MATRA UPAYA TANGGUH THINK SAFETY

Engineering & Construction

Safety Department

SAFETY MANUAL

SEPTEMBER 2007

Head Office:
Taman Krakatau Blok E 16 No 01
Cilegon – Banten
42161- Indonesia
Phone : ( 0254 ) 389064
Fax. : ( 0254 ) 389160
E-mail : primakon.utama@yahoo.com
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CONTENTS

1. INTRODUCTION

2. COMMITTEE OF SAFETY

3. SAFETY MEETING

4. RESPONSIBILITY

5. GENERAL REGULATION AND PROCEDURES

6. EMERGENCY COUNTER MEASURES

7. REPRIMAND

8. SAFETY PREVENTION MEASURES

9. RADIATION

10.PUBLIC NUISANCE CONTROL

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SAFETY MANUAL

1. INTRODUCTION:
In line with the Government and Client policy on safety this manual is a guideline for
a better and more effective control on safety on the job-site where most accident
occur due to lack of understanding of the situation and through unsafe acts and unsafe
conditions. As this safety plan cannot cover in detail all rules and procedure for safety
and sanitation of field construction due to a variety of construction procedure, local
-regulations and updated Client safety regulations, this safety plan is only as
guideline and must be followed to secure a safe and healthy working environment at
most working job-site and work-shop.

2. COMMITTEE OF SAFETY:
2-1. Committee:
1. PKU Safety Manager attends Safety Committee Meetings organized by
Client, then conducts safety practices or rules discussed or adopted at the
meeting.
2. PKU Safety Manager organizes Safety Committee meetings among PKU
people and its subcontractors, regularly or as necessary, to discuss safety
matters, give instructions and guidance, enforce safety practices, checking
etc.,.
3. Safety organization charts. Emergency communication channels, the Client
instructions shall be put up on bulletin boards for public notice.
2-2. PKU Safety committee consists of a number of section heads involved in the
construction works. Their main purposes are follows:
1). Complying with Government regulations.
2). To carry out safety programs.
3). To instruct safety program and safety regulations now and then
4). To investigate all reported cases of unsafe acts and unsafe conditions or
recommended for improvement.
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3. SAFETY MEETING:
A Safety meeting shall be held once a month, with all members of the committee
attending including PKU sub-contractors as and when necessary and before work starts
five (5) minutes daily lecture to all workers on Job-site.

4. RESPONSIBILITY
4-1. Safety Manager:
Safety Manager will be responsible for the following matters.
1. Organizing and operating Safety Committees as necessary.
2. Coordinating and adjusting work schedules and critical path interfaces, if the
matter will be of safety concern.
3. Daily patrol.
4. Safety training of subcontractors and their employees.
5. Involving himself with work execution plans and installation plans of
machinery and equipment, from safety point.
6. Tool Box Meeting.
7. Team Talks.

4-2. Construction Superintendent:

1. Construction Superintendent shall be responsible for safety,
fire, industrial health & environment control throughout the construction
period.
2. Construction Superintendent shall also organize and chair over
the Safety Committee to ensure that the work is executed safety by all
personnel throughout the job.

4-3. Safety Assistants:

1. Safety assistant shall be responsible to the Safety manager and shall assist
the Safety manager in ensuring that all working job-sites are safe before work
starts.
2. Safety assistant shall carry out safety checks and stop all unsafe acts and
rectify unsafe conditions daily at all working job-sites.
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3. Safety assistant shall feed back to the Safety manager of all violations for
study, rectifications and education of violators.

4-4. Supervisor:
1. Since the Supervisor is at the job-site most of the working time, he is the best
man to stop all unsafe acts and conditions.
Supervisor shall check and confirm work procedure including Safety
procedure before commencement of work and if possible to follow the
regulations as per stated in this Plan.
2. Supervisor will report to the Safety assistant or to Safety manager of all
violations of unsafe acts and unsafe conditions.
3. Supervisor will report to the Safety assistant or any near misses and accidents
(in writing) for study and prevention of further occurrences.
Note: The above should also apply to sub contractor's supervisor and
foreman.

