 Keep shoulders between the side rails to prevent
falls.
 Do not carry anything in hands while climbing the
ladder. Always use a hand line and bag to hoist
tools.
 Keep base of ladder clear of tools and materials
 Maintain 3-point contact with the ladder.
Fall Protection
 Employees/contractors shall be protected by a
fall protection system when working/walking in
any area with an unprotected sides, or edges
that is six feet (6 ft) or greater above a lower
level. Fall protection may be required less than
six feet under certain circumstances – and shall
be a judgment call by the permit issuer.
 Fall Protection System - A system used to safe
guard employees from falls or from falling
objects. It consists of guardrails, ladder cages,
warning lines, barricades, wire mesh, canopy
structures, or a personal fall arrest system.
 Personal Fall Arrest System - A system used to
arrest an employee in a fall from a working level.
It consists of an anchor point, connectors, and
full body harness and may include a lanyard,
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36
deceleration device, lifeline, or suitable
combinations of these.
 Full Body Harness - A device made up of straps
which may be secured about the employee in a
manner that will distribute the fall arrest forces
over at least the thighs, pelvis, waist, chest and
shoulders with means for attaching it to other
components of a personal fall arrest system.
 Shock Absorbing Lanyard - A flexible line of
rope, or strap which generally has a connector at
each end for connecting the body harness to a
deceleration device, lifeline, or anchorage. The
shock absorbing mechanism on the lanyard is
designed to absorb up to 80% of the stopping
force of regular lanyard.
 100% Tie-off - Always being tied off when working
on anything other than an approved structure or
platform.
 Must be trained and understand the proper use,
care, and limitations of fall protection equipment
before use.
 All contractors shall supply and maintain their own
fall protection systems, training, inspection
program and record retention.
 Immediately report a fall where the fall protection
system is involved.
 Visually inspect your safety harness and lanyard
prior to use. If damages or defect are observed, the
system shall be tagged and removed
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Compressed Gas Cylinders

 Store cylinders in assigned places where they
cannot be knocked over or damaged.
 Individually chain cylinders if not in a proper
storage area
 Never drop cylinders or permit them to strike each
other violently.
 Keeps caps on cylinders where caps are provided
for valve protection, except when cylinders are in
use. Never transport cylinders without caps in
place.
 Never transport a cylinder suspended from a sling
(rope or chain). Transport all gas cylinders in
approved racks provided, or by securing on the
bed of a truck. Use of mobile equipment is
acceptable when a safe cradle or platform carrier is
provided to hold the cylinders securely in place.
 Never use cylinders for rollers, supports or any
purpose other than to carry gas.
 Cylinders shall be secured by means of a chain,
cable, or #9 wire. Rope is not an acceptable
substitute. Roll-around carts, metal box frame
enclosures and cylinders mounted on mobile
vehicles are acceptable, provided the cylinders
are secured by a substantial metal enclosure.
Some large volume compressed gas cylinders are
designed to be free-standing and have been
designed with built-in valve protection.
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38
 Open cylinder valve slowly. Use wrenches or
tools provided or approved by the gas
manufacturer.
 Secure the cylinder valves and regulators at the
end of the workday or for prolonged absence from
the job.
 Never tamper with the safety devices on valves on
cylinders or use cylinders without proper
regulators.
 The use of non-regulated, high pressure nitrogen

or compressed air cylinders for routine
maintenance activities is prohibited during normal
plant operations.
 During refinery turnarounds when refinery air or
nitrogen is unavailable, an exception will be made
allowing the use of high pressure nitrogen or
compressed air cylinders to test or calibrate
equipment. In these circumstances, the equipment
testing procedure must include the following items
as a minimum:
o A pressure reducing regulator to reduce the
pressure within the testing range. The
regulator set point must be below the
maximum allowable working pressure
(MAWP) of the equipment being tested.
 A pressure gauge with appropriate range to

accurately monitor within +/- 10% of the testing
pressure. Ideally, the test pressure should be
within 30 to 75% of the pressure gauge scale.
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39
 If the equipment being tested is not already

protected by a relief device, a pressure relief
device (relief valve or rupture disc) is required as
part of the testing system to protect the equipment
from being over-pressured in case of regulator
failure. The relief device set point must be at or
less than the maximum allowable working
pressure (MAWP) of the equipment under test.
 Never attempt to repair or alter cylinder valves. Tag

the damaged cylinders with “DANGER – DO NOT
OPERATE” tags and explain the problem for
vendor’s repairs. Remove damaged bottle from the
unit.
 Protect gas cylinders from exposure to heat at all

times. Place oxygen, acetylene and fuel gas
cylinders a safe distance from ignition sources.
 Do not tamper with numbers or permanent marking
on cylinders.
 Do not place cylinders of any type gas inside an

enclosure, vessel or tank.
 Segregate storage areas for breathing air cylinders
from all other cylinders.
Fire Extinguishers
All hot work requiring a fire watch will have a fire
extinguisher on the job site under the control of the
fire watch. Charged fire hoses will be specified by
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40
Operations on the permit. Fire watches must be
trained in the use and care of fire extinguishers.
All fire extinguishers shall have a current inspection.
Any fire watch must wear a bright colored vest and
radio/air horn.
Portable Fire Extinguisher “Quick Checks”

 This guide can be used for the inspection of fire
extinguishers located on golf carts, Gators, welding
machines, etc. and is intended to be used by the
equipment user/owner.
 NFPA 10, Portable Fire Extinguishers, explains in
section 1-3 that a quick check simply determines
whether the extinguisher is available for use and
appears to be in working order.
 “It is intended to give reasonable assurance that
the fire extinguisher is fully charged and operable,”
the code states. The quick checks must be done
on a monthly basis.
 If you have questions or problems with the visual
inspection, call your supervisor, foreman or Rental
Company if equipment is rented.
 Use the following checklist for your monthly fire
extinguisher inspections:
 Is the extinguisher in the proper location?
 Is the extinguisher accessible and visible?
 Is the operating tag of the extinguisher facing out?
 Is the tamper seal of the extinguisher intact?
 Does the extinguisher feel full? Use your best
judgment by lifting the extinguisher
 Is the shell of the extinguisher in good condition?
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41
 Is the stored pressure of extinguisher within the
allowable range?
 Is a hazardous material identification system label
on the canister?
 Is the discharge nozzle free of clogging?
 Initial and date the back of the service inspection

