HSE TOOL BOX Talks by keralaguest

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									Kuwait Oil Company (K.S.C.)



                              Issued March 2000
                                HSE TOOLBOX TALKS


It is important that KOC’s workforce has the required skills and training to competently
perform their tasks in a healthy, safe and environmentally sound manner.
Toolbox talks are an effective means of increasing the knowledge of workers on the HSE risks
they face, and the precautions required, when carrying out their jobs. They also encourage,
and reinforce safe, healthy and environmentally sound behaviours.
This series of HSE toolbox talks has been developed to assist supervisors to select topics
for presentation to their workers. They are based on good demonstrated practice, but may
be modified as required to suit particular requirements.
KOC Supervisors are encouraged to regularly conduct toolbox talks with their workers,
selecting different topics from this series. Contractor supervisors are also encouraged to
use these topics as subjects for presentation/discussion with workers.

Objective of Tool Box Talks

The immediate supervisor of a small team of workers briefs them on:
     the work to be done
     the hazards associated with that work
     precautions needed to do the job correctly and safely.

Features of a Successful Tool Box Talk

     Given before the start of a task.
     Given by the immediate supervisor of the people who will do the work.
     Face to face.
     Outlines the job or task to be done.
     Breaks it down into steps.
     Highlights key steps.
     Emphasizes critical safety precautions.
     Checks and ensures understanding by the people who will do the work by questioning
      and correcting.
     Summarizes the points made, and asks for any questions before sending the workers
      to do the job.
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Preparation by the Supervisor
    Decide on the topic. Choose something that involves the current job, an accident that
     has occurred, or something relevant to the audience.
    Write down the key points you need to cover in the talk, which should be about ten
     minutes long.
    Write down why these key points are important to the people you are talking to. Do
     they make the job easier, safer, quicker?
    Put the points in a logical order.
    Gather any visual aids with which to illustrate the talk. These could be booklets, tools,
     examples of good and bad practices.
    Check that the place is suitable, so that everybody can see and hear.
    Tell the audience the time and the place of the talk.
    Check out the venue and the visual aids.


    Keep a record of the people who attended, and the topic discussed.
    Follow up questions that could not be answered at the meeting.

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                     TABLE OF CONTENTS

1.    Explosive Ordnance
2.    Responsibility for Safety
3.    Client/Contractor Relationship - Safety Rules and Regulations
4.    Complacency
5.    Housekeeping
6.    Office Safety.
7.    Packed Lunches
8.    Inclement Weather Rules
9.    Heat Stress and Heat Related Illness
10.   Fire Prevention – Buildings
11.   Use of Fire Extinguishers
12.   Using Personal Protective Equipment
13.   Hand Safety
14.   Fall Protection
15.   Respiratory Protection
16.   Self Contained Breathing Apparatus
17.   Portable Gas Detection Equipment
18.   Hydrogen Sulphide
19.   Accident/Incident Reporting
20.   Ahmadi Hospital and Ambulance Procedures
21.   Property and Environmental Damage Reporting
22.   Accident and Evacuation Procedures
23.   Working Inside Gathering Centers
24.   Confined Space / Vessel Entry
25.   Cranes and Overhead Power Lines
26.   Working in The Desert
27.   Desert Animals, Reptiles And Insects
28.   Working on Flowlines
29.   Work Near Crude Oil
30.   Work Over Water
31.   Driving Safety
32.   Road Safety - Wet Roadways

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                 TABLE OF CONTENTS (Cont.)

33.   Driving in The Desert
34.   Work Permits
35.   Excavations
36.   Electrical Lockout
37.   Valve Lockout and Tagging
38.   Line Breaking
39.   Workshop Practice
40.   Machine Guarding and Use
41.   Hand Tools
42.   Use of Compressed Air
43.   Pneumatic Tools
44.   Sand Blasting (Shotblasting)
45.   Electrical Safety
46.   Portable Electric Tools
47.   Welding (General Rules)
48.   Electric Arc Welding
49.   Gas Welding and Cutting
50.   Compressed Gas Cylinders
51.   Scaffolding
52.   Ladders
53.   Forklift Operation
54.   Heavy Transport Equipment
55.   Working with Heavy Equipment
56.   Lifting and Rigging
57.   Radiography and X-Rays
58.   Material Handling and Storage
59.   Storage and Handling of Chemicals
60.   Using Solvents
61.   Use of Explosives
62.   Demolition Safety Procedures

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                                      TOOLBOX TALK # 1

                                    EXPLOSIVE ORDNANCE

PREPARATION :       Ask EOD section if they have posters or illustrated booklets that you can
                    hand to each person at the talk.

1. Always be aware that unexploded ordnance could be in your work area. Inspect your
   areas, especially new work places for any suspicious objects. Report any findings to your

2. Types :
   a. Grenades, Rocket propelled grenades (RPG), Mortars, Shells, Mines.
   b. Allied Sub-ordnance, Rockeyes, Bombs. Shells.

3. Biggest danger is allied sub ordnance - many did not explode on impact, some are

4. Do not enter any area which is not certified "Cleared". If you are not sure if an area is
   cleared, supervisors should contact Safety Div (EOD) on the KOC fire radio channel.

5. Do not enter bunkers and weapon pits, there may be grenades or booby traps.

6. If you are driving do not leave black top road except on cleared sand roads. In many
   cases the hard shoulder contains unexploded sub-ordnance.

7. Be careful on the beaches - mines are still being washed up on the shore.

8. Do not collect souvenirs of bullets, shells, etc.

9. If you see anything which looks suspicious, or of which you are not sure, leave it alone
   and call your supervisor.

If you have some booklets hand them out to attendees.

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                                   TOOLBOX TALK # 2

                            RESPONSIBILITIES FOR SAFETY

1.   All employees are responsible for safety in KOC. Compliance with KOC Fire & Safety
     Regulations and safe work practices is mandatory.

2.   KOC Fire & Safety Regulations are available from Fire & Safety Dept. and all employees
     should read the regulations and be familiar with the content.

3.   The correct personal protective clothing must be worn at all times (Refer to Tool Box
     Talk #12)

4.   Always use the appropriate safety appliances to enable you to carry out your duties in
     a safe manner.

5.   Employees are encouraged to pursue safety as an equal goal to production,
     maintenance, engineering, office work, or any other job function.

6.   KOC Management is dedicated to providing a safe and healthy work place and the
     equipment and procedures to safely overcome any work place hazard.

7.   Do not take any risk which may cause an injury or other accident. Report unsafe
     conditions and acts to your supervisor.

8.   KOC Fire & Safety Dept. is available for consultation concerning all work place hazards.

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                                   TOOLBOX TALK # 3


1.   Contractors’ employees must comply with KOC (client) safety rules and regulations.
     When addressing KOC safety instructions, take all reasonable action to comply.

2.   Report any KOC safety requests to your supervisor immediately.

3.   KOC insists on the following compliance :
     a.    Always use required protective clothing and equipment. (i.e. Hard hats, Safety
           belts, etc).
     b.    Supervisors must obtain permits for excavations, hot work, cold work, etc before
           starting work.
     c.    All cranes and mobile equipment must have a current inspection/test certificate
           available at all times.
     d.    When moving to a new job, supervisors must first obtain a KOC work permit and
           an EOD clearance certificate before starting work.
     e.    Follow all traffic rules. Do not run stop lights or stop signs, obey traffic signs
           and drive at a safe speed for road conditions which does not exceed posted

4.   All employees are expected to follow the KOC Fire & Safety Regulations and prevent
     accidents from happening.

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                                   TOOLBOX TALK # 4


While the oil well fires were burning we had a constant reminder of how dangerous the work
area was. Now the fires are out and we have to constantly remind ourselves to work safely
and not to take foolish risks. So, remember the following rules :

1.    Every day, remind yourselves and your fellow employees not to become complacent.
      Follow all safety rules, and if you are in doubt ask your supervisor for guidance.

2.    Bad road conditions and poor driving are the No. 1 cause of accidents in KOC areas.
      Be aware of slippery roads and slow down when roads are wet. Follow all safe driving
      habits. Report dangerous road conditions to your supervisor immediately.

3.    Ordnance and explosives will be a hazard for many years. DO NOT TOUCH suspicious
      objects. DO NOT pick up any objects when you don't know what they are. Ordnance
      experts will remove ordnance hazards in work areas as necessary so report suspicious
      objects to your supervisor.

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                                    TOOLBOX TALK # 5


PREPARATION :      Have a look around the area and make a note of examples of good and
                   bad housekeeping to illustrate your talk.

1.    Waste materials and rubbish are a fire risk and an accident hazard. They must be kept
      to an absolute minimum and placed in either scrap or rubbish containers.

2.    Waste containers shall be located at suitable places on site.

3.    Do not allow oily rags to accumulate, they can ignite spontaneously.

4.    Spilled liquids must be wiped up immediately.

5.    Waste food should not be mixed with dry refuse. Food bins should have tightly fitting
      lids and be emptied not less than once per day

6.    Do not obstruct walkways, roadways, gangways or stairways.

7.    Do not bring more material from the materials yard than is needed. It gets in the way
      and leads to waste.

8.    Return surplus materials to the material yard or store.

9.    Ensure that tools are kept in tool boxes when not in use.

10.   All work areas must be kept orderly and clean on a DAILY basis.

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                                     TOOLBOX TALK # 6

                                       OFFICE SAFETY

PREPARATION :      Have a look around the offices and make a note of hazardous items or
                   conditions to illustrate your talk.