5. GENERAL REGULATION AND PROCEDURE

5-1. Work permits:
PKU will comply with and clear CLIENT permit system for the piping work
enforced in the site.
Supervisor shall ensure that all work permits, clearances, firewater use,
scaffolding and lifting, etc., are in order before commencement of work.
1). Ensure to cancel the work permit at the end of the day.
2). Ensure renewals of other permits 1 day before date of expire.
3). Ensure you know what type of work you are doing and follow the procedure
(Hot work or Cold work) accordingly.
4). Ensure all fire fighting equipment are in good working condition e.g. fire
extinguishers; fire hoses are near place of work including permits, during
work.
5). Ensure proper signboards/warning signs are placed, hung or easily
noticeable.
6). Ensure to use proper tools.
7). Ensure proper housekeeping daily at the end of the day.
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5-2. Personal protective equipment & clothing

All workers are required to use proper clothing, long sleeves, pants, safety shoes
and safety helmets (Approved type).
1). Safety Helmets : Safety Helmets shall be worn in all areas of the construction.
2). Safety Goggles : Safety Glasses shall be worn in all areas of the construction.
In addition, goggles and fare shields shall be worn when
chipping, grinding, and using hazardous chemicals. Proper
goggle and welding hoods shall be worn when cutting or
welding.
3). Ear Plugs : Ensure use of earplug when working in areas where noise
Level exceeds 85 DBA or requirement in the construction
area.
4). Dust Mask/ Dust Respirators:
Proper respirators shall be worn when exposed to dust,
fumes or mist when they exceed established health
standards.
5). Gloves: Ensure use of welding gloves for welding.
Ensure use of fitter’s gloves for lifting hot or sharp edged
materials and during flame cutting, etc.
6). Safety Belts : Ensure use of approved type of safety belts when working at
heights of 2 meters and above must be fastened ( hook up )
to a reliable structural member.
7). Safety Shoes : Safety shoes shall be worn in all of the construction area;

5-3. Safety Training

PKU shall provide Safety training to each and every person of PKU and his
subcontractor who are permitted to come for work in the CLIENT premises.
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5-4. Safety check and inspection

Machinery and equipment, tools, jigs, materials and temporary facilities brought
to site shall be checked for inspection before use. Inspection shall be carried out
in accordance with applicable rules of clients and with PKU own rules to be
made separately.
The Safety manager and his assistants on the working job-site shall carry out
daily safety inspection and check.
Any violation will be promptly corrected and reported to the Safety manager for
immediate follow up action.

5-5. Safety patrol

PKU will join in the joint safety patrol together with clients or with its
subcontractors and give advices or take actions for improving unsafe
environments, leading to safe working conditions.

5-6. Cleaning and Housekeeping

Construction waste shall be collected to places to be designed by the clients and
be disposed of in accordance with the client's instruction. Access traffic ways and
walkways shall be kept clear, making it rules by checking the work places in the
end of day;
Sort things to order, make tidy, keep cleaning, be sanitary and act disciplinarily.

5-7. Tool Box Meeting

Before work in every morning, tools box talks shall be given before workers
gathered, delivering work instructions or matters commonly attended to. These
talks shall be followed by short radio gymnastic exercises.

5-8. Team Talks

After the toolbox meeting, small group talks shall be had among working teams
on specific subjects scheduled for the day's work.
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5-9. Construction items:

1). Work at elevated places
- For all works to be done at 2 meter and above the ground, the use
of safety belts for workers is a must and if necessary scaffolds
“Approved type " ramps, ladders and platforms shall be provided.
- Do not forget to place signboards “Scaffolding Safe For Use” or
“Do not use “shall be displayed at the scaffold.
- Ensure the scaffolding ramp is free from grease, oil, materials or
equipment.
- Ensure the type of work you are doing and erect the correct type
of scaffold i.e.
Heavy duty or Light duty "A" frame type.
- Ensure to use metal tubular of the correct size, boards, steel
ladders and sole plates and install safety barriers of scaffolding platform.
2). Entry into existing Vessels, Tanks or Equipment
- Obtain the necessary permits clearances and ensure equipment is gas
free.
- Install dueling fans for constant internal flow of air after spading.
- Ensure proper clothing for that particular work.
- Ensure that the standby worker is present all the time when someone is
working inside.
- Ensure fire fighting equipment and rescue equipment is near place of
work or near manhole of vessels.
- Ensure proper housekeeping at end of day.
- Ensure supervisor is present when carrying out works.
3). Blasting and Painting
- Obtain the necessary permits and
clearance.
- Ensure usage of proper Blasting hood,
masks, etc.
- Rope off area and use proper shielding.
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- Hang or place warning signboards “KEEP OFF BLASTING IN
PROGRESS” Note: Sandblasting work shall be followed Government
regulation.

