SHEM-08.03 Material Handling1

Classification: Internal Use
Operation Management System SHEM No. SHEM-08.03
Rev. # ( 0 ) Date Mar, 2021
Material Handling & Storage Next Review Date Feb, 2024
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TABLE OF CONTENTS
1. PURPOSE
2. SCOPE
3. GLOSSARY, FORMULAE & DEFINITIONS
4. ROLES AND RESPONSIBILITIES
5. PROCEDURE
6. LEGAL AND REGULATORY REQUIREMENT
7. CONTROL OF RECORD
8. COMPETENCY
9. CONTINUAL IMPROVEMENT
10. REFERENCE AND IMPORTANT LINKS
11. ATTACHMENTS
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1. PURPOSE:
The purpose of this sub-element is to ensure that effective systems exist covering
material handling and storage and to provide detailed requirements and guidance
towards world-class processes and best practices/best available techniques for
handling and storage of materials in a compliant and safe manner at normal
operation, maintenance, TA’s etc to ensure safety and well-being to all.
2. SCOPE:
This management system applies to all activities and locations where people are
required to handle and/or store materials and manual handling of materials within
Petrokemya premises including permanent buildings, installations and locations as
well as temporary activities and locations.
3. GLOSSARY, FORMULAE & DEFINITIONS:
GLOSSARY DEFINITION
BS British Standard
It is a colorless, tasteless and flammable gas. The OSHA

Carbon Monoxide
maximum permissible exposure level is 50 ppm, measured as
(CO)
an 8-hour time-weighted average (TWA).
CGA Compressed Gas Association
An inquiry raised to Global Assurance via a controlled form in
Clarification order to provide explanation on the intent of OMS standard
requirements.
Class 1A
flammable liquid Flashpoint is below 22.8° and boiling point is below 37.8°
(NFPA)
Class 1B
flammable liquid Flashpoint is below 22.8° and boiling point is at/or above 37.8°
(NFPA)
Class 1C
flammable liquid Flashpoint is above 22.8° and boiling point is below 37.8°
(NFPA)
Term used to identify liquid water formed by condensing steam.
Condensate Condensate can be found at a variety of temperatures and
pressures. Typical ranges are from 50°C (122°F) to several
hundred degrees C, and from 1 atmosphere to 40 atmospheres
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GLOSSARY DEFINITION
of pressure.
Any vessel of 227 liters (60 US gallons) or less capacity used for
Container
transporting or storing liquids.
Deutsches Institut für Normung (The German institute for
DIN
standardization).
ECM Enterprise Content Management
An area of a building separated from the remainder of the
building by construction having a fire resistance rating of at
Fire Area least 1 hour and having all communicating openings into other
areas protected by assemblies having a fire resistance rating of
at least 1 hour.
The concentration (in percent) of a gas or vapor in air at which
flame will propagate. When the concentration is below the
Flammable Limits Lower explosive limit (LEL), the mixture is too lean; when above
or Explosive Range the upper explosive limit (UEL), the mixture is too rich. The
concentrations between the LEL and the UEL are called the
'flammable limits’ or ‘explosive range'.
Any liquid having a flash point (closed cup) below 37.8°C (100°F)
and having a vapor pressure not exceeding 40 psia (absolute
Flammable Liquid
pressure measured in pounds per square inch) at 37.8°C
(100°F).
The minimum temperature at which a liquid gives off vapor
within a test vessel in sufficient concentration to form an
ignitable mixture with air near the surface of the liquid. Although
Flash Point
other properties influence the relative hazards of flammable
liquids, the flash point is the most significant factor. The relative
hazard increases as the flash point decreases.
FM Factory Mutual
HiPo High Potential
JQP Job Qualification Program
JSA Job Safety Analysis

Legal Obligations imposed on an organization, including those that
Requirements are statutory or regulatory.
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GLOSSARY DEFINITION
LEL Lower Explosive Limit
Any item which is used to secure a load to lifting appliances but
which is not in itself capable of lifting or lowering loads such as:
 Chain sling shackle
Lifting Gear  Fiber sling eyebolt
(Tackle)  Girder clip swivel
 Hook ring
 Spreader beam plate lifting clamp
 Wire rope sling link
Line Management Supervisors, Managers, and Senior Managers.
Management Detailed procedures or policies that explain the implementation
System methodology to meet the requirement of SABIC OMS standard.
MOC Management of Change
MSDS/SDS Material Safety Data Sheet/ Safety Data Sheet
NFPA National Fire Protection Association, USA
NIOSH National Institute for Occupational Safety and Health, USA
OMS Operations Management System.