1.    Offices are relatively safe work areas but accidents and injuries still happen.

2.    Do not run in corridors, WALK.

3.    Discuss types of accidents and injuries.

4.    Do not stand and talk in front of closed doors, you may be hit if it is opened from the
      other side. Discuss the dangers.

5.    Do not read when walking.

6.    Ensure that power cords to office machines are not worn or damaged. Power cords
      should be laid so that they do not cause tripping hazards.

7.    Always close drawers and doors by using the handle, to avoid trapping your fingers.

8.    Do not put pencils, pens, scissors, etc. in stands with the point uppermost.

9.    Do not make your own electrical repairs or connections - call an electrician.

10.   Put cigarette ends in ashtrays, never in trash bins.

11.   Do not lean back in chairs on two legs.

12.   Report all defects in furniture e.g. missing casters, screws missing from areas of

13.   Make sure you know what to do in the event of a fire in the office (location of fire
      alarms, extinguishers, emergency exits, assembly points).

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                                   TOOLBOX TALK # 7

                                   PACKED LUNCHES

1.   It is essential that each employee appreciates and understands the great efforts made
     by all those concerned in producing a healthy, nutritious packed meal.

2.   All the preparation and packaging will :

     a.    Prevent food contamination.

     b.    Retain quality and nutritional value.

     c.    Facilitate an efficient handling and distribution system.

3.   Since all the necessary precautions are taken to provide these hygienic packed
     lunches by the catering staff, and because they have no further control after
     distribution, the following points must be adhered to:

     a.    Consume the contents of the lunch package as soon as possible (but do not
           open the lunch package until it is needed).

     b.    Do not add anything to a cold packed lunch, the fact that you may be introducing
           something of a less hygienic quality in a less hygienic environment is
           dangerous. Nor should anything HOT be added, since the possibility of
           contamination and temperature may encourage bacteriological propagation.

     c.    Try to keep the lunch in a shaded/cool place and never leave the package open.
           To do so will invite contamination from insects and/or air borne particles.

     d.    Take care not to damage the package. Never eat a lunch where the package has
           become damaged if it could have come into contact with any site materials.

     e.    Always wash your hands prior to handling, eating and especially after personal

     f.    Dispose of any left over food and packaging only to a designated waste area.

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                                    TOOLBOX TALK # 8

                              INCLEMENT WEATHER RULES

1.   Weather in Kuwait can become inclement and poses a variety of hazards.

2.   Sand storms, or a "Shamal", can occur in only a few hours. Winds will blow from 50 to
     60 miles per hour and visibility can become very poor.

3.   Do not drive into the desert during a strong sandstorm. Stay on roadways and do not
     exceed 50 kilometers per hour.

4.   If you are outside during a Shamal you should move indoors or find cover from the
     wind and sand. Always have a pair of goggles with you when working out of doors.

5.   Do not try to walk through a Shamal. Stay indoors, in a vehicle, or at a minimum, stay
     where you are.

6.   Assistance or transportation can be requested by radio.

7.   During the winter months (November through February) the temperature can drop to
     freezing. During the winter keep a heavy coat for use.

8.   In the spring, heavy rains will fall in Kuwait. The rain and oil that will wash onto roads
     will make driving very hazardous. DURING HEAVY RAINS REDUCE SPEED. Off road,
     the speed limit in such conditions should not exceed 50 KPH and may need to be

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                                      TOOLBOX TALK # 9

                          HEAT STRESS & HEAT-RELATED ILLNESS

Heat stress is a result of normal physical exertion. However in Kuwait, temperatures can
exceed 500C or 1200F which may lead to heat-related illness such as heat exhaustion or heat

Quick action in the early stages can usually reverse heat-related illnesses.

Heat Exhaustion

1.    Heat exhaustion can occur if a person becomes too hot, expends too much energy, and
      does not drink enough fluids.
2.    The symptoms of heat exhaustion are:
      -       Profuse sweating
      -       Muscle cramps, generally in the legs and abdomen
      -       Nausea
      -       Dizziness
3.    First aid for heat exhaustion is :
      -       Help the victim to lie down in the shade or air conditioned area.
      -       Give water in small amounts every 2 to 3 minutes until the victim recovers.
      -       Call for assistance by radio from the Ahmadi clinic.
      -       DO NOT give ice.
      -       Apply cool water to the back of the neck and wrists.

4.    Muscular cramps might occur as a result of salt depletion. In such cases, increase the
      salt intake of the victim.
Heat Stroke
1.    Heat stroke is very rare but is potentially life threatening.
2.    Heat stroke may occur after heat exhaustion has set in and has the following
      symptoms :
      -       High body temperature (very hot to the touch).
      -       Dry skin (the victim stops sweating).
      -       Rapid, shallow breathing.
      -       The victim will be disoriented or may become unconscious.
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3.   First Aid for heat stroke:
     -     Call for medical assistance immediately.
     -     Move the victim into shade or air conditioning.
     -     Keep the victim lying down on his side.
     -     Pack ice, if available, around the victims wrists, under the arms, and groin area.
           Use water if ice not available.
     -     If victim is conscious give small amounts of water to drink every 2 to 3 minutes.
     -     Remove clothing from chest to torso.
     -     Do not allow stroke victim to swallow ice and DO NOT give salt.
     -     Keep the victim calm and wait for medical assistance to arrive.

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                                      TOOLBOX TALK # 10

                                FIRE PREVENTION - BUILDINGS

1.     Switch off all unnecessary electrical equipment when you leave a building.

2.     Do not use home-made, taped, electrical connections, plugs, sockets, etc.

3.     Do not overload electrical sockets.

4.     Smoke only in approved Smoking Areas.

5.     Only use proper ash-trays, DO NOT put cigarette ash or butts in the trash bin.

6.     Security guards patrolling the buildings, offices, etc, shall be particularly alert for fires.
       Those found in the early stages can usually be controlled.

In the event of fire:

1.     On locating a fire, sound the fire alarm.

2.     Call Burgan Fire Station by telephone (66669, 22221, 22222, 3986373), giving your name
       and the exact location of the fire.

3.     Only if you can do so at no risk to yourself should you endeavor to attack the fire.

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                                   TOOLBOX TALK # 11

                                USE OF FIRE EXTINGUISHERS

PREPARATION :      Assemble a range of different types of fire extinguishers.

1.   Explain the different types of fire extinguishers and their uses/limitations:

     -      Dry Powder
     -      Foam
     -      Water
     -      Carbon Dioxide (CO2)
     -      Halon.

2.   K.O.C Fire Division is available to train employees on proper fire extinguisher use.

3.   Fire extinguisher must be inspected before being used for standby or safety watch use.
     Make sure that fire extinguishers gauge pressure is acceptable, that the hose is in good
     condition, the nozzle is unobstructed, and that the lever pin is in place.

4.   Replacement or additional fire extinguishers are maintained by Burgan Fire Station.
     This equipment can be requested by supervisors as needed.

5.   In the event of a fire:
     -   Use the fire extinguisher but only if safe to do so – DO NOT TAKE UNDUE RISKS.
     -   Sound the fire alarm
     -   Evacuate to the Assembly Area and report to your supervisor
     -   Report fires immediately to Burgan Fire Station (Tel: 66669/22221, 22222/3986373).

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                                  TOOLBOX TALK # 12


PREPARATION :    Get examples of all the different types of personal protection equipment
                 needed for your job.

1.   Using personal protective equipment is a requirement of everyone's job. All personal
     protective equipment is available from company stores.

2.   Overalls must be worn in all central process areas (GC’s, booster stations, tank farms

3.   Safety helmets are required in ALL field work areas. The only exceptions for not
     wearing safety helmets are inside offices, when riding inside vehicle, etc.

4.   Eye protection must be worn when working around blowing sand, pressurized
     equipment, when using striking tools such as chipping, when working around
     operating equipment, and when handling with chemicals.

5.   Leather and rubber gloves are available and are required as applicable.

6.   Foot wear must be of sound construction, and steel toes are required for many jobs.
     Athletic shoes are not allowed in the company workplaces.

7.   Hearing protection is required when working in noisy areas.

8.   Respirators are also supplied as necessary or when required by the permit to work.
     You may request a respirator from your supervisor.

9.   Turn in damaged safety equipment to your supervisor for free replacement.

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                                   TOOLBOX TALK # 13

                                      HAND SAFETY

1.   Injuries to hands and fingers are the most frequent type of injury.

2.   A small scratch or cut can become infected easily, which can lead to serious health

3.   Even the smallest injury must be reported to your supervisor and proper first aid will be

4.   To prevent hand injuries, wear work gloves when handling equipment such as piping,
     slings, using sledgehammers, carrying heavy equipment, etc.

5.   Inspect materials to be handled for burrs, splinters, cracks, etc and avoid these

6.   Rubber gloves are available and must be worn when handling chemicals.

7.   Welders gloves are available and must be worn when welding or torch cutting.

8.   Also, inspect hand tools for safe condition and use hand tools in a safe manner.

9.   Take great care and ALWAYS WEAR YOUR GLOVES when striking anything (e.g.
     chisels) with a hammer.

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                                   TOOLBOX TALK # 14

                                   FALL PROTECTION

PREPARATION :    Have a safety harness and lanyard available to show correct fitting &
                 methods and attachment.

1.   Fall protection is required for persons working at height when a fixed platform or
     scaffolding cannot be provided.