tag
 If you remove the extinguisher, remember to
immediately replace it with a properly working one.
Electrical Safety
 All workers not qualified for electrical work must
remain at least 20 feet away from any un-insulated
live electrical devices. The 20 feet rule includes
any tools or equipment that the worker is using.
 All electrical energy sources must be isolated and
the Lock Out / Tag Out Procedure used to prevent
any exposure to electrical shock.
 Inspect all portable electrical tools before each use.
Use only approved connections.
 Do not modify or change, in any way, the electrical
plugs or receptacles. This includes removing
prongs to make a connection.
 Portable cord and plug connected equipment and
flexible cord sets (extension cords) shall be visually
inspected, before use on any shift, for external
defects (such as loose parts, deformed and
missing pins, or damage to outer jacket or
insulation) and for evidence of possible internal
damage (such as pinched or crushed outer jacket).
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42
Cord and plug connected equipment and flexible
cord sets which remain connected once put in
place and that are not damaged need not be
visually inspected until they are relocated.
 Portable equipment shall be handled in a manner
that will not cause damage. Flexible cords may not
be used for raising or lowering equipment and may
not be hung in a manner that will damage the
cords outer jacket.
 Procedure 12 Electrical Safety is designed to
ensure that anyone working with or near electrically
energized equipment is protected from electrical
hazards. It includes minimum requirements for
extension cords, receptacles, and plugs on
portable hand tools and a process for periodic
testing and/or visual inspection of electrical cord
sets and receptacles that are not part of the
permanent wiring of a building or structure.
 Ground fault circuit interrupters (GFCI) will be used
for portable tools and lighting at all times. Inspect
and test all circuits before each use. GFCI’s will be
checked each shift before entry into a confined
space.
Grounding
The purpose of IEA-PRO-009 Temporary Grounding
of Portable Equipment this procedure is to provide
instructions on how to apply temporary grounds to
portable equipment along with identifying the specific
material needed. This procedure will also identify the
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43
needed equipment and specifications for grounding
equipment in close proximity to power lines.
 The procedure will cover but not limited to
generators, sandblasting machines, fuel tanks,
compressors, blast pots, welding machines, light
stands, frac tanks and equipment in close proximity
to power lines.
 Barricades shall be used with safety signs, to
define the 20’ exclusionary zone for non qualified
worker, when it is necessary to prevent access to
work areas where exposed energized circuits are
present.
 A qualified electrical technician shall perform all
electrical repairs.
 Grounding of portable equipment must be
performed by electrically qualified personnel or
personnel designated by IEA Engineering.
 HRO electricians are considered to be electrically
qualified personnel.
 References: HSSE Field Manual – Procedure 12-
Electrical Safety
 EA-PRO-009 Temporary Grounding of Portable
Equipment
 Electrical Safety Policy IEA-POL-001
Temporary Electrical Cables Routed at Grade

 Cables should be routed in a way as to minimize
traffic around the cable.
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44
 If a cable must be routed through a walk way, a
ramp or scaffold bridge shall be constructed over
the cable.
 Cable shall be labeled or identified with red
barricade tape or something comparable.
 A fence of scaffold materials shall be constructed
on both sides of the cable route to permit crossing
the cable at only designated locations where the
cable is protected by a walkway, ramp or scaffold
bridge.
 Electrical cables can be covered in a variety of
ways. The list below is not all inclusive.
 Cable tray can be used to route cables at grade.
With the cable tray having raised sides, a top
cover does not have to be built over the cable.
Cable tray must have red barricade tape
identifying the hazard of the energized cable.
*** Caution ***
 At no time are any nails to be nailed into a

material in close proximity to a cable
 A wooden cover may be built along side the cable;
after the wooden trough is constructed it can then
be placed over the de-energized cable.
 Special attention must be made to verify the cable
is not damaged due to protruding sharp objects.
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45
 Sturdy PVC pipe may be used to cover cable at
grade. This will be approved on a case by case
basis.
Inspection
 After the electrical cable is covered, the insulation
integrity shall be tested with a 1000v dc megger
test.
 The final inspection will be performed by an
electrical supervisor, electrical specialist, electrical
engineer or a designee.
Contractor Tools and Equipment

 All equipment brought into the Refinery must be
inspected and in safe working operating condition.
All guards and safety devices must be in place and
must meet all applicable Refinery, manufacturer
and government requirements.
 All portable electrical equipment will be inspected
by the contractor and marked with the appropriate
inspection colors per the Houston Refinery
inspection and testing process.
 Follow the Refinery maintenance procedures for all
inspections, at a minimum.
Transfer of Flammable Liquids to Containers,

Equipment and Vehicles
 The vehicle or equipment operator will use the
following precautions while refueling:
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46
 Any employee refueling a vehicle from the pumps
will wear flame retardant clothing.
 Select appropriate fuel for vehicle or equipment.
 Ensure that the vehicle or equipment engine is
shut off.
 Connect grounding cable to the metal of the
vehicle or equipment prior to refueling.
 Set meter to zero.
 Stand where fumes/vapors will not be breathed in.
 Begin refueling operation.
 Observe for leaks while refueling.
 When refueling is complete, remove the nozzle,
shut the pump off, record amount used, zero the
meter, replace filter cap and disconnect the
grounding cable.
 Fuel will only be pumped into approved fuel tanks
or safety cans having no visible structural defects
or leaks. If tanks are unattached to vehicle or
equipment, they must have a sign indicating the
correct fuel contents.
 Gasoline and diesel fuels will be stored in
approved tanks/containers only. Signs will be
properly affixed to the tank or container that
correctly identifies the fuel.
 An approved fire extinguisher must be readily
available during all refueling operations.
Cranes (Refinery Lifting Procedure, Fixed and

Mobile Cranes, “Above the Hook”)
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47
To ensure the safety of personnel and equipment
when cranes or other lifting devices are used. This
procedure shall be used in conjunction with all other
applicable rules and procedures in the Houston
Refining LP’s HSE Field Manual to ensure work is
completed in the safest possible manner.
 Rental and Contractor cranes must be inspected
prior to use in the Refinery complex. The Refinery
Crane and Rigging Department would be the
primary group to perform the inspections. The
Refinery Crane and Rigging Department
Supervisor will designate an alternate qualified
inspector if a Refinery Crane and Rigging
Department member is unavailable. The crane
inspector will complete the Mobile Crane Pre-
Operational Inspection Form. The cranes will be
inspected at the crane and rigging yard. All cranes
shall have proof of a formal annual inspection.
Crane Inspection
 Daily and monthly inspections are required for all
cranes. All inspections shall be executed using
required Refinery forms.
 A daily inspection Form must be in any crane that
is in use. Refinery Crane and Rigging Department
may audit use of crane inspections at any time.
Rigging Strategies
 Contractors using rigging shall be trained by their
employer in selection, inspection and rigging
practices.
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48
 Each contractor will need to have their slings
inspected by their designated competent person
verifying compliance and documenting inspection
process (e.g. inspection tags)
 All slings will be inspected prior to using the slings
on site.
 Any rigging that meets the retirement criteria shall
be discarded or removed from the Refinery.
 Softeners or sling protectors must be attached to
sharp points that sling may come in contact with
 Contractors performing rigging practices using
fixed equipment to lift from must know the weight of
the object they are lifting and size the correct
rigging needed for the lift.
 No slings will be attached around insulated
equipment or where the slings may come in
contact with the insulation.
General Lifting Requirements