A senior level individual from the Senior Management Team and
OMS Champion senior managers who demonstrate knowledge to implement,
review and update Petrokemya management system.
The percentage of actual adoption in terms of documentation
OMS Compliance
and implementation, against the applicable Management
Rate
system requirements in OMS.
OMS Document
Petrokemya Management System document issuers / authors.
Developers
A document that mainly enlists a set of Management system
requirements developed to outline what needs to be done in
OMS Element
order to achieve operational excellence for a specific business
aspect.
A subject matter expert who is accountable for the
OMS Element internalization of applicable requirements for specific OMS
Leader Management system, usually within the line management roles
of the organization.
A measure to define the successful achievement of expected
outcome that resulted from implementing the Management
OMS Performance
system requirements for one or a group of OMS elements. It
represents the percentage of achieved results versus the
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GLOSSARY DEFINITION
expected results.
An individual responsible for the coordination of OMS
OMS Specialist development and implementation, who interfaces with OMS
element owners and management.
OMS Sponsor Petrokemya President or his delegate.
A subject matter expert who is accountable for the
OMS Sub-Element internalization of applicable requirements for specific Sub OMS
Leader Management system, usually within the line management roles
of the organization.
OSHA Occupational Safety and Health Administration, USA
PHA Process Hazard Analysis
PK Petrokemya
Any closed vessel having a liquid capacity over 227 liters (60
Portable Tank
U.S. gallons) and not intended for fixed installation.
PPE Personal Protective Equipment
PSDS Product Safety Data Sheet
QA Quality Assurance
QAD Quality Assurance Department

Qualified Material Individual who is qualified by training and experience to operate
Handling Operator a specific type of material handling equipment.
RACI Responsible, Accountable, Consulted and Informed
For the purpose of OMS Standard, these are registered
SABIC Affiliates companies with facilities (operating plants, warehouses, tank
and Subsidiaries terminals & pipelines, etc.) that are in the SABIC group e.g. AR-
RAZI, GAS, YANPET and SABIC Europe.
For the purpose of OMS Standard, these include SABIC
Corporate Functions (Manufacturing, Corporate Finance, Human
Resources, Technology & Innovation, Shared Services, Strategy
SABIC Divisions & Planning, E&PM, Procurement Services, Employee Services,
General Services and Corporate Communications) and Strategic
Business Units (Chemicals, Polymers, Performance Chemicals,
Innovative Plastics, Metals and Fertilizers).
A Factory Mutual-Approved or Underwriters Laboratories-Listed
Safety Can container less than 18.9 liters (5 gallons) in capacity which has a
spring-closing lid and spout cover and so designed that it will
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GLOSSARY DEFINITION
safely relieve internal pressure when subjected to fire exposure.
A material safety data sheet (SDS), safety data sheet (SDS), or

product safety data sheet (PSDS) is an important component of
product stewardship and occupational safety and health. It is
intended to provide workers and emergency personnel with
procedures for handling or working with that substance in a
Safety Data
safe manner and includes information such as physical data
Sheets (SDS)
(melting point, boiling point, flash point, etc.), toxicity, health
effects, first aid, reactivity, storage, disposal, protective
equipment, and spill-handling procedures. SDS formats can
vary from source to source within a country depending on
national requirements.
SCW Services and Central Workshop
Senior
Leader of a department who is Senior Manager position.
Management
The term 'shall' as used in this document is intended to
Shall describe a mandatory requirement.
SHEM Safety, Security, Health & Environment Management
The term 'Should' as used in this document is intended to
Should describe a highly recommended, but not mandatory
requirement.
SME Subject Matter Expert.
SMP Standard Maintenance Procedure
SMT Site Management Team (Director) and President.
SOP Standard Operating Procedure

Steam Water, in vapor form, is odorless and can be invisible at super-
heated temperatures. When water is heated at atmospheric
pressure, it will boil when the temperature reaches 100°C
(212°F). As the pressure is increased, the boiling temperature of
the water and temperature of the steam increases. Water
flashing to steam expands about 1600 times at atmospheric
pressure.
Storage tank Any vessel having a liquid capacity greater than 227 liters (60 US
gallons) that is intended for fixed installation.
TA Turnaround
Test certificate A document signed by an authorized person containing the

prescribed particulars relating to the proof load test, or
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GLOSSARY DEFINITION
certificate issued by the manufacturer.
TWA Time-weighted Average
UEL Upper Explosive Limit
UL Underwriters Laboratories
Table 2 Glossary, Formulae & Definitions
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4. ROLES AND RESPONSIBILITIES
The following positions are assigned to the following responsibility to ensure

compliance to this management system.
R: Responsible A: Accountable C: Consulted I: Informed
Third-party contractor
EHSS Senior Manager
department Manager
SHEM-08.03 EL/SEL
Department Senior
Maintenance staff
Office Based staff