2.   In these circumstances, a safety harness must be used where persons can fall more
     than 2½ meters (8 feet).

3.   The safety harness with a lanyard must be of an approved type supplied by the

4.   Lanyards may not be more than 1½ meters (5 feet) in length.

5.   Safety harness and lanyard must be in good condition and inspected before use.

6.   The lanyard must be anchored to a suitable fixed point and to the harness. Where free
     movement is required, a running line is recommended (e.g. when working on top of
     tanks) to avoid the need to frequently unclip the harness.

7.   Fall protection is also required when working from a manlift, crane basket, or over open
     water or crude oil lagoons.

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                                     TOOLBOX TALK # 15

                                 RESPIRATORY PROTECTION

PREPARATION :        Get examples of all the different types of respiratory protection

     Type of Respirator                  Use                             Limitations
Dust respirators          To protect from nuisance and Check manufacturer limitations
                          dust – use in blowing sand, near
                          crude oil smoke, or in shops
                          when sanding, sawing wood, etc.
Chemical respirators      To protect from mist or vapour – Check manufacturer limitations.
                          used when entering vessels,
                          spray painting or when other
                          toxics cannot be removed from
                          the work area.
Canister gas masks        For specific gases based on Not to be used for dusts, mists,
                          canister type               vapours unless approved by
Self-Contained      In high concentrations of toxic Time limit on usage.
Breathing Apparatus gases, in oxygen deficient
(SCBA)              atmospheres, any environment
                    hazardous to life, emergencies
Supplied air breathing In hazardous situations e.g. high Not to be used in situations
airline apparatus      concentrations of toxic gases, in which     are      immediately
                       oxygen deficient atmospheres      dangerous to life.

1.      Respirators are available upon request from your supervisor.

2.      Burgan Fire Station can issue Self-Contained Breathing Apparatus (SCBA) or air line

3.      Any employee who is assigned to wear SCBA or supplied air respirator must first
        receive proper training.

4.      Medical approval is required for personnel required to wear supplied air respirators.

5.      Check Fire & Safety Regulations for further details on respirator usage.

6.      Refer to Toolbox Talk #16 for details of SCBA and supplied air respirator usage.

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                                   TOOLBOX TALK # 16


1.   Self Contained Breathing Apparatus (SCBA) is available from Burgan Fire Station.

2.   SCBA is required when emergency work is performed in a potentially toxic
     environment, such as repairing a leaking well head when hydrogen sulphide is present.

3.   For normal work in areas where a toxic atmosphere is possible, an air line supplied
     respirator is required, such as entering a crude oil storage tank or entering a desalter
     which may still have non-explosive levels of hydrocarbon present.

4.   The limits for working without air supplied respirators for particular substances are :
     -     Hydrogen sulphide                           10 parts per million
     -     Sulphur dioxide                             2 parts per million
     -     Hydrocarbon vapour (mixed)                  100 parts per million
     -     Oxygen content                              18 % minimum
     If there is any possibility of levels exceeding these limits, respiratory protection must
     be worn.

5.   Occupational Hygiene is available to measure all toxic substances on request.

6.   Any employee assigned to use an air-supplied respirator must be trained before using
     this equipment. The Fire Div. will conduct SCBA and air line supplied respirators on
     request. Burgan Fire Station also issues and maintains this equipment.

7.   In all cases where SCBA is used, there must be a standby safety watch positioned in a
     safe location, from where the use of SCBA can be viewed at all times.

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                                   TOOLBOX TALK # 17


1.   Gas detection equipment is available through the Occupational Hygienist. The
     Occupational Hygienist can analyze and determine specific amounts of the following
     a.    All petroleum gases and vapour including crude oil, gasoline, jet fuel, diesel, etc.
     b.    Hydrogen sulphide.
     c.    Sulphur dioxide.
     d.    Carbon monoxide.
     e.    Oxygen limits.
     f.    Other compounds can be analyzed upon request.
2.   Daily gas tests are conducted on request by Occupational Hygienist necessary
     precautions based on findings will be given to supervisors and employees.

3.   On occasion, a hydrocarbon and oxygen detector will be needed for continuous

4.   All gas detection equipment must be calibrated regularly and repaired as necessary to
     ensure that correct measurements are taken.

5.   If in doubt about the presence of a potentially dangerous gas, your supervisor must
     contact an occupational hygienist and measurement will be taken.

6.   Examples of when gas detection equipment must be used are as follows :
     a.    Before welding, torch cutting, or using sources of ignition around any equipment
           which is or was in petroleum service (i.e crude oil, gasoline, natural gas, diesel,
     b.    Prior to entry into any confined space or excavation.
     c.    When ever strong or irritating odours are reported.

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                                   TOOLBOX TALK # 18

                                  HYDROGEN SULPHIDE

1.    Hydrogen sulphide (H2S) is an extremely poisonous gas which, at low concentrations,
      smells like rotten eggs. At higher concentrations (above about 100 PPM) persons
      exposed to hydrogen sulphide lose their sense of smell.

2.    Hydrogen sulphide is found in the West Kuwait (Minagish) and South-East Kuwait
      (Burgan) oil fields and in the Divided Zone. It may also be present in South Tank Farm.

3.    Hydrogen sulphide has different effects as exposure levels increase. The exposure
      levels and effects are :

                Exposure level                             Health effect

       Less than 1 PPM                  H2S can be smelled (rotten eggs). No harmful

       Less than 5 PPM                  This amount can be smelled and is safe for 8 hours
                                        exposure without respiratory protection.

       Less than 15 PPM                 This amount can be smelled and is safe for 10
                                        minutes exposure without respiratory protection.

       100 PPM                          Eyes, nose, throat, become irritated. No
                                        permanent effects. LOSS OF SENSE OF SMELL

       500 PPM                          Dizziness, headaches, nausea, abdominal pains
                                        after 15 minutes, dangerous after 30 minutes
                                        exposure, rapidly produces unconsciousness and
                                        death if effective resuscitation is not applied.

       1000 PPM                         Victim is instantly unconscious and breathing
                                        stops. Death follows very quickly (1-2 minutes).

PPM - Parts Per Million.

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                                    TOOLBOX TALK # 19

                             ACCIDENT/INCIDENT REPORTING

PREPARATION :     Get examples of all the different types of Report Forms.

1.   All work related injuries, including minor injuries, must be reported promptly to your
     Supervisor for determination of appropriate action. (KOC Accident Report Form)

2.   All Near Misses should be reported on the appropriate Near Miss Forms which are
     available at various locations.

3.   All injuries, other than minor first aid injuries, shall be referred to Ahmadi hospital.

4.   Persons may be sent to the hospital by normal vehicle. In cases where it is dangerous
     to move the victim - e.g. spine and head injuries - an ambulance should be called by
     radio or telephone to Burgan Fire Station . (See also Toolbox Talk #20 Ahmadi Hospital
     and Ambulance Procedure).

5.   Make sure that the exact location and problem are clearly stated when reporting
     accidents/injuries (also see Toolbox Talk # 22 - Accident and Evacuation Procedures).

6.   All injuries shall be fully investigated by both the victim’s supervisor and, where
     necessary, a member of the Safety Dept. The supervisor shall submit a full report to
     Fire & Safety Dept.

7.   The report shall include all necessary photographs, drawings, etc and shall include
     recommendations for eliminating the cause of the accident.

8.   In serious cases, Burgan Fire Station staff will, where necessary, notify the police or
     other Government bodies.

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                                  TOOLBOX TALK # 20


1.   The Ahmadi hospital is staffed 24 hours per day and equipped to handle any illness or
     injury. All illnesses or injuries whether personal or project related should be reported
     to your supervisor and then to Ahmadi hospital.

2.   You should receive permission from your supervisor prior to reporting to the hospital
     with minor illnesses or injuries.

3.   Serious illness and/or injuries may be reported immediately to the hospital if an
     emergency condition exists.

4.   An ambulance staffed by paramedics can be requested at any time when an employee
     is too ill or injured to travel without medical assistance. If in doubt about whether an
     employee needs an ambulance, be conservative and call for an ambulance.

5.   An ambulance may be called by:
     -     telephone to Burgan Fire Station (Tel: 66669/22221, 22222/3986373).
     -     radio on the "Fire channel".
     (DO NOT call the ambulance or hospital direct by radio, this causes confusion.)
6.   Do not take chances with illness or injuries.     Report to the hospital and Ahmadi
     hospital staff will ensure care.

                                          Page 26/69
                                                                               Issued March 2000
                                    TOOLBOX TALK # 21


1.   Accidents which cause damage to property or to the environment must be reported,
     even where there is no personal injury.

2.   Examples of damage accidents which must be reported, include the following:
     -     The bursting of a grinding wheel.
     -     Collapse or failure of a crane, derrick or other lifting appliance.
     -     Explosion or fire causing damage to building, equipment or materials.
     -     Major electrical short circuit or fire.
     -     Vehicle accidents.
     -     Explosion or rupture of pressure vessel.
     -     Spillage of caustic, acidic or toxic chemicals.
     -     Damage to underground services during excavation work.
2.   All the above shall be reported as soon as possible to your Supervisor, to Burgan Fire
     Station (Tel: 66669/22221, 22222/3986373) and Fire & Safety Dept.

3.   The scene of the accident shall be left unchanged until an investigation has been
     carried out, except as is necessary to rescue personnel and prevent any aggravation of
     the incident.