When operating cranes or making material,
personnel or overhead hoists in the refinery, refinery
personnel and contractors shall comply with OSHA
regulations, the manufacturer’s specifications and
limitations, and best work practices, including but
not limited to the following:
• No operation of cranes within 20 ft. of overhead
electrical lines (see Procedure 12: ELECTRICAL
SAFETY).
• Rated load capacities, recommended operating

speeds, and special hazard warnings or
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49
instructions must be posted on all cranes.
Instructions shall be visible to the operator of the
equipment.
• Horns, flagman, standby personnel or other means
of warning shall be used prior to making a lift and at
any time the load is moving.
• Tag lines are required for control of suspended
loads.
• No work will be allowed under a suspended load.
• Cranes operated on plant roads shall follow all
plant traffic rules and shall require an escort if the
load or boom could interfere with the operator’s
vision.
• Areas within the swing radius of the rear
superstructure of the cranes shall be barricaded or
a flagman shall be posted to protect personnel and
equipment in the area.
• All required safety devices and safety interlocks
shall be in service and operating properly.
Outrigger Operation
 Set‐up of cranes 15 ton and above: immediate
area around cranes 15 ton and above must be
clear of all nonessential personnel before
extending outriggers. Only personnel assisting in
the setup of the crane shall be present and must
stay in constant contact with the crane operator.
 Set up of cranes below 15 ton: Before the set up
of any machine with direct deploy outriggers (carry
deck, drott, etc.) to make a lift, the area around all
outriggers shall be barricaded in such a way to
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50
ensure safe deployment of all outriggers, and
area shall be clear of personnel, including the
rigger. In addition, the crane operator and rigger
shall maintain visual and/or two way radio contact
while outriggers are operated.
 The exception is when a machine with direct
deploy outriggers is being parked and to be left
unattended. The rigger shall place an orange cone
at the left front outrigger and clear the area where.
Overhead Cranes
Pre-Shift Inspection
 All operators must be trained.
 Only use lifting devices you are familiar with and
trained to use.
 Is there a “Do Not Use” tag on the crane?
 Is the annual inspection current?
 Operate all of the controls to ensure they operate
correctly without sudden jerking.
 Know location of emergency stop.
 Inspect intended path of travel for adjacent work
activities and personnel.
 Move crane several feet in each direction.
 Conduct an inspection of the crane and all lifting
devices before each use.
 Insure the Crane and Lifting Device can handle the
weight of the load.
 Remember 1 TON = 2000lbs.
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51
LIFE CRITICAL PROCEDURES & WORK
PERMITS
 HSE-FM-001: SAFE WORK PERMIT

 HSE-FM-004: HOT WORK PERMIT
 HSE-FM-005: CONFINED SPACE ENTRY
 HSE-FM-006: LOCKOUT/TAGOUT
 HSE-FM-007: LINE BREAK
 HSE-FM-009: WORKING AT HIEGHTS
 HSE-FM-011: EXCAVATIONS
 HSE-FM-023: BREATHING AIR QUALITY
Violation of any Life Critical Procedure could

potentially result in Loss of Life. Life Critical
violations may result in immediate removal from
Refinery property.
The following information regarding Life Critical

Procedures is for informational purposes and is not
designed in any way to replace existing training
requirements.
Permit Checklist and Memory Joggers

 Are all energy sources identified and included on
the Lock out Tag out (LOTO) or Energy Isolation
List (EIL) form?
 ALL BLEED VALVES NEED ONLY BE TAGGED
BY OPERATIONS.
 Are special devices needed for Lock out?
(Electrical systems, valves with hard to secure
handles)
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52
 Is an electrical breaker involved, is the breaker
labeled properly?
 Are locks, tags and special devices in the proper
place? (Bleed valves tagged open, electrical
switches locked in open position, chains through
wheel)
 Check equipment for energy sources. (Depress
start/stop switches, check pressure gages, rod out
bleed valves, verified with O2 and Combustible
Meter)
 Are there additional sources of energy? (Heaters,
low voltage systems, electrical heat tracing, steam
tracing, utilities hard piped to system)
 Are there any reactants? (Catalyst, polymer,
peroxides)
 Is there any instrumentation involved? (Impulse
lines, float gauges, seal pots, varecs)
 Have all utilities used for clearing been
disconnected at the vessel? (Hoses, hard piping)
 Is a GFCI or low voltage needed for tools and
lighting?
 Has the line, vessel or equipment been cleared,
steamed, washed and purged properly?
 Is there adequate air flow in the work area? (Air
mover needed?)
 Is the WCR at the job site? (Has the SDS been
checked?)
 Have all units that may be affected been
contacted?
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53
 Do not use any Davit or Lifting Arms located on
towers, vessels, tanks, etc
 When removing lead-based paint or asbestos
insulation, make the appropriate contacts.
 Have YOU identified your Rally Point locations and
Evacuation Routes?
 Have YOU located the Safety Shower/ Eye Wash
station and verified operation?
 Have YOU checked the Breathing Air Certificate of
Analysis “C of A”? Blue and red tag in use?
 Have YOU checked to see if an Engineering
Package is required for the job?
 Have YOU charged a steam hose or lance? Is it
ready if needed for Flare Header opening?
 Have YOU checked the fire extinguisher gauge
and inspection date?
 Have YOU barricaded off the area and danger
tagged properly
 Have YOU informed each member of the work
group of the permit requirements?
 HSSE DEPARTMENT can be called as a resource
if needed.
Work Permits and Preparation

 Persons desiring entrance into process areas, tank
farms, or other restricted areas must request
permission from Operations. At a minimum, a Safe
Work Permit will be required for work that could
impact process equipment
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54
 Permits and the JSA are to be posted at the job
site.
 Permits are issued by the Operations Dept. and
designated permit writers in the area where the
work is to be performed. Operators and permit
writers will be able to make rounds and answer
your questions. Learn the operators, permit writers
and supervisors in your areas. If you are not sure
always ask.
 All Safe Work Permits can be written for up to
seven days, but must be updated each shift if work
is ongoing, or at least once in a 24 hour period
when the work is not continuous. The original book
copy and the permit hard copy shall be updated.
 The permit updates section must be initialed by the
Equipment Owner to indicate that gas checks have
been performed (if applicable) at the beginning of
each shift and the area has been checked for
operating conditions that may have changed
making it unsafe for the permit to be updated.
 Safe Work Permits not reviewed within 24 hours of
the last update shall be terminated and a new Safe
Work Permit shall be required.
NOTE: The daily review will not be considered

valid and work will not start until the atmospheric
tests and results section and the permit update
section has been completed and initialed by the
Equipment Owner and Work Crew Representative.
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55
 Any emergency alarm other than a test will void
all permits. Permits will be initialed or re-issued for
contractors to resume work.
 All Contractors performing the work will follow all