Operations staff
SN Activity description
Concerned
Manager
staff
SMT
Evaluate applicability of
4.1 A C R - R - - - -
this sub-element
Develop L3 documents to
4.2 adequately implement this A R R - R I I I I
sub-element
Ensure adequate
4.3 implementation of this sub- A R R R C R R R R
element
Identify training
4.4 A R R - R I I I I
requirements
Develop and track
4.5 A R - - R - - - -
performance indicators
Identify all regulatory
4.6 requirements relating to A I I R - I I I I
this management system
Comply with all regulatory
4.7 requirements relating to A R R - - R R R R
Perform periodic
inspections to verify
ongoing compliance with
4.8 A R R - - I I I I
regulatory and internal
requirements relating to
Periodically meets with
4.9 system administrator for A R R R R I I I I
reviewing OMS Action Plan
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EHSS Senior Manager
department Manager
SHEM-08.03 EL/SEL
Department Senior
Maintenance staff
Office Based staff

Operations staff
Concerned
Manager
staff
SMT
and KPI progress and
update.
Ensure to have SOP for
equipment Purging by
steam. Consider related
4.10 A R R - - I I - -
hazard such as vacuum,
hot service, steam
hammering.
Identification for nitrogen
sign on storage tank and
4.11 A R R - - I I - -
equipment under nitrogen
purge are executed.
Maintain Special PPE
4.12 cabinet in the required A R R - - I I - -
area.
Follow Portable container
4.13 - A R - - R R - R
storage instructions
Ensure to develop SMP for
4.14 A A R - - R R - R
manual Safe lifting
Ensure employees trained
4.15 A R R R R I I I I
on SHEM-08.03
Develop SOP for Gas
4.16 A R R - - I I - -
cylinder handling
Develop SOP/guidelines for
4.17 process purging, N2, A R R - - I I - -
Steam, etc.
Ensure Safe Nitrogen
Handling during normal
4.18 A R R - - R R - R
operation & T/A SHEM-
08.03
Complete checklist to
4.19 ensure all material storage - A R - - R R R R
are safe.
Follow SOP before chemical
4.20 - A R - - I R - -
loading or unloading
Be aware about safe
4.21 A R R - - R R R R
handling of material to
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EHSS Senior Manager
department Manager
SHEM-08.03 EL/SEL
Department Senior
Maintenance staff
Office Based staff

Operations staff
Concerned
Manager
staff
SMT
prevent injury & incident.
Follow Work Permit &