4.   A report should be submitted to Fire & Safety Dept. within 24 hours.

5.   Burgan Fire Station will organise any necessary coordination with Kuwait government
     agencies (Police, Fire Dept.).

                                            Page 27/69
                                                                                 Issued March 2000
                                    TOOLBOX TALK # 22


1.   Accident procedures for the KOC are as follows :
     a.     If an injury, fire, or other accident occurs, report to your supervisor immediately.
     b.     Report the accident by radio or telephone to Burgan Fire Station immediately
     iii.   Make certain that you report the exact location and nature of the problem.
     iv.    In case of an emergency, identify the service required – Fire, Safety, Ambulance.
2.   If an area has to be evacuated, go to an assembly point and report to your supervisor.
     Your supervisor will pick an evacuation meeting area if this applies to your job.

3.   Fire, Safety and Medical assistance are available within minutes to any KOC location.
     So do not move an injured employee other than as a lifesaving measure.

4.   Do not attempt to fight a fire if there is any threat to you. Also do not alter an accident
     scene, such as moving vehicles or equipment.

5.   The rule during an emergency is DO NOT TAKE UNNECESSARY RISKS. Evacuate the
     area, call for help and assist the injured.

                                           Page 28/69
                                                                                  Issued March 2000
                                   TOOLBOX TALK # 23


1.   Gathering Center (GC's) and Booster Stations (BS’s) are collection and processing
     areas for crude oil and natural gas.

2.   Most jobs inside a GC or BS require a Work Permit.

3.   When working in an operating GC or BS always check in at the control room and obtain
     the Work Permit from the KOC personnel before starting work.

4.   Absolutely no hot work or vehicle entry is to be performed inside a GC or BS until a gas
     test and a hot work permit are issued.

5.   Always treat equipment such as piping, pumps, compressors, etc, as if it is under
     pressure. Follow valve lockout and tagging and line breaking safe work procedures.

6.   Use electrical lock out and tag out methods before working on any electrical

7.   Excavations inside GC's and BS’s require special permission and an excavation permit
     so underground piping and electrical cables can be identified.

8.   Before leaving the GC or BS report to the control room:
     - to return the Work Permit
     - to advise operations personnel of the status of the work
     - to advise that you are leaving site.

                                         Page 29/69
                                                                               Issued March 2000
                                   TOOLBOX TALK # 24

                           CONFINED SPACE / VESSEL ENTRY

1.    Entry into any vessel is potentially dangerous due to the possibility of oxygen
      deficiency, presence of flammable gas, hydrogen sulphide, or other toxic substances.

2.    Never enter a confined space / vessel until a Vessel Entry Permit has been issued by
      the Department concerned & the occupational hygienist.

3.    A confined space / vessel includes tanks, drums, large piping, exchangers drains,
      pipes or any other equipment that may contain toxic substances or a lack of oxygen.

4.    Any place deeper than 1.5 metres (e.g. excavation, pit, sump) should be considered as
      a confined space

5.    All confined spaces must be ventilated and have a constant flow of moving air before a
      permit can be granted. Air blowers shuld be installed if necessary.

6.    Gas tests are required before any vessel entry permit can be issued. The tests must
      include the following:
         flammable (combustible) gas
         oxygen content
         toxic substances which may be present, such as carbon monoxide, or hydrogen
7.    Gas test limits for a normal vessel entry are oxygen at 20.9%, combustible gas at 0%,
      and hydrogen sulphide at 0 parts per million.

8.    If gas test results are out of the normal range, then special equipment such as
      respirators, protective clothing and forced and forced air ventilation will be required.

9.    The results of gas tests and any special precautions must be written on the vessel
      entry permit.

10.   Gas tests are good for no more than 1 regular shift. Continuous gas testing may be
      required and will be provided by the occupational hygienist.

11.   Work in confined spaces should always be done as a “buddy system”, and using

                                          Page 30/69
                                                                                Issued March 2000
                                   TOOLBOX TALK # 25

                         CRANES AND OVERHEAD POWER LINES

1.    Overhead power and communications lines are a constant hazard for cranes.

2.    Crane operators and supervisors must always survey a job and note the location of
      power and communication lines. Make certain that the signal man, rigger and other
      personnel also know that powerlines are in the work area.

12.   When driving a crane to a new location, place the boom at the lowest angle and use a
      flagman to direct the crane.

13.   Never drive, or move a crane on a roadway with the boom up or extended. This should
      eliminate striking overhead lines.

14.   If a power line is pulled down by a crane, DO NOT approach the crane. The threat of
      electrocution is to employees close to the crane. The driver should not leave the crane
      until the power source has been switched off.

15.   Damage to communication lines must be reported immediately.

                                          Page 31/69
                                                                               Issued March 2000
                                   TOOLBOX TALK # 26

                                WORKING IN THE DESERT

1.   All employees working in desert locations must be informed of the following safety
     policies :
     a.    Ambulance procedures.
     b.    Work permit procedures.
     c.    Explosive ordnance safety rules.
     d.    Personal protective equipment.
     e.    Other safety regulations which pertain to the work assignment.
2.   Before driving in the desert, the vehicle must be inspected and equipment for travelling
     in the desert must be obtained.

3.   All employees must be prepared for desert weather conditions and temperature.
     Supervisors must inform employees of desert hazards during winter (i.e low
     temperature and high winds, low visibility) and summer (i.e extreme heat of 55" C or
     higher, heat stress, and highwinds).

4.   High wind is a constant hazard especially due to poor visibility and the potential of eye
     injuries. All drivers must drive slowly and all employees must have eye protection in

5.   Also remember that there are animals, reptiles and insects in the desert such as dog
     packs, snakes (some poisonous) and scorpions which can be dangerous. Be watchful
     and do not attempt to handle or catch desert animals, reptiles or insects.

6.   If someone is bitten or stung, radio or telephone Burgan Fire Station for immediate
     assistance. Keep the person calm and lying still. A doctor or paramedic will give you
     advice on the radio concerning first aid.

7.   Always remember explosive ordnance safety rules. Do not touch suspicious items.
     Report suspected ordnance to your supervisor immediately and advice Burgan Fire

                                          Page 32/69
                                                                                Issued March 2000
                                     TOOLBOX TALK # 27

1.    There are several kinds of animals, reptiles and insects in the desert which are
      potentially dangerous. Leave all of these creatures alone and they will not pose any
      threat to you.
2.    Do not feed wild dogs or cats. Leaving food out will also encourage mice and rats.
      Rabies is prevalent in the Mid-East and becoming friendly with wild dogs and cats
      could result in getting bitten by a animal with rabies.
3.    Sand vipers, a poisonous snake, have been found in KOC work areas.
4.    Scorpions are also common in Kuwait as are spiders and other insects which bite.
5.    Report any animal and snake bite or scorpion sting by radio or telephone to Burgan
      Fire Station.
6.    If mice, ants, mosquitoes, or other pests become a problem in the work area, a
      contractor is available to exterminate vermin and insects. Any requests for these
      services should be directed to the occupational hygienist.
If a person is bitten by desert animal or insect, the following First Aid should be performed:


If the victim is more than 10 minutes from the hospital, place a band above the bite or above
the joint closest to the bite.

Do not move the person. Keep the victim calm and call for Emergency Assistance.


If available place an ice pack, or ice cube on the sting. Transport the employee if he is
suffering from shock to the close hospital.


Ice cubes or an ice pack should be used to relieve pain. If the bite does not heal within a few
days, or becomes infected, the victim should report to the hospital.


The victim should immediately report to the hospital for tests and, if necessary, treatment.
The Medical Officer of Health should diagnose the bite and notify the detail to the Veterinarian
for observation of the animal.

                                           Page 33/69
                                                                                  Issued March 2000
                                  TOOLBOX TALK # 28

                               WORKING ON FLOWLINES

1.   Construction and repair of flowlines is potentially hazardous due to the presence of
     flammable hydrocarbons (crude oil and natural gas).

2.   A hot work permit and gas test are required before welding, torch cutting, or grinding
     on any flowlines.

3.   All feasible precautions must be used to remove hydrocarbons from flowlines before
     breaking into the lines or carrying out any hot work. Stopples must be installed and gas
     tests conducted before any source of ignition can be used.

4.   Cold cutting flowlines also requires a permit. Once a cold work permit is issued, all
     equipment must be intrinsically safe, non-sparking or cannot create a source of

5.   Daily permits and gas tests are issued by the Dept. Concerned and hot work and cold
     work permits be issued daily, before work begins.

6.   Since most flowline work is in the desert you should always watch for ordnance in the
     work area.

7.   Remember - DO NOT TOUCH suspicious objects. Report these suspected ordnance to
     your supervisor immediately and advise Burgan Fire Station.

                                         Page 34/69
                                                                               Issued March 2000
                                   TOOLBOX TALK # 29

                               WORKING NEAR CRUDE OIL

1.   Crude Oil should always be treated as a hazardous, and flammable substance.

2.   NEVER drive through standing crude oil. Several very serious fires have occurred
     when people have driven through crude oil and the engine or exhaust system ignited
     the oil.

3.   Roads can become very slippery when covered with crude oil. The speed limit is 25kph
     when driving on roads that are coated with crude oil.

4.   You cannot swim in crude oil. The oil is too light to support weight. NEVER work over
     standing crude oil, such as in an excavation, oil lagoon, inside a tank, etc. Supervision
     must have crude oil removed before work can be done.

5.   Any employees performing work near crude oil must be issued with a hot work permit
     before starting work. Gas tests must be done, stopples must be used in pipes, crude
     oil must be removed from the area, and all other safety requirements must be in place
     before a hot work permit can be issued.