PPE requirements and special instructions
checked or written on the permits.
 If a job is abandoned for 2 or more hours then the

permit will be suspended until the area is re-
evaluated by both the Equipment Owner and
Work Crew Representative.
 Permits will be valid for 12 hours during

turnarounds when maintenance works 12 hour
shifts.
Permit Process Workflow

 After signing into the unit, the worker will meet the
equipment owner at the job site and communicate
the work activity that is to be performed.
 The equipment owner will inspect the area using
the oxygen/combustible gas meter to determine
oxygen and flammability readings if necessary and
ensure that the area is free from recognizable
hazards. Oxygen reading must be 19.5% to 23.5%
or equal to atmospheric conditions. Flammability
must be zero for jobs which have a potential
ignition source. Other direct reading instruments
such as PID meters will be used to determine
toxicity when necessary. The permit-qualified
Contact (POC)
56
person will verify atmospheric readings and
ensure the area is free from recognizable hazards.
 The following personnel will sign the safe work
permit based on the type of permit issued
authorizing work to begin; the Equipment Owner,
Work Crew Representative (WCR).
 The personnel performing work will comply with all
HSSE procedures that apply to the work activity.
 The Safe Work Permit and JSA will be posted at
the designated location until job completion.
 Should the WCR be replaced before completion of
the job, he will review the permit requirements with
his replacement and the replacement will sign the
permit.
 Sounding of the Refinery Emergency Alarm in your
area, except for testing purposes, immediately
voids all work permits. They will have to be initialed
or re-issued after the “All Clear” is sounded.
Unit Sign in and notifying operations in person is

required for the following examples, but are Not
Limited To:
NOTE: - JSA will be required prior to perform

the job tasks
- These exempt areas are not exempt
from the Confined Space Entry Permit
requirements, if applicable.
 ERT Training Bldg, Fire Training Group and

Fire Stations
Contact (POC)
57
 Maintenance Bldg, Central Maint Shops,
Coker Shop, C&P Maint Shop, Permanent
T/A Fab Shop by North Fire Stations,
Contractor Hill
 Shipping, Stores
 Veolia and Brock Compounds
 Administration Building, Gate Security
Buildings, Medical Building, Time Office
Building and Safety Supply
 Site D
 Ops and Maint Change Houses
 FCCU, Coker, Crude and Capital Bag & Tag
Areas
 Nomex Trailers
 Sandblast Yard, Laydown Yards, Scrap Metal
Yard
 PTRA Railroad Tracks
 Wax Building
 Operation of Global Thermal Oxidizer Area
Safe Work Permit (Procedure 1) the following are

examples of tasks that would require a safe work
without gas check:
 Battery powered, intrinsically safe tools
 Abrasive blasting on new equipment
 Abrasive blasting tanks, structural members,
piping and equipment previously in service which
does not contain a flammable or combustible
material and/or does not have a vapor space
above a flammable or combustible material
Contact (POC)
58
 Asbestos and lead removal
 Radiography work and radioactive tracer testing
 Elevated work, Scaffolding
 Insulating with asbestos or non-asbestos,
refractory or non-refractory materials
 Any work that has lead exposure potential
 High pressure water cleaning
 Hot Bolting (See Hot Bolt sections of Procedure 07
Line or Equipment Opening)
 Cold cutting (e.g. hand pipe cutter)
 Painting
Safe Work Permit (Procedure 1) the following are

examples of tasks that would require a safe work
with gas check:
 Electric soldering irons, drill motors, hammers,

saws, and other similar tools
 Any work involving line or equipment opening with
potential exposure to hazardous materials
 Temporary bullpen (smoking permits)
 Tar pots
 Portable gasoline, diesel or propane-powered
equipment
 Mechanized excavation equipment (e.g.
backhoes, ditch witch)
 Lawn mowers, weed cutters, etc. within the battery
limits of an operating area, or within tank dike
walls.
Contact (POC)
59
 Sustained vehicle operation within operating
areas (forklift, picker, air compressor, and light
bank, etc.) If the engine/vehicle is turned off for
more than one hour, the permit is suspended until
the area can be gas checked
 Work conducted in any temporary enclosure
Hot Work Permit (Procedure 4)

 Any work or the operation of any equipment that
may create a source of ignition.
 Electric or gas welding
 Gas cutting torch, gas torch soldering, brazing
 Grinding (electric or pneumatic)
 Sandblasting on tanks or equipment that have a
vapor space and are in service or have not been
cleared of flammable or combustible materials
 Any use of open flame
NOTE: if unsure of classification, contact an HSSE

Representative for clarification.
Confined Space Permit:

All Confined Space Entries require a Confined
Space Entry Permit and either a Safe Work or Hot
Work Permit (see Procedures 1&4). All sections of
the Confined Space Permit must be properly
completed including the authorized signatures
(Equipment Owner, Work Crew Representative,
Chief or the First Line Supervisor, and the Safety
Attendant). The permit should be posted at the
entry in a permit-only plastic bag.
Contact (POC)
60
 The Equipment Owner will perform all initial and
periodic atmospheric testing for the confined space
entry and document it on the Confined Space
Permit (both copies).
 Each hazard that could potentially have a direct
impact on the confined space entry must be
identified and controlled according to this
procedure and other applicable procedures (such
as Procedure 4: Hot Work Permit).
 The Confined Space Permit is valid only for 24
hours, then it must be closed and a new permit
issued if the work is not complete. If work does not
begin within two hours of permit issuance or if work
ceases for two hours or more, the permit is
suspended and requires the Entry supervisor
approval for reactivation, including retesting of the
confined space atmosphere…
Confined Space (Proc. 5 Confined Space Entry)

This procedure applies to all Refinery employees, as
well as all contract employees working in the
Refinery.
Confined Space Entry- means the action by which

a person passes through an opening into a permit-
required confined space. Entry includes ensuing
work activities in that space and is considered to
have occurred as soon as any part of the entrant’s
body breaks the plane of an opening into the space.
Confined Spaces- are areas which

Contact (POC)
61
 Have limited or restricted means for entry or exit

including (but not limited to): tanks, vessels, vessel
skirts, storage bins, hoppers, vaults, pits, cooling
towers, heaters, excavations four feet or more
deep, tank cars, sewers and under some identified
compressor deck
 Are large enough and so configured that an
employee can bodily enter and perform assigned
work
 Are not designed for continuous employee
occupancy
Welding in Confined Spaces

 During welding jobs within confined spaces, one of
the following requirements must be achieved:
 2000 cubic feet per minute (CFM) of air flow per
welder
 Local exhaust ventilation
 Ventilation 6-12 inches above the welding point
(i.e. using a Coppus blower, hoses, etc.) or
supplied-air respiratory protection for entrants
Special Requirements, Considerations, Exceptions