Procedure for Grounding
4.22 Equipment before loading A R R - - R R R R
or unloading flammable
material.
Follow SMP before
4.23 chemical loading or - A R - - R I R R
unloading.
Ensure all raw material
4.24 truck & ISO tank inspection A R R - - R R - R
form are received with SDS.
Check the condition of all
gas cylinder quantity &
quality of specification
4.25 - A R - - R R R I
during receiving and
acceptance from supplier.
Attachment 3
Develop SMP/SOP for Gas
4.26 A R R - - R R - I
cylinder handling
Ensure the material is well
organized, Attachment 2
checklist Reviewed, proper
4.27 A R R - - R R R R
action is taken to
implement SHEM-08.03
Requirement.
Table 3 Roles and Responsibilities
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5. PROCEDURE
5.1 Material Handling and Storage
All Storage of all materials shall comply with the following requirements:
5.1.1 PPE Requirement and Availability during Chemical Handling:
5.1.1.1 Area Owner will ensure that his area is having Special PPE cabinet
in the most suitable location. It consists of special personal
protective equipment (respiratory protection and chemical-
resistant suit, safety goggles & rubber gloves).
5.1.1.2 The Concerned department Manager shall ensures that these PPE
are checked on a periodic basis and part of safety task book.
5.1.1.3 Operation areas who deal with pyrophoric materials shall have
special PPE cabinet for pyrophoric material special suit and other
PPE.
5.1.1.4 The PPE in this cabinet is checked as part of call file checklist
record.
5.1.2 Area Sr. manager shall ensure relevant identification labels and warning
signs shall be in place for all stored materials.
5.1.3 All Tanks and pressure vessels shall be labeled by Owner with name and
hazard classification of the material stored, in accordance with the
applicable local standards/regulatory requirements. In the absence of
any local standards/regulatory requirements, NFPA 704 Standards
requirements shall be followed.
5.1.4 All Piping shall be labeled by Owner in a manner that allows relevant
personnel to quickly identify the service/contents of the piping. Piping
that handles hazardous materials/non-hazardous shall at least be clearly
labeled with name, flow direction and color coding scheme of the
material as per local regulation/standards.
5.1.5 Temporary and permanent storage of all materials shall be neat and
orderly.
5.1.6 Unobstructed access and movement shall be provided by owner to fire
hoses and extinguishers as well as for firefighting personnel.
5.1.7 Exits and aisle ways shall be kept clear at all times.
5.1.8 Storage racks shall be secured to the floor / wall and secured to each
other.
5.1.9 Damaged racks shall not be used for storage.
5.1.10 Step ladders and mobile ladders shall be made available to assist access
to material on racks at high elevations. Employees shall not be allowed
to climb racks.
5.1.11 Incompatible materials are not allowed to be stored together.
5.1.12 Smoking shall be prohibited in storage areas.
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5.1.13 Area owner shall ensure clear identification of the materials and
maximum quantities allowed to be stored in storage locations (or
sometimes even in specific cabinets/shelves) is important to prevent
unnecessary risks. Assistance shall be provided when moving excessive
loads. In general, objects over 23 kilograms (50.7 pounds) shall be
handled by two or more employees depending upon the shape of the
object.
5.1.14 Storage of material shall comply with the following requirements:
5.1.14.1 0.5 m to 1.0 m clearance shall be maintained under sprinklers.
Automatic sprinkler system controls and electrical panel boxes
shall be kept free and unobstructed
5.1.14.2 Storage of flammable liquids in open containers shall not be
permitted.
5.1.14.3 The requirements for containers shall be as per the applicable
standards/regulations.
5.1.14.4 In the absence of any applicable standards/regulations, Factory
Mutual-Approved or Underwriters Laboratories-Listed container
less than 18.9 liters (5 gallons) in capacity, which has a spring-
closing lid and spout cover and so designed that it will safely
relieve internal pressure when subjected to fire exposure, shall
be used.
5.1.15 Rolling objects on open shelves shall be blocked or wedged. In multiple
decking, heavier material shall be stored on the lower levels.
5.1.16 Area owner shall ensure adequate aisles shall be maintained for
unobstructed access. In the absence of any applicable standards/
regulations, it shall be in accordance with the following requirements:
5.1.16.1 Access aisles of at least 1.2 meters shall be maintained
5.1.16.2 Within indoor liquid storage areas, main aisles shall be a
minimum of 2.4 meters wide
5.1.16.3 Access ways in outside storage areas shall be a minimum of 3.6
meters wide
5.2 Flammable Material Handling and Storage
5.2.1 All department Sr. Manager shall ensure an adequate procedures (SMPs,
SOPs) are in place to safely handle flammable materials.
5.2.2 Each user must ensure Hot Work Permit procedure and SOP/SMP is in
compliance before loading or transferring flammable Liquid. Failure to
follow the procedure will lead to potential of having fire & cause injury.
The SOP for loading or unloading of specific chemicals shall include
appropriate personal protection equipment that must be use and the
details of that operation (SOP criteria as linked to SHEM-03: Standard
Operating & Maintenance Procedures). Petrokemya maintains an
updated list of hazardous materials being transport by road in & out of
their site.
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5.2.3 Updated hazard rating (fire, health, reactivity & special) labels as per
NFPA 704 requirements data for all Petrokemya hazardous chemicals are
available in ECM.
5.2.4 Operation Manger is responsible to ensure that all shifts shall maintain a
visual check, if any discrepancies, an immediate report to area Sr.
Manager to be done by Operation supervisor.
5.2.5 Operation supervisor is responsible to ensure the grounding maintained
for ISO tank & truck loading & unloading as per SOP. This is to prevent
static electricity build up during transfer, which is potential for fire.
5.2.6 Smoking (including the use of electronic cigarettes) and carrying of
matches, lighters, and other spark-producing devices shall not be
permitted in any area where flammable liquids are stored, handled, or
used.
5.2.7 Area owner shall ensure “No Smoking” signs shall be clearly posted in
such areas.
5.2.8 Area owner shall ensure flammable liquid containers and storage tanks
shall be posted with hazard identification labels as per applicable
standards/regulations. In the absence of any local
standards/regulations, the labels shall be as per NFPA 704
requirements.
5.2.9 Area owner shall ensure flammable liquid containers installed for filling