6.   Always wear gloves when handling equipment coated handling crude oil.

                                         Page 35/69
                                                                               Issued March 2000
                                  TOOLBOX TALK # 30

                                  WORK OVER WATER

PREPARATION :    Assemble examples of protection equipment (e.g. buoyancy aids, lifebelts)

1.   When persons are working over or near water they shall wear approved buoyancy aids.

2.   There shall be suitable rescue equipment readily available - Lifebelts, ropes, rescue

3.   There shall be a proper procedure for rescue persons from the water and all employees
     shall be familiar with it.

4.   All boats used for water transport shall be soundly constructed and supervised by a
     competent person.

5.   Other than docks and jetties, all open sides of working places from which a person can
     fall into water shall be fenced or appropriately barricaded.

                                        Page 36/69
                                                                             Issued March 2000
                                   TOOLBOX TALK # 31

                                     DRIVING SAFETY

PREPARATION :     Get a tyre pressure gauge and know the correct tyre pressures for each
                  type of vehicle.

1.   Inspect your vehicle every day before driving, including checking oil, tyre pressure,
     recheck engine fluids, clean windows, clean head and tail lights, etc.

2.   Tyre pressures must be set to the manufacturers recommended pressures. Never
     lower tyre pressures because it is hot. If you have to reduce tyre pressure to cross soft
     sand, re-inflate when you get back on the gravel or black top. Soft tyres flex more than
     correctly inflated tyres, generating higher tyre wall temperatures, which can lead to a

3.   Obey local speed limits on streets and highways.

4.   Do not run through red lights. It is against the law.

5.   On dirt roads, or diversions roads, do not exceed 45kph. Remember it takes longer to
     stop on dirt and gravel that it does on dry pavement.

6.   Always wear your seat belt. It is the law. A seat belt can save your life and prevent
     serious injuries. This includes all passengers where seat belts are provided.

                                          Page 37/69
                                                                                Issued March 2000
                                    TOOLBOX TALK # 32

                        ROAD SAFETY – DRIVING ON WET ROADS

In winter, some of the road conditions in KOC areas become wet and slippery due to rain, and
serious accidents and injuries have occurred.

Particularly when driving off black top roads (gatch or sand roads), rain water mixed with
sand can cause very slippery, hazardous conditions.

In order to avoid such accidents you should follow these safety rules.

1.    During rain, reduce speed to suit the road conditions.

2.    When driving on sand/gatch roads, do not exceed 50kph – if conditions are bad, reduce
      speed further.

3.    REMEMBER stopping distances are longer on wet roads. When travelling behind other
      vehicles on wet roads, ensure that you keep a good distance back, in case the vehicle
      in front stops suddenly.

4.    Report dangerous road conditions to your supervisor.

                                          Page 38/69
                                                                              Issued March 2000
                                    TOOLBOX TALK # 33

                                  DRIVING IN THE DESERT

1.   Before setting off, check the vehicle-fuel, oil, tires and controls.

2.   Carry the following provisions/equipment (as a minimum):
     -     at least 2 large bottles of drinking water (minimum of 3 liters per person)
     -     a shovel
     -     a tow rope with an eye and shackle at each end
     -     a good torch or flashlight
     -     a jacket, it can get cold after dark.

3.   Notify your supervisor of the route being taken and expected time of return.

4.   Take a radio or mobile telephone and stay in contact regularly.

5.   When off the road, as far as possible, follow existing tracks and wheel marks.

6.   If you see an area ahead which looks soft, either sand or salt marsh, stop your vehicle
     on firm ground and do a reconnaissance on foot.

7.   If you breakdown or the vehicle gets stuck, DO NOT leave your vehicle and try to walk
     out. Stay with the vehicle at all times except if you can see a roadway or other
     inhabitation within 1 km. Keep in the shade and keep physical movement to a

8.   Open the trunk and hood of the vehicle so that any passing vehicle or aircraft can see
     you need assistance.

                                           Page 39/69
                                                                                Issued March 2000
                                    TOOLBOX TALK # 34

                                      WORK PERMITS

PREPARATION :     Get copies of the different types of permit. Know how they are applied
                  and the responsibilities of the different people involved.

1.   Work permits are required before working in any company “Hazardous” and
     “Restricted” areas.

2.   The purpose is to authorize work to be carried out under controlled conditions and to
     specify the precautions to be taken.

3.   Work Permits are required for all the following activities:
     - hot work
     - cold work
     - entry into a confined space
     - vehicle entry into a restricted or hazardous area
     - electrical work
     - excavations
     - use of radioactive materials.

4.   Applications for work permits are made to the Department (Issuing Authority) in whose
     area the work is to be done.

5.   The Issuing Authority will authorize the Work Permit and specify any precautions to be

6.   Most permits are renewed every shift change.

7.   Work Permits must be returned to the Issuing Authority on completion of the work or
     on expiry of the permit.

     don't know if the permit has been issued, ask your supervisor. Make sure you
     understand what the permit is for and that you understand what you can and cannot

                                           Page 40/69
                                                                             Issued March 2000
                                   TOOLBOX TALK # 35


1.   It is very important to know the location of buried piping electrical lines, etc, before
     excavating. Buried lines must be identified, marked and stated on excavation

2.   An Excavation Notification Certificate must be obtained, IN ADDITION TO OTHER
     WORK PERMITS, prior to starting any excavation work, regardless of the depth.

3.   Excavation Notifications must signed by the appropriate KOC Engineers.

4.   Where only hand tools are used a COLD WORK PERMIT is required in addition.

5.   Where excavations using powered plant a HOT WORK PERMIT is required in addition.

6.   Where excavations below 1200 mm an ENTRY PERMIT is required in addition.

7.   If employees are to enter an excavation the following rules apply :
     a.    Excavation spoil must be moved at least 1½ meters away from the edge of the
     b.    Shoring must be used, or the excavation must be sloped to prevent collapsing
           when the excavation depth is greater than 1.5 meters.
     c.    Ladders or stairs must be provided when excavations are more than 1½ meters
     d.    Ladders, when required, shall not be more than 8 meters apart.
8.   Excavations in SOLID rock are the only types exempt from shoring or sloping.

9.   In some cases, excavations will need to be gas tested before employees may enter.
     This is required when crude oil, gasoline, or other hydrocarbon is in an excavation.
     Other precautions, such as respirators may be required depending on gas test results.
     The Occupational Hygienist will conduct gas tests and record results on a work permit.

                                         Page 41/69
                                                                               Issued March 2000
                                   TOOLBOX TALK # 36

                                  ELECTRICAL LOCK OUT

PREPARATION :         Get copies of Work Permit and Electrical Permit/Clearance Forms.


2.    All lock outs must be performed by a qualified electrician.

3.    An Electrical Permit (lock out form) must be used to record electrical lock out (Show
      copy of Form).

4.    The Main Work Permit must also show the name/signature of the person responsible
      for electrical isolation of the equipment. (Show copy of Form)

5.    High voltage equipment must also be grounded after lock out to discharge any residual

6.    When a lock out is done under a work permit, the lock out form must be attached to the
      top of the work permit.

7.    A gang lock (multi-lock) should be locked onto the switch gear and all other crafts will
      attach padlocks before starting work.

8.    Locks will be released only after each craft has completed work on the equipment.

9.    When work is completed, each craft must sign-off on the work permit and release the
      craft lock.

10.   An Electrical Clearance Certificate must be completed by the person responsible for
      the work before de-isolating the equipment. (Show copy of Form)

                                          Page 42/69
                                                                                Issued March 2000
                                  TOOLBOX TALK # 37

                           VALVE LOCK OUT AND TAGGING

1.   In certain cases, piping must be worked on which is depressured, but not blinded, for
     jobs such as replacing a gasket, cold cutting a line, changing a valve, etc.

2.   All valve(s) used to isolate piping and/or equipment must be closed and locked or
     sealed closed. A "DANGER - DO NOT OPERATE " tag must be placed on the valve(s)
     by the person responsible for the isolation.

3.   This procedure also applies to double block and bleed valves.

4.   Stopples or other approved line plugging methods, must be in place before hot work
     may be done on the line. Also, a hot work permit must be issued before welding,
     cutting, grinding, etc. on piping in hydrocarbon service.

5.   Tags may be removed only by the person who installed the tag or by a person of
     Superintendent authority or higher.

6.   Always make certain that piping is depressurised and that a work permit has been
     issued before working on piping, valves, pumps or other related equipment.

                                        Page 43/69
                                                                            Issued March 2000
                                    TOOLBOX TALK # 38

                                      LINE BREAKING

1.   Dismantling piping for repairs or replacement must be done with EXTREME CAUTION.
     Check to make sure the line has been depressured and that a valid permit has been

2.   When opening a line at a flange, start by slightly loosening, or "breaking" all bolts in an
     even manner. Use a wedge or flange spreader to ensure that there is no trapped
     pressure before removing bolts.

3.   Bolts should be completely loosened at opposite sides of the piping to evenly
     distribute pressure on the flange. In other words, DO NOT loosen bolts in a clockwise,
     or counter-clockwise manner as this puts unnecessary strain on the flange.

4.   When using a cold cutting device, such as a "pipe cutter" or "water cooled hacksaw",
     always make sure a cold work permit has been issued.

