Incidents

Safety Manual Process Industries

Safety Manual Process Industries

The Safety Manual

Safety Manual Process Industries. Managers and technical experts responsible for the management of a facility’s safety program will generally develop a manual that is available to all employees. The content and scope of the 'Safety Manual for the Process Industries' will vary according to each company’s needs and circumstances. Provided below is an outline Table of Contents for such a manual.

  1. Introduction
  2. Safety Policy and Philosophy
    1. Regulatory Inspections / Litigation
    2. Safety Meetings
    3. Training/Recordkeeping
    4. Process Unit Entry/Exit Procedures
    5. Smoking Policy
    6. Personnel Working Alone
    7. Bulletin Boards
    8. Housekeeping
    9. Safety Signs and Color Coding
    10. Machinery Guarding
  3. Employee Exposure and Medical Records
    1. Notification
    2. Record Keeping
    3. Medical Examinations
    4. Access
  4. Incident Reporting and Investigation
    1. General
    2. Near Miss Incident Reporting
    3. Occupational Injuries and Illnesses
  5. Hazardous Materials
    1. Chemical Inventory List
    2. Material Safety Data Sheets Management
    3. Labels
    4. Contractor Notification
    5. Recordkeeping
    6. Hazard Communication Program
    7. HAZWOPER
    8. Combustible and Flammable Liquid Storage and Handling
    9. On-Line Blending
    10. Asbestos
    11. Benzene
    12. Hydrogen Sulfide
    13. H2S Detection Equipment
    14. Sulfur Dioxide
    15. Ammonia
    16. Hydrofluoric Acid
    17. Sulfuric Acid     
    18. Caustic Soda (NaOH) 
    19. Caustic Potash (KOH)
    20. Chlorine
    21. Hexavalent Chromium
    22. Mercury
    23. Pyrophoric Iron Sulfide
  6. Environmental
    1. Solid Waste Handling
    2. Spill Prevention Plan
    3. Screwed Pipe
    4. Sewers and Drains
  7. Electrical
    1. Area Classification
    2. Equipment Grounding
    3. Ground Fault Interrupters
    4. Electrical Power Generation, Distribution and Transmission
    5. Overhead Lines
    6. Climbing Electrical Line Poles
    7. Working on Switchgear
    8. Stray Electric Currents
  8. Authorization to Work
    1. Permits and Procedures
    2. Energy Isolation Procedures
    3. Gas Testing Policy
    4. Hot Work Permit
    5. Welding
    6. Engineering and Administrative Controls
    7. Sign Requirements
    8. Permit Requirements
    9. Tank Roofs
    10. Fire Watch
    11. Atmospheric Testing
  9. Lockout / Tagout
    1. Locks and Tags
    2. Lockboxes
    3. Blinding and Equipment Isolation
    4. Barricades
    5. Restoring Service to Equipment
  10. Confined Space Entry
    1. General
    2. Permit System
    3. Contractors
    4. Rescue and Emergency Services
    5. Block Valve Pits
  11. Alarm Systems
    1. Critical Alarms
    2. Shutdown Systems
  12. Combustible Gas Detectors
    1. Portable
    2. Fixed
    3. Calibration Schedule
  13. Driving
    1. Reporting Accidents
    2. Heavy Vehicles
    3. Light Vehicles
    4. Vehicle Backing
    5. All-Terrain Vehicles
    6. Use of Mobile Phones/Texting
    7. Forklift and Truck Operations
    8. Vacuum Trucks
  14. Compressed 
    1. Oxygen
    2. Acetylene
    3. Transporting Cylinders
    4. Storage
  15. Tank/Vessel Cleaning
    1. General
    2. Tank Preparation
    3. Chemical Cleaning
    4. Loading/Unloading Flammable Liquids and Compressed Gas
  16. Personal Protective Equipment (PPE)
    1. Safety Glasses
    2. Goggles
    3. Face Shields
    4. Fire-Resistant Clothing
    5. Respiratory Protective Equipment
    6. Breathing Air Quality
    7. Hearing Protection
    8. Face Protection
    9. Facial Hair Policy
  17. Fall Protection
    1. Ladders and Scaffolding
    2. Fall Protection System
    3. Fall Arrest System Equipment
    4. Fall Protection Anchor Points
  18. Health
    1. Hearing Conservation
    2. Audiometric Testing
    3. Contact Lenses
    4. Heat/Cold Stress
    5. Bloodborne Pathogens Exposure Control Plan
    6. Vaccination and Follow-up Procedures
    7. Carcinogenic Materials
    8. Radiation Safety
    9. Refractory Ceramic Fiber (Asbestos Substitute Fibers)
  19. Emergency Management
    1. Emergency Notification
    2. Securing Buildings for a Toxic Gas Release
    3. Fixed Fire Detection and Extinguishing Systems
    4. Fire Water Systems
    5. Portable Fire Extinguishers
    6. H2S Emergencies
  20. First Aid
    1. Treatment
    2. Training
    3. First Aid Kits
  21. Hand and Power Tools
    1. Hand Tools
    2. Abrasive Wheel Machinery
    3. Pneumatic Tools
    4. Liquid Fuel Tools
  22. Cranes, Chain Hoists, Sling Ropes
    1. Overhead Hoists
    2. Winch Trucks
    3. Wire Ropes, Chains, and Slings
    4. Tag Lines
    5. Lifting and Rigging
    6. Aerial Cages
    7. Critical Lifts
  23. Excavations, Trenching, Shoring
    1. Safety Sign Requirements         
    2. Permits
  24. Simultaneous Operations (SIMOPs)
  25. Pipelines
    1. Pipeline Locating and Repair
    2. Leak Repair on Shut-In Line
    3. Probe Rods
    4. Cold Leak Repairs on Live Lines
    5. Corrosion Probe/Injection Quill In-Service Removal                          
    6. Expandable Pipe Plugs
  26. Offshore Operations
    1. Fueling Requirements
    2. Offshore Boat Use
    3. Helicopter Safety
    4. Personnel Baskets
  27. Laboratories
    1. Process Analyzer Building Entry
    2. Use of Nitrogen
  28. Office Safety

Citation

The material in this article is taken from the 2nd edition of the book Plant Design and Operations.

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