shall be electrically grounded and bonded to prevent static electricity
from causing a spark. The bond or ground or both shall be physically
applied or shall be assured by the nature of the installation.
5.2.10 Area owner shall ensure electrical grounding and bonding systems shall
be included in preventive maintenance schedules to ensure the systems
are regularly checked for electrical continuity. In addition, the exposed
visible portions of grounding and bonding systems shall be visually
inspected by the employee before each liquid transfer.
5.2.11 Ground wires shall be uninsulated for ease of inspection for mechanical
damage.
5.2.12 Where possible, interlocking of filling systems shall be installed to help
guarantee electrical continuity.
5.2.13 During flammable liquid filling operations, a wire bond shall be provided
between the storage container and the container being filled. The
bonding wire shall be grounded.
5.2.14 When dispensing from drums, the drums shall comply with the
applicable standards/regulations. In the absence of any applicable
standards/regulations, drums shall be equipped with Factory Mutual-
Approved or Underwriters Laboratories-Listed dispensing devices.
5.2.15 Flammable liquid transfer by means of air pressure acting directly on the
liquid shall be prohibited.
5.2.16 Flammable liquids shall not be stored in open containers. In addition,
containers shall not be stored close to heated pipes or other heat
sources or exposed to the rays of the sun unless the containers are
specifically designed/approved for outside storage.
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5.2.17 Tools, lighting and electrical equipment in areas where flammable liquid
is present shall meet the hazardous area classification requirements.
5.2.18 Flammable liquid storage cabinets shall not have a capacity for more
than 455 liters (120 gallons) of flammable liquids.
5.2.19 No more than three cabinets shall be located together in a single fire
area. Groups of cabinets must be separated by no less than 30 meters.
5.2.20 When flammable liquid storage cabinets are located indoors, vent
openings shall be sealed with securely fitted bungs or must be vented to
the outside. At least one portable fire extinguisher having a rating of not
less than 20-B shall be located outside the door opening into an area
where more than 60 gallons of flammable liquid are stored.
5.2.21 Storage tanks shall be designed, built and installed in accordance with
recognized good engineering standards for their material of
construction.
5.2.22 Special drainage, impounding areas, and/or diking shall be provided to
contain any discharge from aboveground storage tanks as per the
applicable standards/regulations. In the absence of any applicable
standards/regulations, it shall be as per NFPA 30.
5.2.23 Drainage systems shall be designed and operated to prevent discharge
to public waterways, public sewers, or adjoining property.
5.2.24 Department Sr. Manager shall ensure that all his employees, who use,
handle, store, and/or are otherwise exposed to flammable liquids shall
receive hazard communication training including general and chemical-
specific information record.
5.2.25 Department Sr. Manager shall ensure that above ground storage tanks
that are not inherently grounded (e.g. tanks on concrete or non-
conductive supports) shall be provided with a grounding system.
5.2.26 When flammable liquids are transferred from one container to another, a
means of bonding the two containers shall be provided prior to starting
the transfer.
5.2.27 Flammable liquid tank trucks and railroad tank cars shall be electrically
bonded and grounded to the loading rack.
5.2.28 Not more than a 1-day supply of flammable liquids in approved portable
containers (or not more than 95 liters (25 gallons), whichever is greater)
may be stored in a single fire area outside of an approved flammable
liquid storage cabinet.
5.3 Portable containers (material handling & storage):
This section states the requirements mandated by SAF-23, which applies to
flammable/combustible liquids stored in portable containers that individual
capacities do not exceed the following:
1. 60 gal (230 L) capacities for over pack drums
2. 119 gal (450 L) for drums or other containers
3. 660 gal (2500 L) for portable tanks
4. 793 gal (3000 L) for intermediate bulk containers
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5.3.1 Requirements:
1. Portable container materials, their volumes and their characteristics
shall be limited to what is specified in the Table 9.4.3 of NFPA 30
except non-metallic containers shall not be permitted for liquids
whose flash points are lower than 94°C (200 F).
2. Storage of portable containers shall be limited to a single area on the
ground level.
3. It shall not be more than 30 gallons of Class 1A and 120 gallons of
combined Class 1A, 1B, 1C flammable liquids shall be stored in a
single liquid storage cabinet of portable containers.
4. No more than three liquid storage cabinets shall be used in the same
control area for portable containers.
5. Portable containers Location, quantities, storage height, separation
distances, fire protection shall comply with NFPA 30 2018, Refer to
safety engineer for further clarification.
6. The storage area of portable containers shall be graded to divert
possible spills away from buildings or surrounded by a curb at least 6
in. (150 mm) high.
7. For portable containers, the curbed area shall have a storm drainage
system.
8. Storage area shall be protected against tampering and trespassing.
9. Storage area shall be kept free of weeds, debris and other
combustible materials for a distance of at least 10 ft. (3 m) around the
perimeter of the stored materials.
10. A canopy shall be provided over the storage area. The canopy shall
allow dissipation of heat or dispersion of flammable vapors and fire-
fighting access and control.
5.4 Gas Cylinder Handling and Storage
5.4.1 Initial inspection check list (Attachment 3) for receiving compressed gas
cylinders shall be used to check the condition of the cylinders by Material
department or the other department who are directly receiving it from
vendor/supplier. Unsafe cylinders not matching the criteria of the
attachment 3 shall reject back to the vendors. The reason for rejection
shall be communicated to the vendor by email and PK material section
with reporting of eSHEM. The reporter of eSHEM shall ensure to provide
all the details as per attachment 5 of this management system record.
5.4.2 Initial inspection checklist (Attachment 3) shall be recorded for one (1)
year from the date of inspection by Material department or other
departments who are directly receiving by vendor.
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5.4.3 Plant Inspection Checklist for Compressed Gas Cylinders (Attachment 2)