5.   When cold cutting a pipe, use a pipe cutter slowly and prevent the piping from
     "snapping" apart.

6.   Allow any residual product in the pipe to drain out and remove product from the area
     before performing any hot work.

7.   All piping must be stoppled, or equally plugged, gas tested and have a hot work permit
     issued before grinding, welding, torch cutting, or using other sources of ignition.

                                          Page 44/69
                                                                                 Issued March 2000
                                   TOOLBOX TALK # 39

                                  WORKSHOP PRACTICE

Hold the toolbox talk in the workshop.

1.    Workshops shall be kept tidy and free from waste materials, rubbish, etc.

2.    Gangways shall be clearly marked and kept free of obstructions.

3.    Each machine shall have its own clearly marked area.

4.    Where necessary guards or screens shall be placed to prevent particles and chippings
      from machines striking persons on adjacent machines or in the walkways.

5.    All rubbish shall be placed in bins or drums, which shall be emptied regularly. Oil rags
      shall not be accumulate because of the risk of auto-ignition.

6.    High pressure compressed air shall not be used to blow swarf, sawdust, filings, etc.

7.    Where overhead gantry cranes are installed, they shall only be operated by competent
      persons. They shall be fitted with travel alarms.

8.    Welding areas shall be fully screened to prevent the UV light affecting non-involved

9.    Oil spillages shall be cleaned up immediately.

10.   Fire equipment must not be obstructed and must be in good working condition.

11.   Eye protection must be worn be when operating workshop equipment. Hearing
      protection is also available and recommended for use when operating equipment.

                                          Page 45/69
                                                                                  Issued March 2000
                                   TOOLBOX TALK # 40

                                  MACHINE GUARDING

1.   All machinery must have dangerous parts guarded to prevent access including gears,
     chain and sprocket drives, belt drives, shafts, spindles, chucks and other rotating

2.   Grinding machines, lathes, and similar machines, must have transparent guards used
     to contain cutting and chips.

3.   Hand held and mounted saws and grinders must have blades and discs guarded.

4.   Push sticks must be used to feed table saws.

5.   All machinery must have one of the two following shut-off features ;
     a.    An emergency push button within easy access that will disconnect power.
     b.    A safety trigger which will shut the device off as soon as the trigger is released.
6.   Eye protection is always required when using hand held and fixed machines.

7.   Machinery operators must avoid wearing loose clothing which may tangle in rotating
     machine parts.

8.   Never tape down the safety trigger of a power tool.

                                          Page 46/69
                                                                                Issued March 2000
                                  TOOLBOX TALK # 41

                                      HAND TOOLS

1.   It is important to maintain hand tools in good condition. In particular attention should
     be paid to:
     a.    Wooden handles shall be kept free from splinters and cracks.
     b.    Wood handles for hammers and sledgehammers shall be secured with tapered
     c.    Steel wedges, spanners, hammers, etc, shall be free from burrs.
     d.    Non-sparking brass tools, chisels, etc, should be trimmed down to prevent
           "mushrooming" the head of the tool.
2.   Files should have proper handles. Avoid using files with bare tangs.

3.   Always wear eye protection when using striking tools.

4.   When using a hammer to strike a spanner, chisel, etc, the tool being hit shall not be
     held by hand. Always hold a striking tool in place with rope, stiff wire loop, or other
     means to keep the hands away from being hit by the hammer.

                                         Page 47/69
                                                                               Issued March 2000
                                 TOOLBOX TALK # 42

                              USE OF COMPRESSED AIR

1.   The use of compressed air for cleaning or drying shall only be permitted when other
     more acceptable methods are impracticable.

2.   Under no conditions the maximum pressure permissible for such purposes shall be 0.7
     bar/10 psi. Air lines shall be fitted with an appropriate pressure regulator.

3.   Under no conditions shall compressed air be used to blow dust or dirt off an
     employees skin or clothing, or for cooling purposed.

4.   Any person handling compressed air shall wear eye protection.

5.   Compressed air hoses used for cleaning or drying shall be fitted with a proper nozzle
     which includes and on/off valve.

6.   Under no circumstances, except in an emergency, shall the air supply be cut off by
     kinking the hose.

7.   Hose couplings shall be fitted with pins or other means to prevent accidental

8.   Horseplay with compressed air is extremely dangerous and is prohibited.

                                        Page 48/69
                                                                               Issued March 2000
                                    TOOLBOX TALK # 43

                                    PNEUMATIC TOOLS

PREPARATION :     Assemble some typical pneumatic tools.

1.   Pneumatic tools must be inspected for proper operation before use, including :

     i)     Safety clips in place to prevent the tool from ejecting out of the holder.

     ii)    Air hose connections are wired together.

     iii)   The tool is not leaking internally.

     iv)    The safety trigger automatically shuts off when released.

2.   NEVER use nitrogen to power pneumatic tools.

3.   Air tools can be very noisy. Ear plugs or ear muffs should be worn when using
     pneumatic tools.

4.   Eye protection is also very important when using air tools, especially grinders,
     chipping devices, wire brushes, etc. Wear goggles when using air tools.

5.   Do not pick up, or lower air tools by the air hose. Use a rope, tied to the tool to raise
     and lower pneumatic tools.

6.   Check the speed of the tool, particulars grinders and drills.

7.   Make sure grinding wheel, discs and tools are correctly in order to avoid failure.

                                           Page 49/69
                                                                                Issued March 2000
                                    TOOLBOX TALK # 44

                             SANDBLASTING (SHOTBLASTING)

1.    Sand blasting can be hazardous and precautions must be taken to avoid accidents.

2.    A work permit is required before blasting in Restricted Areas (gathering centers, in tank
      farms, etc.)

3.    Only qualified persons are allowed to sandblast.

4.    Filters must be used to prevent oil mist and high levels of carbon monoxide from
      entering the air hose. Filters should be changed out regularly.

5.    Air hose couplings must be pinned or wired together.

6.    Sand blast nozzles must be equipped with safety release grips, or "dead man grips" so
      the nozzle will shut off it dropped.

7.    Sand blasting equipment must be properly grounded (earthed) to prevent static build

8.    Never by pass sandblasting safe guards such as wiring dead man grips shut, working
      without air filters, etc.

9.    Ensure proper protective equipment is worn:
      -     Sand blast hoods must be of approved design and always used.
      -     Employees supporting the sand blasters must wear goggles as minimum eye
            protection and face shields must be readily available.
      -     Hearing protection is required if noise levels exceed 85 dBA (decibels).

10.   Sand blast areas must be clearly marked with barricade tape and partitions set-up to
      prevent sand from entering adjacent work areas.

11.   Take account of wind direction and strength.

12.   A special procedure is required when sand blasting well heads. Check with the Dept.
      concerned before blasting well heads.

                                          Page 50/69
                                                                                 Issued March 2000
                                    TOOLBOX TALK # 45

                                   ELECTRICAL SAFETY

PREPARATION :     Get a defective extension lead or electric power tool so you can point out
                  the faults.

1.   All electrical equipment must be in good condition, and inspected prior to us show
     common defects to look for.

2.   Electrical devices must have a plug with good prongs and without cracks, cords must
     not be frayed, and no exposed, or taped over wiring is allowed. All joints shall be made
     with proper plugs and sockets.

3.   Electric cords must be kept out of water and crude oil. Electrical cords must also be
     protected from fraying when used on platforms, laid over railings, etc.

4.   Portable electric tools should be double insulated. Double insulated tools all have
     plastic housings. Portable power tools with metal casings have only single insulation
     and must be grounded prior to use.

5.   Electric devices must be de-energized and locked out before commencing any repairs.
     All analysis and repair of electrical devices must be performed by a certified electrician.

6.   Temporary wiring must follow recognized standards. Placing bare wire into outlets is
     strictly prohibited.

                                          Page 51/69
                                                                                 Issued March 2000
                                   TOOLBOX TALK # 46

                              PORTABLE ELECTRIC TOOLS

PREPARATION :     Get some portable electric tools and extension leads together. Identify
                  defects and use as examples.

1.   Portable electric tools should be 110 volts supply.

2.   Portable electric tools should be double insulated. Double insulated tools all have
     plastic housings. Any single insulated tool must have a dedicated ground. Single
     insulated tools have metal housings.

3.   Damaged or defective tools must be taken out of service immediately and returned to
     the electrical shop for repair point out typical defects.

4.   Cable plugs must be intact and not altered in any manner. Placing bare wire into an
     outlet is strictly prohibited.

5.   Cables must be kept clear from stairways, platforms, walkways, etc, where a tripping
     hazard may occur.

6.   All guards supplied by the manufacturer must be in use with all tools.

7.   Temporary lighting systems must have all lamps protected with strong wire guards.

                                         Page 52/69
                                                                              Issued March 2000
                                   TOOLBOX TALK # 47

                               WELDING (GENERAL RULES)

PREPARATION :     Assemble a complete set of Personal Protective Equipment that a welder
                  should use.

1.    Wear proper protective clothing. Eye, face and arm/hand protective equipment must be
      in use during all welding. Welder’s assistant must also wear proper protective

2.    Leather gauntlets, aprons, spats and other suitable protective clothing must be worn.

3.    Ensure that the appropriate Hot Work Permit has been issued and the red copy has
      been sent to Fire & Safety Dept.

4.    A gas test must be carried out prior to welding and the area must be clear of flammable
      gases and others flammable materials, eg. papers, rags, oil, etc.

5.    Install welding screens where possible to prevent other persons getting "Flash".
      Helpers must wear proper protective clothing, including eye protection.