4). Lifting works

- Obtain the necessary lifting permits and clearance.(certificate, insurance,

license, etc.,)
- Always study and check with crane foreman for advice before lifting
heavy loads.
- Check the ground where the crane is to place.
- Allocate a signalman who must wear a colure vest. .
- Signalman or foreman must stand at area where he can see the load and
also the operator during lifting.
- A union signals system with whistle, hands and or transceivers must be
agreed prior to lifting operations with crane operator.
- Stop lifting works if risky conditions are detected after trial lift
approximately a lift of 10cm from ground.
- Do not lift during bad weather i.e. strong winds, rain or night time
without any lighting systems.
- Always use guy ropes to control load when lifting in order to avoid
swaying.
- Supervisor and safety to be at site during lifting operation of heavy loads.

5). Traffic regulation

- Ensure to obtain the necessary vehicle entry permits.
- Ensure licensed drivers operate all motorized equipments.
- Ensure all vehicles have road taxes and are insured.
- Ensure all vehicles are in top working condition.
- Ensure proper parking of vehicles, do not park at the "NO PARKING
AREAS" at fire hydrants, fire fighting equipment and entrances etc.,
- Ensure drivers to follow Plant speed limits.
- Ensure proper ear thing of vehicles (Static Electricity).
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6). Equipment (Welding machine)

- Obtain necessary permits for equipment (if any).
- Ensure equipment is clean (no oil leaks) and in top working condition.
- Ensure equipment has proper guards for belting, fan, pulleys etc.
- Ensure equipment is fitted with anti electric shock device.
- Ensure all equipment is tested everyday before work to certify safe
opening condition.
- Ensure all exposed terminals be covered safely with insulation type.
- Always stop the engine for replacement of oil and fuel. Let engine cool
for at least two (2) minutes before refueling.
- Ensure proper ear thing of equipment.
- Ensure that proper fire extinguisher with current/valid certification is
mounted on the welding machine.

7). Compressed Gas Cylinder

- Always store gas cylinder in well-ventilated location under shade.
(Referable to store in racks if possible )
- Always store gas cylinders in upright position away from overhead
power lines, electrical switchboards.
- Ensure gas cylinder caps are capped on and turned off properly if not in
use or for transport.
- Ensure to tag separate empty cylinders from full ones.
- When in use ensure that gas cylinders are placed in upright position
mounted in gas trolleys.
- Ensure gas cylinders valves are free from oils or grease.
- Keep gas cylinders in use away from falling sparks, fire and electrical
power switches.
- Ensure that all hoses for gas cutting are free from leaks, cracked, bad
joints and connections.

5-10. Smoking and Matches

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a). Ensure that smoking within the plants is strictly prohibited except at
approved location i.e. smoking shed, offices.
b). Ensure that lighters, matches are not allowed into plants.

5-11. Alcoholic drinks

Ensure that no alcoholic drinks or those under the influence of such will be
permitted to enter plants and job-site.

5-12. Gambling
All forms of gambling are strictly prohibited within plants and job-site.

5-13. Drugs
All drugs related cases are strictly prohibited.

5-14. Camera and Photographs

Do not bring in cameras into the plants without authorization from respective
clients.

6. EMERGENCY COUNTERMEASURES
6-1. Countermeasures beforehand
In order to cope with the contingencies of accidents, social upheavals and or
natural disasters, emergency task force and their communication channels will
be organized and established in consultation with the clients and subcontractors.

6-2. Accident reporting and recording

In the occurrence or in the fear of any accident, first finder shall be requested to
take a prompt action for recovery in cooperation with other eyewitnesses on the
spot, and report it to his company or to PKU. On receipt of the report, the Task
Force will immediately report it to the client for advice, taking remedial actions
immediately.