 When using diesel or gasoline powered equipment,
or any equipment that has the potential to generate
harmful contaminants in the vicinity of a confined
space entry, care should be taken to keep the
exhaust fumes or contaminants from entering the
confined space.
Contact (POC)
62
 The Work Group Representative (WCR) and
work crew must take the necessary steps to guard
against the possible hazards of gas leaks from
torches or hoses, and to guard against the
depletion of oxygen by torches or other flames in
closed or partially closed confined spaces.
Breathing air equipment may be required.
 When possible, low voltage (48 volt or less)
explosion-proof lights should be used. The
transformer must remain outside of the confined
space at all times and be protected by a ground
fault circuit interrupter. The user must visually
inspect extension cords before they are used,
regardless of the date of the last inspection.
 Exception: 120 volt portable electric lights
protected with a ground fault circuit interrupter
meet the shock prevention intent of the above. The
ground fault circuit interrupter shall be kept outside
of the confined space. Use of ground fault circuit
interrupter must be included on the permit.
 Portable (battery powered) lighting shall be kept at-
the-ready outside of the confined space opening.
This lighting shall be used in the event of failure of
the principle system and shall be capable of
providing explosion proof illumination for a period
of at least one hour.
 An approved dry chemical fire extinguisher shall be

available at the entrance to confined space, or in
the case of large or complex confined space
configurations at or near the hot work activity while
Contact (POC)
63
welding/cutting operations are in progress. The
object is to have proper fire suppression capability
immediately available to the hot work area.
 Any job that could increase flammable gas

concentrations inside the confined space must be
discontinued until the entry/welding job is
complete.
 Oxygen and acetylene hoses used inside of
confined spaces shall be inspected prior to entry to
assure no leakage. Oxygen and acetylene hoses
must be removed form the space or disconnected
at the cylinder when not in use or during periods
when the confined space is not occupied or when
oxygen and acetylene hoses will be idle for an
extended period (2 hrs or more) when the confined
space is occupied.
 Compressed gas cylinders, except those
containing breathing air for RESCUE or ESCAPE,
shall not be allowed inside the confined space.
 Air moving equipment should be arranged based
on the configuration of the space and the type of
ventilation required. Air moving equipment shall be
rated for Class I Division I explosion proof electric
service or shall be powered by compressed air. All
compressors shall be placed away from exhaust
fumes or other air contaminants that may be
present in any area of the plant. If the use of an air
mover is not specifically required on the entry
permit, the entry supervisor should evaluate, on a
job by job basis, the positioning of a stand by air
Contact (POC)
64
mover at the access opening. Ventilation devices
driven by air hoses shall exhaust out of the
confined space. Approved electric driven
ventilators may blow into (positive pressure
ventilation) or exhaust from the space (negative
pressure ventilation).
 All air movers shall be equipped with a bonding
cable and clamp. The cable shall be attached to
the confined space at all times, or if the confined
space is an excavation the cable shall be attached
to a grounding rod.
 Excavations or other confined spaces with no roof
whose length is greater than four times the depth,
or those with no toxic or flammable material
carrying lines passing through the excavated
volume may not require ventilation at the discretion
of the Entry Supervisor.
 Provided that the tube sheet is still in place,
standing inside of a horizontal exchanger channel
head, to perform work such as plugging tubes, or
hydro-blasting tubes, where there is no restricted
egress and for a depth of 4’ or less, will not require
a confined space entry permit. All other isolation
and decontamination requirements still apply.
 Provide that the tube sheet is still in place, standing
on a walking and working surface and reaching
into a horizontal exchanger channel head to
perform work will not require a confined space
entry permit. All other isolation and
decontamination requirements apply.
Contact (POC)
65
 All Confined Spaces shall be continuously
monitored by qualified attendants for Oxygen and
LEL (flammability) while personnel are present in
the space. A minimum of one meter, with the
qualified attendant, will be used per confined
space. Consideration should be given to space
configuration and equipment service that may
require additional meters and monitoring capability,
such as H2S, SO2 and CO
 All attendants will be trained, have proof of training
and have a radio and wearing a brightly colored
vest.
Excavation (Proc. 11 Excavations)

 A Safe Work Permit or Hot Work is required for all
Excavations (Trenching and Digging) depending
on the equipment being used.
 All soil in the Refinery is considered to be Class “C”
 Excavation Competent person must perform the

planning and execution shall be assigned to a
competent person. Prior to starting an excavation,
the competent person shall evaluate the
excavation work scope including work methods,
potential hazards and employee protection
requirements associated with the excavation work.
Methods shall be implemented to identify and
physically locate underground hazards such as
sewers, pipelines, electrical installations, etc.
Contact (POC)
66
 All excavations over 5 feet in depth shall be
sloped, shored and/or shielded.
 Competent person must ensure all pipeline or
utility owners are notified before the excavation
begins when excavations are conducted in areas
where pipeline or utility rights-of - ways are
located.
 Excavation Competent person must conduct a

daily inspection to ensure all protective measures
are in place and adequate.
o Daily, prior to starting work: inspects and
assesses excavation integrity, protective
systems and adjacent areas.
o Inspect excavation area following rain storms
or other hazard-increasing events.
o If there is evidence of possible cave-ins, soil
cracking or slides, all work will cease until
necessary precautions have been taken to
protect personnel and equipments.
o Other activities in “close proximity” to
excavation area (e.g. railroad tracks,
roadways, other excavations, power line
poles).
o If water accumulates within an excavation, all
personnel must exit the excavation until the
water level is safely removed or controlled and
a firm working surface is provided
Contact (POC)
67
A Confined Space Permit is only required if
workers are going to enter an excavation that is
or greater than 4 feet in depth.
NOTE: Excavations that are less than 4 feet in

depth and examination of the ground and work area
by a competent person provides no indications of
cave-ins; basic PPE is required. Excavation is equal
to or greater than 4 feet in depth requires additional
PPE while working in the confined space such as
but not limited to; safety harness.
Precautions
 No mechanized equipment (backhoes, pickers,
etc.) will be used within 20 feet of any overhead
lines (including power, control or communication
lines) without first contacting a refinery Electrical
Supervisor, Electrical Engineer, Plant Shift
Superintendent or their designee. (See procedure
12: ELECTRICAL SAFETY)
 No “teeth” will be allowed on the buckets of any
mechanical equipment (backhoe, bulldozer, etc.)
used for excavation work. A flat bar may be
attached across the teeth to prevent the snagging
of any underground obstruction.
Line Break (Procedure 7)

 Requirements for opening of any process
equipment with potential to contain an energy
source are described in Refinery Procedure 7-
Equipment and Pipe Opening. The equipment
Contact (POC)
68
owner in charge of the area must verify lock
out/tag out (see Procedure 6 LOCKOUT AND
TAGOUT) with maintenance personnel, and be
present during the first break and until the
equipment is shown to be clear. Equipment Owner
will inform all personnel in the immediate area
when the equipment and surrounding area is clear
and specified work or preparation for that work may
begin.
 Prior to performing any equipment and pipe
opening, workers must:
 Locate the nearest safety shower.
 Clear area of personnel not actually performing the
work (including watch).
 Select appropriate PPE. Refer to the Refinery PPE
Procedure at the end of this section.
 Consider the possible “Line of Fire” prior to the
start of the task. For flanges, the line of fire can be
in any radial direction from the flange. Position
yourself on the side opposite of the break.
 Determine the need to establish a barricaded area
around potentially impacted areas (a minimum of
10 feet).
 Line Break is the physical opening or breaking
apart of a portion of chemical process piping,
tubing, hose, vessels or equipment which contains
or may contain hazardous or unknown material or
an energy source. Physical breaking includes but is
not limited to, unscrewing, unbolting, and cutting of
screwed, flanged, cemented, welded, or other
types of connections on pipelines or process
Contact (POC)
69
equipment. Subsequent breaks in lines or
equipment are considered line breaks if any
potential exists for exposure or release of energy.
 The key part of the permit is to identify the material
and the proper PPE for the task. PPE can only be
downgraded by Operations of HSSE.
 All contractors must train their employees on the
proper use, limitations and care of PPE. It is the
responsibility of the contractor to decontaminate
and/or clean the PPE after use.
Lockout/ Tag out (Procedure 6)