for plant compressed gas cylinders shall be used to check the condition
of the cylinders by Material department and end-user every quarterly,
from the date mentioned in the initial inspection checklist record
(attachment 3).
5.4.4 Plant Inspection Checklist for Compressed Gas Cylinders (Attachment 2)
shall be recorded for one (1) year from the date of inspection by Material
department or the other department who are directly receiving it from
vendor. The department receiving cylinders from material section shall
confirm the initial inspection checklist (attachment 3) date to perform the
Plant inspection checklist (attachment 2), each quarterly record.
5.4.5 Any department storing cylinder in their area shall ensure that after the
initial inspection with checklist attachment 2 and then at least every 03
months they shall inspect the cylinders with Plant inspection checklist
record.
5.4.6 All the requirement in this section is also applicable for any temporary
storage area in Plant, laydown, T/A plot plan, Project or other area inside
the Plant. The respective department / section / Project from PK shall
ensure compliance of proper inspection and storage requirement in
addition to all other requirement.
5.4.7 A Gas Cylinder call-file system shall be developed and recorded by all
Owner/End-User of the gas cylinders.
5.4.8 Cylinders shall be stored in accordance with applicable
standards/regulations requirements.
5.4.9 Flammable gas storage areas shall have a Class I electrical classification.
5.4.10 Acetylene cylinders shall always be stored valve end up.
5.4.11 Full and empty cylinders shall be stored separately.
5.4.12 Cylinder valves shall be closed when work is finished.
5.4.13 Cylinders shall be transported, used and stored in racks and secured
against falling with suitable chains or support. The support shall extend
to the upper one third of the cylinder.
5.4.14 The area where cylinders are being used shall be well ventilated.
5.4.15 Cylinder transportation shall comply with applicable standards and
regulations.
5.4.16 Only cylinders that meet applicable standards/regulations shall be
accepted. In the absence of any applicable standards/regulations, the
cylinder shall be accepted if the following conditions are met:
5.4.16.1 Compressed gas cylinders shall be legibly marked with either
the chemical or trade name of the gas. Such markings shall be
by means of stenciling, stamping, or labeling, and shall not be
readily removable. Cylinders on which the labeling is missing or
illegible shall not be used. It is also preferred that it be painted
according to the color code as per Attachment#1.
5.4.16.2 Each cylinder is to be pressure-tested at the frequency specified
by NFPA and be indelibly marked with the date of such test
record.
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5.4.17 Cylinders shall be free from corrosion, pitting, dents or other signs of
physical damage
5.4.18 Protective safety caps shall be in place (hand-tight) when delivered or
when the cylinder is not in use
5.4.19 Material safety data sheet (also known as a safety data sheet) must be
available or provided by the vendor
5.4.20 Cylinder fittings and valves shall meet the applicable standards /
regulations
5.4.21 Cylinder hoses for fuel gas service shall meet the applicable standards /
regulations. In the absence of any applicable standards/regulations, they
shall meet the following requirements:
5.4.21.1 Specification IP-7 for Rubber Welding Hose, Compressed Gas
Association and Rubber Manufacturer Association shall be
complied with.
5.4.21.2 Fuel gas hoses shall be red in color, oxygen hoses green, and
inert gas and air black.
5.4.22 When parallel lengths of oxygen and fuel gas hose are taped together
for convenience and to prevent tangling, not more than 4 inches per foot
shall be covered in tape
5.4.23 Hoses showing leaks, burns, areas of wear or other serious defects shall
be replaced.
5.4.24 Pressure-reducing regulators shall meet the applicable standards/
regulations. In the absence of any applicable standards/regulations, they
shall meet the following requirements:
5.4.24.1 Only Underwriters Laboratories (UL)-listed or Factory Mutual
(FM)-approved pressure-reducing regulators shall be used
5.4.24.2 Pressure-reducing regulators shall be used for the gas and
pressures for which they are labeled
5.4.24.3 Cylinder flash-back protection shall meet the applicable
standards/regulations. In the absence of any applicable
standards/regulations, it shall be provided on oxy-acetylene
lines by a UL-approved flame arrestor to prevent burn-back into
hoses and the regulator.
5.4.25 Cylinders shall be stored in accordance with applicable standards /
regulations. In the absence of any applicable standards/regulations,
cylinder storage shall meet the following requirements:
5.4.25.1 Smoking and open flames shall not be permitted in storage
areas or within 20 ft. (6.1 m) of storage areas.
5.4.25.2 Cylinder storage areas shall be fenced off and clearly marked
with 'NO SMOKING' and 'NO OPEN FLAME' signs
5.4.26 A separate area shall be provided for each individual material stored.
The name of the material in each storage area shall be prominently
posted
5.4.27 Gas cylinders shall be stored a minimum distance of 20 ft. (6.1 m) from
storage of flammable and combustible liquids and solids
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5.4.28 Oxygen cylinders shall be stored at least 6 meters away from cylinders
containing combustible gases, or from any highly combustible materials.
Exception: The minimum separation distance for the cylinders shall not
apply when they are separated by masonry walls with a fire resistance
rating of 2 hours
5.4.29 Different flammable gases shall be permitted to be stored together in a
group
5.4.30 Cylinders shall be stored where they are not exposed to physical
damage, tampering by unauthorized persons, or subject to
temperatures above 54°C (130°F)
5.4.31 Liquefied flammable gas cylinders shall be stored in the upright position
or such that the pressure relief valve is on the vapor space of the
cylinder.
5.4.32 Cylinders shall be stored away from stairs and in assigned places where
they will not be knocked over or damaged by passing or falling objects.
5.4.33 Petrokemya staff shall comply with the applicable standards/regulations
regarding handling and use of cylinders. Also, the following good
practices for cylinder handling and use shall be followed:
5.4.33.1 Contents of a gas cylinder shall be verified and the properties
of the gas shall be known before using.
5.4.33.2 Where compressed gas cylinders are designed to accept valve
protective caps, the user shall keep such caps on compressed
gas cylinders at all times except when being filled or
connected for use.
5.4.33.3 Leaking cylinders with the valve fully closed shall if possible be
removed to a location remote from other cylinders or work
area.
5.4.33.4 A leaking cylinder, or a cylinder that has been exposed to fire,
shall not be transported without consulting the supplier for
advice under these circumstances.
5.4.33.5 Lubrication of any cylinder’s valves and fittings with oil or
grease shall never be done because it is unnecessary and
highly dangerous.
5.4.33.6 Cylinder valves shall be closed before moving cylinders.
Cylinders shall also be appropriately secured.
5.4.33.7 Valve protection caps shall not be used for lifting cylinders
5.4.33.8 Cylinders shall be kept far enough away from welding or
cutting operations that sparks, hot slag or flame do not reach
them.
5.4.33.9 Cylinders shall be secured while connected to a portable
welding machine to prevent them from being knocked over or
thrown off in transit.
5.4.33.10 Cylinder shall not be lifted to an elevation with ropes wrapped
around them. Cylinders shall instead be lifted using a cage
with correct lifting lugs.
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5.4.33.11
Empty cylinders shall not be disposed of. They shall be
removed promptly from the plant areas and returned to the
empty cylinder racks provided. Only the owner of a cylinder
shall authorize its disposal.
5.5 Usage of Gas cylinders Hoses & fitting:
5.5.1 Only trained and qualified person is allowed to work on gas cylinder.
Any component part or hoses related to gas cylinder must be original
and it shall be approved & certified, fabricated ones are not accepted.
Only Underwriters Laboratories (UL) listed or Factory Mutual (FM)
approved pressure reducing regulators shall be used.
5.5.2 Before a regulator removed from a cylinder, the cylinder valve shall be
closed and the regulator relieved of gas pressure. The valve cap shall be
replaced, the cylinder clearly marked as "empty," and returned to a
storage area for pickup by the supplier.
5.5.3 Concerned Operation/Maintenance Sr. manager shall ensure
development SOP/SMP procedure for any work involved with gas
cylinder replacement. Such as CO Cylinder Replacement in Poly area &
Fabrication Group Welding Activity.
5.5.4 Analyzer specialist maintains SMP for work involving gas cylinders
replacement including Analyzer shelter gas cylinders also.
5.5.5 QA Analyst maintains SOP for work involving gas cylinders replacement
for QAD area.
5.5.6 Gauges used for oxygen service shall be marked, “USE NO OIL OR
GREASE”.
5.5.7 When regulators or parts of regulators, including gauges, need repair,
the work shall be performed by skilled mechanics who have been
properly instructed.
5.5.8 Cylinders shall be stored where were not exposed to physical damage,
tampering by unauthorized persons, or subject to temperatures above
54°C (130°F).
5.6 Handling of Specific Materials
Dept. Sr. Manager shall ensure that all his personnel potentially exposed to
hazardous chemicals/materials shall adequately trained by their depts. in the
safe use of such chemicals/materials before they are allowed to work with
them.
5.6.1 Identification of Workplace Hazard
5.6.1.1 Carbon Monoxide (CO) = a chemical compound consisting of
one carbon and one oxygen.
5.6.1.2 CO is a colorless, odorless, and flammable gas at room
temperature. Therefore, it has no WARNING properties!
5.6.1.3 The most likely route of exposure is through inhalation.
5.6.1.4 One of the most dangerous industrial hazards. Its Time
Weighted Average (TWA) concentration is 25 ppm.
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5.6.1.5 CO simply disrupts the oxygen transport to all tissues in the