6-3. First Aid kids for Medical emergency

PKU will provide first aid kids in its site office, as well as in its subcontractor's
site office for medical emergency.
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6-4. Safety surveillance

In the event the accident or casualties happened, PKU Task Force shall -make,
investigation of the accident to look into its cause, to prevent reoccurrence.
Preventive action shall be made with the data collected being kept for future use.

6-5. Reporting and Recording

Reporting to the authorities concerned as well as to the client shall be either
initiated by PKU, or by its subcontractors. In the latter case, copied set of the
following documents shall be submitted to PKU.

7. REPRIMAND
As reprimand against violators or in the existence of possible violation, of laws and
the regulations of clients and PKU, following actions may be taken;
1). Let violator(s) out of work or entry into the premises.
2). Advise replacement of the subcontractor's site manager or its .supervisor(s).
3). Take any other actions deemed as necessary.

8. SAFETY PREVENTION MEASURES

8-1. Explosion and fire
When there is risk of explosion and fire in the vicinity from hot work, full
protection shall be made for construction work in close or its surrounding areas,
so that the hot work will not trigger any accident.
a. Appoints safety man in charge of hot work- and fire, each from PKU
and its subcontractors at their site offices.
b. For welding and painting work where there are risks of catching a fire,
PKU and its sub-contractors shall take preventive measures against such
risks before starting work, checking the machinery and equipment they will
use, providing good air ventilation, considering wind direction, checking
ambience especially against possible toxic gas and/or oxygen deficiency.
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c. Restrict and fully control the dangerous and flammable substance to be
fraught to the site where hot work will be inevitable.

8-2. Working at Heights, Scaffolding Safety

In order to prevent falls from heights, try best from planning stage to shift as
much as possible the working at heights to working on the grounds. For work
at heights, provide complete scaffolding and staging with access walkways for
work at heights.
a. When working at height, erect sound staging with safe access ladders.
When it is difficult to provide staging, either provide safety net or use
lifeline to secure safety belt.
b. Before erecting or disassembling scaffoldings, check for sure if
preparations have been fully made, for work planning, appointment of
supervisor and foreman, number of workers teams, type and size of
structure to erect, scaffolding materials readiness etc.,
Stretch tiger ropes around the work area to sign off limit place, except for
entry of those concerned for work execution and inspection.
c. As protection against falls, workspace floor openings or ledges shall be
enclosed with handrails or ropes stretched on poles with a warning sign.
d. For working at height places, too aged or too young workers, workers
having high blood pressure or heat troubles shall not be used.
e. Ails and emergency exists must be kept clear and free of materials at all
times. Use safety belts or harness when working at heights.

8-3. Tool and materials fallen from heights.

In order to prevent accidents from falling materials, mind following points
especially.
a. Maintain good communication for coordination with working teams or
individual workers on the work to be undertaken, try to minimize the up
and down type of works as much possible.
b. Prohibit tossing tools and materials.
c. When to store or place materials and tools on working floors, beams
and ails at heights, fix the long materials with wires or ropes, put small
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pieces into sacks or boxes. Clear things no longer required down the high
place to the ground.

8-4. Materials Handling and Rigging

When operating such construction equipment as cranes and winches, and
handling heavy materials stuff, either licensed operators or those qualified
competent workers from training shall be used. Only construction equipment,
which has cleared inspection checks, shall be used.
a. Protection covers or stockade shall be provided around rotating equipment or
driving belts.
b. Licensed operators or those appointed as qualified shall be permitted for
handling construction equipment, on which tagged shall names of persons
in charge. Only those construction equipment and tools fit for purpose shall
be used.
c. Handling of heavy stuff and/or objects having long length shall be made in
reference of the applicable rules of CLIENT.
d. Machinery and tools shall be used to the extent possible in place of human
power when handling materials and equipment.
e. When marking transportation and assembly work that require joint
operation, appoint a commander in chief and follow his instruction.