 It is the policy of the Refinery to protect all
employees and contractors who are engaged in
servicing, maintenance, inspection, construction
and/or similar activities on equipment. This is
accomplished by ensuring the control of hazardous
energy sources, by means of lockout/tag out
procedures, to prevent energization, start-up or
release of stored energy that could cause injury to
workers. This procedure is in compliance with
OSHA Standard for Control of Hazardous Energy
(Lockout/Tag out).
 Before starting work on any equipment, all energy
sources to the equipment must be isolated, locked,
tagged, and tested.
Blinding
 Maintenance- personnel who arrive at the unit will
follow the LOTO procedure below before beginning
the installation of blinds.
Contact (POC)
70
 Operations will indicate the location of required
blinds by filling out and applying a “GREEN BLIND
LOCATION TAG” at the location of each blind point
for maintenance personnel.
 Maintenance personnel will notify operations when
they are set up and ready to make the line break.
 Equipment Owner will remain with the
maintenance personnel who are installing the
blinds until the equipment is shown to be cleared.
 Maintenance personnel will install the blinds. If the
GREEN BLIND tag is removed as part of blind
installation Maintenance must replace the tag after
work is complete.
 When the maintenance personnel have completed
the installation of the required blinds, they will
report to operations that blinding is complete.
 Equipment Owner will verify the correct
placement of the blinds and remove the “GREEN
BLIND LOCATION TAG” and fill out and apply an
“ORANGE BLIND INSTALLED TAG” to each blind
location. If a blind is part of more than one lockout
situation, a separate tag for each lockout should be
applied to that blind.
 Equipment Owner and Work Crew
Representative (WCR) will initial the Energy
Isolation List, indicating that the blinds have been
installed.
 Operations Lockout is now complete.
 Maintenance personnel arrive at the area satellite
control room and are accompanied to the work site
by the Equipment Owner. If there are multiple
Contact (POC)
71
crafts persons then an individual from each craft
would be required to secure the appropriate permit
and would be designated as its WORK CREW
REPRESENTATIVE (WCR).
 Equipment Owner will review the Energy Isolation
List (EIL) and variances, if applicable, with WCR as
they look at each energy isolation device.
 The WCR from each craft will verify that an
operations controlled access lock and/or tag are on
all lockout devices, including the electrical
switchgear. Then he/she will initial the spaces
corresponding to each device on EIL.
 The WCR will apply a general craft lock AND
his/her personal lock to the Lock Box. (If the WCR
will not be a part of the work crew, the WCR will
apply a general craft lock only.)
 The permit is issued by the Equipment Owner
and placed in a pouch located at the work site L by
the WCR.
 The WCR reviews the LOTO with his/her work
crew and ensures that each work crew member
places a personal lock on the Lock Box.
Contractors must use a single-keyed lock that
identifies the owner of the lock and their company.
Work Proceeds
 The WCR for each craft will ensure that all work
crew members apply or remove their personal lock
as they join or leave the crew during the workday.
Operations Shift Change

Contact (POC)
72
 Equipment Owner informs their relief of all
lockouts in their assigned area. Remove their
personal locks from the lock box (Leaving only their
craft lock) if their blinding job is incomplete. If the
oncoming shift plans to continue the job, then the
new crew will add their personal locks to the lock
box.
 Equipment Owners on the oncoming shift will
renew the permit(s) according to the permitting
procedure.
Maintenance Work Day Ends (Job Incomplete)

 WCR will ensure that all work crew members
remove their personal locks from the Lock Box,
leaving only their general craft lock.
 WCR writes job status on the permit and returns it
to operations as required by the permit procedure.
Maintenance from Other Crafts or On Additional

Shifts
Repeat steps 10-15 of Initial Setup of LOTO
Job Completion
 On completion of their work, each craft will ensure
that all job related trash, material, tools and
equipment have been removed from the work site
and properly disposed of or stored.
 As each craft completes their work on the
equipment, each WCR ensures that all work crew
members remove their personal locks from the
Lock Box.
Contact (POC)
73
 WCR removes their general craft lock from the
Lock Box.
 WCR writes job status on the permit and returns it
to operations as required by the permit procedure.
 Maintenance personnel will coordinate with
Equipment Owner as they remove blinds (if
applicable) perform necessary cleanup, remove
their personal locks and their general craft lock
from the Lock Box, and turn in their permit. If
Equipment Owners remove any blinds, they must
first evaluate any hazards of the job task before
proceeding and then follow same procedures as
maintenance.
 Maintenance is required to return the ORANGE
BLIND tag to the Equipment Owner after the blind
is removed.
Group Lock out

A lockout in which a Work Crew Representative
places a single craft lock along with the personal
locks of all work crew members or tag with work
crew signatures on the applicable lock box thereby
affording protection for all of the members working
within that Work Group.
Industrial Hygiene (IH)

Contractors are responsible for their employees
Industrial Hygiene issues. These issues may include
but are not limited to PPE and personal monitoring.
Refinery IH will assist as necessary.
Contact (POC)
74
Hazard Communication/ Material Safety Data
Sheets (Hazard Communication)
 All chemicals at the Refinery have Safety Data
Sheets (SDS) available. These can be obtained
from your job representative, Operations or HSSE
 If there are any new chemicals or agents utilized
during the task, they must be approved through the
Refinery Chemical Approval process prior to use.
This includes contractors transporting chemicals
and agents on-site as well.
 All cleaning and decontamination agents shall be
processed prior to coming on-site.
 All portable containers must be labeled.
 Contractors are responsible to train employees in
the HAZCOM standard.
 The contractor is responsible to provide training to
his/her employees on the hazards associated with
the chemicals and the operations of the Refinery to
which they may be exposed.
 All permits issued will list the chemicals and the
potential for exposure.
Asbestos and Lead

 Prior to removing insulation or paint from a line,
vessel, tank, or other process equipment, the
potential for the presence of Asbestos and/or Lead
must be determined. If this is unknown, the
appropriate tests must be conducted and/or
additional precautions determined prior to initiating
any maintenance work. Refer to Proc. 15 Asbestos
Abatement or Proc. 17 Lead Removal for specific
Contact (POC)
75
additional information. Report any suspect
material prior to disturbance.
 All abatement projects must be performed by
trained/qualified contractors.
 Complete the asbestos/lead tracking prior to
working on asbestos/lead.
Industrial Radiography (Proc. 13 Radiation Safety)

 Site HSSE personnel will periodically conduct and
document audits on industrial radiography jobs.
 The audits are to ensure the radiographers are
complying with state regulations and meeting the 2
mR/hr barricade regulatory limit.
Work on NORM-Contaminated Equipment