body.
5.6.1.6 CO Exposure is a serious health and safety hazard
5.6.1.7 CO is especially a hazard in enclosed spaces
5.6.2 Sources of CO
5.6.2.1 Incomplete combustion of anything containing carbon (fossil
fuels, wood, tobacco) – Especially high in exhaust from internal
combustion engines.
5.6.2.2 CO is a metabolic product of methylene chloride (common
ingredient in paints and solvents)
5.6.2.3 Maybe be produced within the body by catabolism (breakdown)
of hemoglobin
5.6.3 Carbon monoxide (CO) handling shall comply with the following
requirements:
5.6.3.1 Sr. Manager shall ensure that all his personnel handling CO shall
be familiar with the hazards of CO, be able to recognize the
symptoms of overexposure and take appropriate actions if any
person is affected/overcome by CO. SDS shall be referred to for
hazards of CO
5.6.3.2 Vehicles with internal combustion engines shall not be operated
inside closed buildings without adequate ventilation.
5.6.3.3 Appropriate ventilation as per the applicable standards/
regulations shall be provided. In the absence of any applicable
standards/regulations, ventilation shall be provided when
carrying out operations where there is a possibility of
generating and/or accumulating CO. Exhaust ventilation shall be
provided at the point where CO is being generated.
5.6.3.4 All personnel handling CO shall be made aware of the exposure
possibility and shall be provided with portable CO monitors to
detect a rising or high level of CO. In addition, an air mover shall
be provided for situations in which CO levels are encountered or
can accumulate at dangerous concentrations, as per the
applicable standards/regulations. In the absence of any
applicable standards/regulations, an air mover shall be provided
where CO levels above 50 ppm are present to keep the work
area safe throughout the work process
5.6.4 Nitrogen handling shall comply with the following requirements:
5.6.4.1 Sr. Manager shall ensure that all each process area defines all
storage tanks under Nitrogen, equipment that normally
operates under a nitrogen purge record.
5.6.4.2 All personnel handling nitrogen shall be familiar with the
hazards of nitrogen, be able to recognize the symptoms of
overexposure and take appropriate actions if any person is
affected/overcome by nitrogen
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5.6.4.2.1 Properties of Nitrogen