8-5. Vehicle and traffic safety

To prevent traffic accidents within the site premises and on public roads,
communication routes for workers, and transportation for articles and materials
delivery shall be decided taking locality and the traffic laws and rules in force
into account.
a. Vehicles to be used must have statutory inspection cleared. Drivers or
operators shall be in possession of licenses.
b. Vehicles shall be operated in accordance with operation plans covering
designated routes to take, safety operation or rules of driving in the city
centers, over railroad crossing etc.
c. Driving inside of the premises shall be made as traffic signs and boards
designate.
d. Cargo loaded shall be fasten, and not in excess of overloads.
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e. Maintain smooth flow of traffic inside of the premises.
Use of microbuses or sharing of private car seas is recommended for
comPKUation. Microbuses for personnel carriage will drive by good
drivers.

8-6. Electrical safety

When distribution boxes pr panels will be installed temporary or generators
will be used, following points shall have to be checked and followed in order
to prevent people from risk of live electrical contracts.
a. Use electrical equipment in good condition, with inspection certificates
b. Qualified workers authorized shall perform Maintenance and inspection
of electrical wiring work and equipment.
c. Electrical apparatus and equipment shall be checked daily before work.
d. Before conducting electrical work or inspection checks, use protection
device for insulated tools, gears and wear safety attunement, to prevent risk
of electrocution from live electrical contacts.
e. When using electrical equipment and tools of removable type, they shall
be equipped with short circuit breakers or Ground Fault Circuit
Interrupters.
Check to ensure if welding machines is equipped with anti-electric shock
device, mega-tested as per clients' checks lists.
f. Provide protection against electric shocks by checking regularly and as
required, ground ear thing connection, sheathing of temporary wiring or
removal cable wires.

8-7. Crane operations

High risks lurk in crane operations and the risk prevention procedures are;
a. When you are going to use cranes, make sure from check lists if all the
required certificates would be available or not, for instance, certificates of
inspection, monthly inspected table, operator's license etc. Checking items
on the lists attached shall make routine inspection.
b. When moving a crane of the site, crane passenger routes will be designated.
A ground guide (signalman) will be provided when moving it in out of the
operation areas.
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c. When setting a crane in position, all crane outriggers will be fully
extended. Pads will be placed under all outrigger jacks.
When requested, ground compaction tests may be conducted for heavy
lifts. Check to see if there will be nothing to hit within the crane operating
range, and nothing to strain under the ground.
d. Stay people away from the working zone of the crane, except those people
working with the crane.
e. Qualified riggers will make Rigging work. All loads must be rigged
properly with use of padding as necessary for slings, at safe angles, with
signalman etc. Wire ropes and slings will be monthly and at regular
intervals checked for soundness.

8-8. Dangerous materials and working in confined space

a. Use of some classified materials will be prohibited, except the where it
will be exceptionally accepted or approved on the condition that full
measures will be provided for workers health protection.
b. Before working in confined space, or using organic chemical solutions,
oxygen deficiency or hazardous gases shall be checked first, and give
continuous ventilation. When welding or cutting work, exhaust ventilation
will be given. Breathing apparatus will be used as required by supervisor's
instruction.

9. RADIATION
Trained radiography personnel must handle all radiation equipment and radioactive
materials. The regulation for storage, handling and transportation must be adhered to
so that no person receives an unnecessary dose of radiation. When Non-destructive
examination with radiant rays will be conducts, PKU inspectors will submit an
inspection plan to client safety manager, so that pre-arrangement can be made through
coordination with other contractors arid sub-contractors, preventing them from
exposures to ionizing to radiation.
9-1. All radiation sources must be stored in leaded metal container chain with lock
for security.
9-2. It must also be stored in proper fenced up bomb pits chain with rock and
international warning sign displayed.
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9-3. Ensure that only authorized personnel are in the working area during
radiography.
9-4. Ensure all radiography personnel are equipped with film badges.
9-5. Ensure all radiography personnel who are handling the isotope are equipped with
dosimeter and survey meters.
9-6. Radiography supervisor must be on site during radiography works

10. PUBLIC NUISANCE CONTROL

Noise and vibration shall be controlled not in excess of limits stipulated by applicable
laws' and regulations.
Industrial effluent shall be disposed of same way, also in accordance with Client
instructions.