 NORM- (PROCEDURE 14: NATURALLY
OCCURING RADIOACTIVE MATERIAL)
 NORM can concentrate in propylene streams.
 External surveys have not indicated that NORM is
present at the Refinery. However, when propylene
equipment is opened during maintenance
activities, internal surveys must be conducted.
Contact HSSE any time such equipment is to be
opened.
 Equipment to be worked on in the refinery are not
required to be decontaminated, but all personnel
working on equipment must receive the proper
training and wear the following minimum personal
protective equipment:
 Full face negative pressure respirator with HEPA
cartridges
Contact (POC)
76
 Chemical or other impervious gloves
 Flame-retardant disposable coveralls with hood
 Disposable shoe covers or rubber boots (when
working inside vessels).
Sampling and Analyses of Process Equipment

prior to Maintenance
 Before contractors are allowed to begin working on
any piece of equipment, it must be decontaminated
and cleared by Operations.
 Operations will sample and analyze the equipment
to determine the PPE requirements for the task.
Supplied Breathing Air

 Breathing air used at the Houston Refinery must
comply with Grade D breathing air requirements
described in NSI/ Compressed Specification for Air,
G- 7.1- 1997 and OSHA 29 CFR 1910.134. No
synthesized or reconstituted air shall be used by
the Refinery or contract personnel. Breathing air
couplings must be incompatible with outlets for
non-respirable worksite air or other gas systems
(i.e. nitrogen/plant air/regular non-grade D
Compressors).
 Air Compressors may be used to supply Grade D
breathing air in lieu of breathing air cylinders.
When using an air compressor, Grade D breathing
air quality tests are required to be performed when
the compressor breathing air system is initially set
up and at least every 90 days thereafter. The use
of breathing air should be stopped and air quality
Contact (POC)
77
testing performed if there is a report of perceived
odor, taste, or other reported unwanted issues with
the breathing air system.
 System modification will also require additional air
quality testing (i.e. different compressor, after
repair work, compressor relocated, etc.). In
addition to Refinery Requirements, all compressor
manufacturer guidelines must also be followed.
 The compressor shall be located in an area that
prevents entry of contaminated air into the air-
supply system. The system will have suitable in-
line air-purifying sorbent beds and filters to further
ensure breathing air quality. Sorbent beds and
filters shall be maintained and replaced or
refurbished periodically following the
manufacturer’s instructions. A tag containing the
most recent change date and the signature of the
person authorized to perform the change. The tag
shall be maintained at the compressor. An inline
carbon monoxide alarm set at 10ppm or below will
be used to monitor carbon monoxide levels.
Carbon monoxide alarms must be calibrated at
least monthly or more frequently according to
manufacturer recommendations. A “bottle watch”
will be assigned to monitor breathing air panels
and carbon monoxide alarms.
 Breathing air cylinders must be tested for oxygen
content at least once prior to use. Breathing air
from compressors must be checked daily prior to
use. The oxygen content must be between 19.5%-
23.5%. Oxygen testing will be performed with a
Contact (POC)
78
properly calibrated, standard hand-held oxygen
meter. Multiple breathing air cylinders comprised to
provide a single source of air, such as 12 pack,
must be tested individually for oxygen content.
 Oxygen test records shall be maintained on-site. A
certificate of analysis from the supplier is required
for breathing air cylinders prior to use.
 Breathing air cylinders and multi-packs must be
tagged after testing to ensure O2 content between
19.5%-23.5% in accordance with Grade D
specifications.
 The breathing air cylinders must be tagged using

the blue contractor O2 tag (Appendix 3) to identify
an oxygen quality check. This tag is available in
the warehouse (item # 2037832).
 All breathing air hose line connections must use
the red “Breathing Air In Use” tag (Appendix 2) to
ensure hoses are not disconnected while in use.
This tag is available in the warehouse (item #
2037831).
 Bottle air must be rechecked every 6 months to
ensure O2% content. Breathing air cylinders and
multi-packs must be replaced at least annually with
fresh ones.
Toxic Substances Control Act (TSCA)

 The Toxic Substances Control Act requires
LyondellBasell to develop a compliance procedure
that addresses the reporting of allegations of health
and environmental effects, the investigation of
Contact (POC)
79
those allegations, and the development of the
necessary reports and notifications to the EPA.
 It is the contractor’s responsibility to report any
information or incident associated with any
chemical or mixture that results in an adverse
health or environmental effect. Report any incident
immediately to your Houston Refinery
Representative.
Environmental Requirements:
 The Refinery has developed environmental policies

and procedures to ensure the site complies with
relevant federal, state, and local environmental.
These policies and procedures cover the
requirements for air emissions, water discharges
(both storm water and process wastewater),
hazardous and non-hazardous waste, and upset
reporting.
 Upsets and spills will be reported in accordance
with the Spill Response and Prevention Plan
(SPCC). The Environmental Department unit
contact (days) or on call representative (night) is
responsible for any agency notifications.
 The contractor must follow all relevant Refinery
environmental procedures and guidelines and
coordinate all related activities with their Refinery
job representative and the Refinery Environmental/
Waste Management Team.
Contact (POC)
80
Wastewater and Storm Water
 If materials to be discharged to the wastewater
treatment system are new or are in concentrations
not normally generated during operating or
maintenance activities, coordination with Utilities
and Environmental personnel must occur prior to
the activity.
 If Utilities cannot viably handle the stream,
Environmental personnel will work with your
Refinery Representative arrange for alternative
storage or disposal.
 No materials, liquids, wastes, chemicals, etc. shall
be discharged to any storm water ditch or on the
ground leading to any ditch. Examples prohibited
materials include: cutting fluids, biodegradebable
products, oils or hydraulic fluid drips, equipment
wash downs, concrete rinse outs, concrete spoils,
and hydrostatic test waters. All water generated
through hydro blasting of VOC contaminated
equipment and wash downs of VOC contaminated
equipment, must be treated through the Utilities
wastewater treatment system. Equipment should
be cleared of liquid volatile organic chemical (VOC)
materials and purged of VOC vapors as much as is
feasibly possible prior to opening to atmosphere.
Solids should be removed after VOC emissions are
minimized.
Waste Issues
 The type and qualities of wastes (both hazardous
and non-hazardous) that may be generated from
Contact (POC)
81
contractor maintenance activities must be
estimated by Operations and Environmental
personnel prior to these maintenance activities in
order to ensure that the proper containers are
ordered and shipments may be scheduled. Each
vessel with the potential to generate hazardous
waste shall be identified by Operations prior to
maintenance activities.
 All non-routine waste should be sampled prior to
being removed from equipment for disposal. This
will expedite the transfer of material off-site for
proper disposal. If material can not be sampled
prior to its removal, the waste must be stored until
it has been analyzed and profiled with an approved
disposal facility. Coordinate with your Refinery
representative and the Environmental group to
determine sampling needs.
 All waste materials must be segregated and placed
into proper containers. Waste must not be mixed
with different types of waste.
 All waste containers, hazardous or non-hazardous,
must be labeled in accordance with Refinery
labeling requirements. The common name for the
waste must be on the label.
 Tarps, covers, or hatches must be kept closed on
all containers when not in the process of being
filled.
 If any Naturally Occurring Radioactive Material
(NORM) contamination is suspected, the HSSE
group should be contacted and handled as
referenced in the NORM Procedure. If detected, a
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82
NORM lay down yard will be established for the
weathering process. The Environmental
Department will arrange for disposal of NORM
waste material as needed.
 The HSSE must be notified if any asbestos will be
removed. The Environmental Dept. will arrange for
asbestos disposal.
 If excavation of an area is needed, use the (Proc.
11 Excavations) as guidance and coordinate with
the Environmental T/A Coordinator to obtain
required environmental approvals.
 All waste disposal activities, on-site and off-site
should be handled and coordinated through the
Solid Waste Coordinator.
Incident Reporting
 It is the responsibility of the contractor to report all
incidents including near misses and injuries to their
Refinery Representative immediately.
 Before the end of the shift, write a preliminary
report for each incident including medical
descriptions of any injury and all actions taken to
prevent recurrence. Contractors will have a person
assigned to manage safety to ensure incidents are
properly managed.
 Contractors will conduct formal incident
investigations for all recordable incidents or as
dictated by the Refinery Representative.
 All incidents will be entered into tracking system by
the appropriate Refinery Representative.
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83
Medical Treatment
 The Contractor may provide minor first aid for
employees if qualified care personnel and facilities
are available.
 The Refinery has EMT’s on site trained to respond
to any medical emergency when needed.
 Any major medical emergency shall be
immediately reported and activate the plant VERT
to respond.
 Any outside emergency assistance will be
coordinated through Refinery VERT. This assures
that the right people are notified and in place when
ambulances or emergency equipment arrives.
Contact (POC)
84
Hand Safety
The Houston Refinery’s Hand Safety procedure 32 emphasizes 10
Cardinal Hand Safety Rules. Use these to your advantage in
avoiding hand injuries.
1) Keep hands away from pinch points and crushing hazards. A