6.    If welding above ground level, contain hot slag with suitable sheeting. Ensure that a
      water hose and/or Fire Extinguishers are within the work area.

7.    In a plant area ensure that all drains within 20 metres are covered with wet tarpaulins
      weighted with hand bags to provide a gas tight seal.

8.    In confined spaces ensure there is adequate ventilation, and use respiratory equipment
      if necessary. If necessary, use forced air ventilation when welding or cutting in any
      confined space.

9.    All welding equipment must be in good condition and regularly inspected.

10.   Some welding/flame cutting operations produce toxic gases. When it is necessary to
      perform such work within poorly ventilated areas, breathing apparatus must be used.

                                          Page 53/69
                                                                               Issued March 2000
                                  TOOLBOX TALK # 48

                                ELECTRIC ARC WELDING

PREPARATION :     Get a range of electric arc welding equipment in use in your area (hold the
                  talk in the welding area).

1.   Refer to Toolbox talk # 47 for General Rules.

2.   Connecting and disconnecting power supply cables from the mains through plug
     and switch boxes to welding transformers and generator sets must be done by a
     skilled electrician.

3.   Ensure that welding generators/transformers are grounded (earthed).

4.   Only approved connectors, fittings etc. may be used.

5.   Ensure ground (earth) return clamps are in good condition and located as close as
     possible to the work position.

6.   All welding arcs taken from the same machine shall be of the same polarity.

7.   In Alternating Current (AC) welding an automatic voltage regulator must be installed
     to ensure safe voltage limits.

                                         Page 54/69
                                                                               Issued March 2000
                                  TOOLBOX TALK # 49

                              GAS WELDING AND CUTTING

PREPARATION :     Get a gas welding kit so you can point out the important features.

1.   Refer to Toolbox talk # 47 for General Rules.

2.   Special care must be taken in the handling and use of acetylene as it has a very wide
     explosive range. Acetylene is also shock sensitive and cylinders must not be abused.

3.   Gas/oxygen cylinders in use must be secured to a welding cart, or other suitable
     structure. (Demonstrate)

4.   All equipment must be inspected prior to use including regulators, hoses, flash back
     arrestors, torches, etc.

5.   All persons involved must be familiar with the identification colours for gas cylinders
     (e.g. acetylene – maroon, oxygen - black)

6.   Cylinder caps must be replaced on gas cylinders prior to moving to a new location.

7.   Take precautions to prevent oil and grease from getting inside oxygen regulators or on
     oxygen valve threads.

                                         Page 55/69
                                                                               Issued March 2000
                                    TOOLBOX TALK # 50

                              COMPRESSED GAS CYLINDERS

PREPARATION :      Get a range of different cylinders in use in your area, or hold the talk at the
                   cylinder store.

1.    Compressed gas cylinders must be handled with care. Large cylinders weigh up to 75
      kilograms, or 160 pounds.

2.    When moving cylinders, use a cart or trolley. Never roll cylinders on the ground.

3.    A minimum of two employees are required to hand carry cylinders. Demonstrate safe
      handling techniques.

4.    Cylinder caps must be in place when cylinders are not in use, especially when
      cylinders are transported.

5.    Cylinders should be stored securely to prevent them from falling over.

6.    Regulators should be inspected daily including accurate gauges, dents or cracks in
      gauge covers etc. Demonstrate using a broken regulator to show faults.

7.    Cylinders should never be placed in use while laying on their side. Cylinders in use
      should be secured in an upright position.

8.    Never oil or grease cylinder valves and/or regulators because of the danger of causing
      an explosion.

9.    Full and empty cylinders should be segregated (kept separate) and `FULL' and `EMPTY'
      notices displayed accordingly.

10.   Vehicles carrying flammable gas cylinders must carry suitable fire extinguishers and
      prominently display the relevant warning signs. Smoking is prohibited.

11.   Cylinders must never be lifted by their valve cap or guard.

12.   Cylinders must be stored so that they are protected from direct sunlight.

13.   You should be familiar with the identification colours for gas cylinders (e.g. acetylene –
      maroon, oxygen - black).

                                           Page 56/69
                                                                                   Issued March 2000
Page 57/69
             Issued March 2000
                                   TOOLBOX TALK # 51


PREPARATION :     Hold the meeting at a scaffold, and point out good and bad features of the

1.    All scaffolding must be constructed and maintained in accordance with KOC Fire &
      Safety Regulations.

2.    Scaffold frames must be tubular steel construction.

3.    Hand rails and toe boards must be included on all scaffolds.

4.    Scaffold planks must be a least 50 millimeters thick, and a minimum of 2 metres in
      length. Scaffold planks must extend past the frame support by at least 30 centimeters,
      and boards must be tied down, or otherwise secured to prevent movement.

5.    An access ladder, separate from the scaffold frame must be used and secured to all

6.    No more than 1.5 metres, is allowed between horizontal bracing, or ledgers.

7.    Diagonal supports are also required on every other scaffold bay.

8.    Rolling scaffolds may not be higher than 3 times the narrowest scaffold width.

9.    All scaffold wheels must be equipped with working brakes, and brakes must be set
      while work is done on the scaffold.

10.   Employees are not allowed to ride on rolling scaffolds which are being moved.

11.   Tubular scaffold which exceed 10 meters in height, by 6 meters in width must be
      secured to the structure at 5 meter intervals.

                                          Page 58/69
                                                                               Issued March 2000
                                   TOOLBOX TALK # 52


1.   All ladders must be in good condition.

2.   Wooden folding ladders must not have any cracks, splinter or broken rungs. Metal
     folding ladders must be free from bends and cracking.

3.   All ladders must have safety feet to help prevent the ladder from slipping while being
     used. Ladders should be erected so that there is 1 unit of horizontal distance from the
     vertical face for every 4 units vertically.

4.   Extension ladders must be secured or tied at the top of the ladder to prevent tipping. If
     tying the extension ladder is not possible then a second person must hold the ladder
     while anyone climbs or works form the ladder.

5.   Fiberglass or wood ladders must be used for access to perform electrical work. Metal
     ladders shall not be used around power lines, for access to transformers, etc.

6.   Ladders should never be painted. Paint will cover cracks or splinters which may make
     the ladder unsafe.

7.   Never stand on the top step of a ladder while working. Work may be performed no
     higher than the second rung from the top of the ladder.

8.   When using an extension ladder for access to a roof, pipe rack, etc, the top of the
     ladder must extend a minimum of 1 meter above the point where work will be done.

9.   The use of home made ladders is strictly prohibited.

                                         Page 59/69
                                                                                Issued March 2000
                                    TOOLBOX TALK # 53

                                    FORKLIFT OPERATION

PREPARATION :      Have the talk around a typical forklift truck.

1.   Employees operating a forklift must be specially trained and certified before
     driving/operation the equipment.

2.   The forklift must be inspected daily before use for the following items :
     i)      Brakes
     ii)     Engine fluids
     iii)    Hydraulic lines
     iv)     Head and tail lights
     v)      Tires
     vi)     Back-up alarm
     vii)    Turn signals
     viii)   Overhead guard
     ix)     Lift controls
     x)      Horn
     xi)     Mirrors
3.   Report any unsafe equipment to your supervisor for repair. Repairs must be made
     before the equipment can be used.

4.   Drive forklifts slowly and sound the horn at corners or intersections to alert other
     employees. Also, always travel unloaded with the forks no more than ½ meter from the

5.   When carrying large loads and the front view is blocked, travel in reverse so a full view
     can be maintained.

6.   Passengers are not allowed on forklifts.

7.   Never allow an employee to ride, or stand on forks to make repairs. A special forklift
     platform must be used for employees using a forklift to gain access to elevated

8.   All loads must be placed on pallets. Do not lift loose equipment.

9.   Beware of blind spots when driving (especially rear).

                                           Page 60/69
                                                                                 Issued March 2000
                                    TOOLBOX TALK # 54

                              HEAVY TRANSPORT EQUIPMENT

1.    Heavy transport equipment includes trucks, dozers, mechanical shovels, side booms,
      cranes, graders and similar equipment.

2.    All the equipment must be properly maintained and in good condition.

3.    All operators shall be properly trained on the type of equipment they are operating, and
      shall hold the appropriate license.

4.    Wheel mounted equipment, other than trucks, shall be fitted with a reversing alarm.
      This applies particularly to mechanical shovels, truck cranes and fork lift trucks.

5.    Passengers shall not ride on equipment unless there is a properly installed seat for
      them, with seat belts.

6.    Load-carrying vehicles shall not be loaded beyond their rated capacity.

7.    Operators shall not refuel equipment with the engine running.

8.    No equipment shall enter a restricted area without a work permit.

9.    Drivers of trucks shall not remain in the cab when the truck is being loaded by crane,
      back hoe, clam shell or similar means.

10.   No person shall work under the elevated body of a tipping truck, or bucket of a
      mechanical shovel, unless it has been securely propped or chocked to prevent
      accidental lowering.

11.   All heavy equipment shall be fitted with a suitable fire extinguisher.

12.   It is prohibited to rest under truck or item of heavy equipment. Many people have been
      killed when the vehicle has moved or been driven off.