large number of hand and finger injuries result when they are
caught between objects. This happens frequently when
handling materials. Inspect materials for slivers, jagged edges,
burrs and rough or slippery surfaces. MATERIAL HANDLING
2) Always consider HAND ERGONOMICS.
3) Use the correct HAND TOOLS for the job and use them
properly.
4) Always wear the proper GLOVES according to a thorough
hazard assessment or job safety analysis. Never wear gloves
when working around rotating equipment.
5) Hand JEWELRY e.g. Rings, bracelets, watches, etc… can
pose hazards when performing a job around electrical, rotating
equipment, and general work. There is a potential hazard of
catching on a moving machine part or a fixed object when the
body is moving rapidly, the hand/finger could be torn off or
severely damaged. Be aware of these hazards and consider
removing hand jewelry prior to performing tasks.
6) Make sure all EQUIPMENT/SAFETY GUARDING is in place
before beginning any job and stays in place until the job is
completed.
7) Always de-energize, perform LOCK OUT/TAG OUT and verify
Zero Energy State on machinery and equipment before
reaching into repair, clean, maintain or make adjustments.
8) Use a cloth or brush when CLEANING up. Never use your
fingers or hand.
9) Know the DANGER ZONES (i.e. line of fire and pinch points).
10) Practice good PERSONAL HYGIENE. Keep your hands
clean. Don’t ignore hand injuries, no matter how slight.
Contact (POC)
85
3 for Me
1. Knowledge
 I know the procedure/ job plan
 I have been trained on the task
 I know where to go for help
2. Commitment
 I will follow procedures/use PPE
 I will say “no” to short cuts
 I will work safely for my family’s sake
3. Attention
 I am alert and aware of my surroundings
 I look for potential hazards
 I expect the unexpected
Always predict the worst outcome of the hazard,
and then decide how to execute your plan safely
Contact (POC)
86
Goal ZERO at Houston

Refining LP:
------------------------------------
We are committed to preventing all injuries, incidents and
work-related illnesses.
1. GoalZERO is sourced out of a personal commitment where

everyone holds themselves responsible for not only their own
safety and well-being, but for that of everyone else.
2. Everyone is valued not only for what they do, but for who they
are. GoalZERO is not only numbers and statistics – but also
relationships and people.
3. We are one team engaged in the safety process because we care
about each other
4. We take safety into account in all aspects of a job; from
concept to start-up, through operating and maintaining
5. We work safely with each other because it is the right thing to
do. We choose to be safe because our co-workers, families and
loved ones are counting on us.
6. When something goes wrong, we respond positively as one
team to learn, share and improve.
7. We seek out opportunities for coaching and welcome being
coached without threat, intimidation or taking offense. A
person doing something at-risk is not a confrontation to avoid,
but an opportunity to share concern, coach, learn, and build
relationships.
We celebrate success!
Contact (POC)

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1

Safety, Health and Environmental

Contractor Name: ________________________

The Site Leadership personally welcomes you to the

When you enter this facility, you are a part of an elite

WELCOME TO OUR FACILITY!

TABLE OF CONTENTS PAGE

Purpose and Scope 5

Contractor Responsibilities 7-8

General Plant Requirements 9-26

Emergency Procedures 27- 29

General Safety Rules 30 - 49

Life Critical Procedures & Work Permits 50- 72

Industrial Hygiene 72- 66

Environmental Requirements 78- 81

Incident Reporting & Medical Treatment 81-82

Rule No 1. Working safely is a first and forever expectation.

Rule No 2. Intervene – act to stop anything you think is unsafe.

Rule No 3. Take the necessary time to complete the task

Rule No 4. Wear proper PPE and follow approved procedures.

Rule No 5. Use equipment correctly – never misuses a dedicated

Rule No 6. Produce products and services that meet or exceed

Rule No 8. Report injuries and incidents promptly.

Rule No 9. When a situation is not understood, move to a safe

Rule No 10. Take care when making changes; document your

PURPOSE AND SCOPE

A publication of this size cannot encompass all of

The primary focus of the Refinery safety program is

Should situations arise which are not covered in

REFINERY HSSE CONTACTS

ALL HEALTH, SAFETY AND ENVIRONMENTAL

2. The Contractor shall supply all safety and

3. The Contractor shall ensure that ANY chemical

4. The Contractor must obtain necessary disposal

6. The Contractor shall designate an HSE

7. The contractor shall report ALL injuries, illnesses

8. Contractors shall actively participate in all

 Attend and pass Safety Awareness 5 (19SA5),

Personal Protective Equipment (PPE)

 Safety glasses with hard side shields.

Back Injury Prevention

Job Safety Analysis (JSA)

Fatigue Day Schedule

Parking and Traffic

Smoking, Matches, and Lighters

 All road closures must be approved at least 24

Cellular Phone Usage

Emergency Alarm System

Contractor Response and Rally Points

Non-Essential Personnel Evacuation of a Unit /

 Only those working in the impacted area need

Non-Essential Personnel Evacuation Plant-Wide

All Personnel Evacuate a Unit

All Personnel Evacuate Plant-Wide

Returning to Work after an Emergency

Personnel must be aware of the location of the

Do not operate vehicles during any emergency.

NOTE: Scaffolds shall not obstruct block valves, fire

* Caution *