                                           Page 61/69
                                                                                Issued March 2000
                                       TOOLBOX TALK # 55

                             WORKING WITH HEAVY EQUIPMENT

1.    Supervisors must strictly control work site - keep personnel clear of operating plant.

2.    Operators must be extra vigilant.

3.    Operators should inspect equipment daily - mirrors, horn, brakes, etc.

4.    Personnel working near/with plant to remain constantly alert.

5.    Personnel must be aware of location of plant at all times.

6.    Beware of blind spots to operator (especially rear).

7.    Remember the reversing alarm.

8.    Personnel beware - operators hearing is impeded due to engine noise.

9.    Supervisor to remain in communication with operators in congested area – hand
      signals, whistle, air horn, visual.

10.   Barrier off site if necessary.

11.   Strict adherence to conditions of permit to work are to be maintained throughout job.

12.   It is strictly forbidden to sleep on rest underneath a heavy vehicle.

                                            Page 62/69
                                                                                Issued March 2000
                                     TOOLBOX TALK # 56

                                    LIFTING AND RIGGING

PREPARATION :      Assemble a number of slings with defects - have the tool box talk in the
                   crane yard.

1.    All crane operators and riggers must be specially trained and certified to perform this

2.    All certifiable lifting equipment must have a current certificate.


4.    Equipment must be inspected daily to ensure it is in good condition, including
      hydraulic lines, engine fluids, tires, load chart is available, etc.

5.    Any defective equipment must be reported to the supervisor and repaired/replaced
      before use.

6.    All slings must be inspected daily before use. Defective slings must be replaced

7.    When directing crane lifting, only qualified rigger or banksman shall give signals to
      crane operators. Signals must be standard approved signals.

8.    Never travel a load over personnel.

9.    Never stand underneath a load being lifted.

10.   Tag lines may be required to control awkward lifts, tandem lifts, etc.

11.   Shackles must be rated for the weight of each load.

12.   All crane hooks must have Safety catches.

13.   A flagman must accompany and direct a crane while being moved. Particular care
      must be used when operating a crane, or moving close to power lines. Make certain
      that ample clearance is kept between a crane and power lines.

14.   The use of “home-made” or modified lifting equipment is strictly prohibited.

                                            Page 63/69
                                                                               Issued March 2000
                                  TOOLBOX TALK # 57

                              RADIOGRAPHY AND X-RAYS

PREPARATION:     Have copies of Radiation Permit and Work Permit available.

1.   All radiography and use of radioactive sources must be conducted by person(s)
     certified/authorised to perform this work.

2.   A Radiation Work Permit is required before carrying out any radiography work or using

3.   A (Main) Work Permit may also be required in Hazardous or Restricted Areas.

4.   Signs stating- "Danger. Do Not Enter-Radiation Hazard" must be placed around the
     area being X-rayed at a distance calculated to provide protection against accidental

5.   Before taking X-ray of any equipment, the technician in charge must inform all
     supervisors and employees working in the area. The area must be evacuated before
     taking an X-ray.

6.   Technicians using radioactive sources must also inspect the area when finished to
     ensure that no radioactive material is left behind.

7.   Radiation readings are taken during X-raying to make sure that radiation levels do not
     pose a hazard to any employee.

8.   When finished X-raying, the technician will inform supervisors that the area is safe to

9.   All radioactive sources are kept in special containers that shield X-rays and prevent
     radiation from leaking out.

                                         Page 64/69
                                                                              Issued March 2000
                                    TOOLBOX TALK # 58

                             MATERIAL HANDLING & STORAGE

1.    All materials shall be properly stored on racks or pallets.

2.    Gangways shall be left to allow easy access to all materials, either by personnel or
      mechanical lifting equipment as appropriate.

3.    Adequate fire-fighting equipment must be provided. Such equipment must be readily
      accessible and not obstructed by the materials.

4.    Manual handling and lifting must be done correctly, using a straight back and bending
      the legs.

5.    Only trained and competent operators shall use fork lift trucks (see Tool Box Talk # 53).

6.    Volatile and flammable materials shall be stored in a separate, well ventilated building
      away from the main stores.

7.    Compressed gas cylinders shall be stored in accordance with procedure No.9.

8.    Mechanical lifting equipment shall only be used within its rated capacity.

9.    When opening wooden packing cases, ensure that all nails are either pulled or bent

10.   Always wear work gloves when handling materials.

                                           Page 65/69
                                                                                   Issued March 2000
                                   TOOL BOX TALK # 59

                         STORAGE & HANDLING OF CHEMICALS

1.   Hazard data sheets shall be available for all chemicals.

2.   Chemicals shall be properly stored in protected, secure, areas away from other

3.   All toxic substances shall have their characteristics, type of hazard and first aid action
     clearly displayed on the container label.

4.   All personnel handling such chemicals shall be :
     -     Fully instructed in the hazards and emergency action.
     -     Equipped with appropriate protective clothing, boots, chemical suits, gloves, eye
           protection, respiratory protection, as necessary.
5.   Chemicals which have a dangerous inter-action, such as acids and solvents, shall not
     be stored close together.

6.   Gases, or chemicals which give off vapour, shall be stored in well ventilated buildings.
     In case of toxic vapours or gases, appropriate respiratory protection shall be
     immediately available.

7.   Suitable safety showers and eye wash facilities shall be available where there are
     acidic or caustic chemicals.

8.   There shall be no smoking or sources of ignition in chemical storage areas.

9.   In case of spillage or leaks of dangerous chemicals the area must be cordoned off and
     Burgan Fire Station notified.

                                          Page 66/69
                                                                                Issued March 2000
                                   TOOLBOX TALK # 60

                                    USING SOLVENTS

1.   Solvents are used to clean equipment, especially to strip tar and oil from any surface.

2.   Types of solvents in use by KOC employees include Sentinel 606, Trimethylene Glycol,
     and others.

3.   Solvents must be approved by the Conservation & Environment Div. before use.

4.   Protective equipment must be worn when handling solvents including rubber boots,
     rubber gloves, and protective coveralls. Paper coveralls are worn when using a non-
     hazardous solvent and rubber coveralls must be used when hazardous chemicals are
     used for cleaning. Respirators may be required while using solvents.

5.   Safety information on each solvent and required protective equipment is attached.
     Safety meeting must be conducted to inform employees of solvent hazards before the
     initial use of a solvent. Your supervisor will arrange the meeting as necessary.

6.   Never heat solvents. This practice may cause the solvent to become flammable or
     decompose gibing off highly toxic fumes.

                                         Page 67/69
                                                                               Issued March 2000
                                     TOOLBOX TALK # 61

                                     USE OF EXPLOSIVES

1.    The use of explosives is strictly controlled by the Kuwait Authorities. They specify the
      conditions for transportation and storage.

2.    Any explosives store must be clean and dry. It shall be kept securely locked at all times
      when not in use and the key shall be kept by a responsible person nominated by KOC.

3.    Any tools used in the store shall be wood or non-sparking material.

4.    Explosive shall not be removed from its immediate wrapping, or cartridge wrapping
      within the store.

5.    Detonators shall be stored and transported separately form the bulk explosives.

6.    All explosives, detonators and associated equipment shall only be issued against a
      requisition signed by an authorized KOC representative.

7.    Explosives shall only be handled or used by a competent Shot-Firer. He shall be
      properly trained and experienced and shall be appointed in writing by KOC

8.    Before setting charges the immediate area shall be cleared of all personnel other than
      those engaged in the blasting work.

9.    Flagmen shall be posted in prominent positions on the perimeter of the area. They
      shall prevent the entry of persons to the area and indicate by signal to the Shot-Firer
      that the area is clear before he fires the charge.

10.   Shots shall normally be fired electrically.

11.   Use of explosives shall cease on the approach of a thunder or electrical storm.

12.   Electrical detonation shall not be used within 1.5km of any radio or transmitter since
      they are capable under some conditions of setting off electrical detonators.

13.   In the event of a misfire no person shall approach the charge until after :
      -     1 hour in the case of a charge fire by fuse.
      -     10 minutes after the last attempt to fire it electrically.
14.   There shall be no smoking lights or other means of ignition permitted within 10 metres
      of any explosives.

                                            Page 68/69
                                                                                    Issued March 2000
                                   TOOLBOX TALK # 62

                          DEMOLITION SAFETY PROCEDURES

1.   Demolition involves dismantling storage tanks, buildings, etc. Potential hazards during
     demolition involve use of cranes, rigging, use of cutting torches, handling debris by
     hand, hauling debris, etc.

2.   When using a crane during demolition the following safety rules are required :
     a.    Employees must be certified to operate cranes and to perform rigging.
     b.    All loads must have a tag line.
     c.    A banksman must accompany and assist in directing all cranes.
     d.    Do not allow people to stand under suspended loads.
3.   When using a cutting torch the following safety rules are required :
     a.    Work permits and gas testing are required prior to torch cutting. Ask your
           supervisor and make sure a permit has been issued before torch cutting.
     b.    Keep fire fighting equipment within easy reach of torch cutting areas.
     c.    Wet down areas as necessary to keep hot slag from starting fires or damaging
           other equipment.
     d.    Ensure that both cut sections will be stable after separation and will not tall or
           topple, causing damage or injury.
4.   When handling and hauling debris or scrap the following rules are required :
     a.    Always wear gloves when handling scrap material.
     b.    Avoid back injuries and get assistance in picking up heavy loads.
     c.    All material to be hauled off must be secured to prevent the load from shifting
           during transport.
5.   Use common sense when working on a demolition job. Make sure you know exactly
     what to do and that you communicate clearly with fellow employees.

6.   Special rules apply to demolition involving ASBESTOS – Check with your supervisor.

                                         Page 69/69
                                                                               Issued March 2000

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