a. Colorless, Odorless and Tasteless gas.
b. Non-combustible & does not support combustion.
c. Boiling point = -195.5ºC; Freezing point = - 210ºC
5.6.4.2.2 Hazards of Nitrogen:
a. Can cause asphyxiation by displacement of oxygen
in breathing air.
b. Less than 16% oxygen in breathing air could result
in human death.
c. Can over-pressure the equipment and result in
equipment expose to CET.
d. Will displace oxygen and Called as a SILENT
KILLER. Refer to SDS for more details.
e. Liquid Nitrogen at -195 deg. C can cause severe
cold burns.
5.6.4.3 All nitrogen piping shall be labeled or identified with appropriate
color code. Record of identification checklist is maintained with
the SHEM-08.03: Material Handling & Storage Sub-Element
Leader record.
5.6.4.4 Entry into an oxygen-deficient or inert atmosphere shall be
avoided. If it is unavoidable to perform a job in an oxygen-
deficient or inert atmosphere, then appropriate Risk
Assessment with SAFER shall be done.
5.6.4.5 All storage tanks that are blanketed or inserted with nitrogen
shall have appropriate signs at the base of the tank near the
access stairway(s).
Caution
Under Nitrogen
Blanket
Figure 1
5.6.4.6 All equipment that normally operates under a nitrogen purge

shall have a warning painted (with minimum sized 2 inch letters)
just above the manways used for entry as follows:
Caution
DANGER, HAZARDOUS
ATMOSPHERE
NITROGEN PURGE
Figure 2
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5.6.4.7 Permanent connections between the utility nitrogen system and

any process system shall only be installed after carefully
analyzing the possibility and hazards of process material
entering the nitrogen system and providing appropriate
protections against such a possibility. The change shall undergo
the Management of Change review process. Connectors or
couplings at nitrogen utility stations shall not be compatible
with other utility connectors such as steam, water or air
5.6.4.8 Nitrogen is called as silent killer and therefore extra precaution
shall be taken by following the Entry Permit procedure.
5.6.4.9 Confined space entry work permit management system (SHEM-
08.10: Work Permits) describes in detail the requirement and
risk involved with confined space entry, nitrogen and toxic
gases. Gas testing is mandatory and required before entering
any vessel or confined space when the decontamination is
completed.
5.6.4.10 Appropriate respiratory protection or a monitor (personal
alarm) that gives an audible alarm if the oxygen content in the
atmosphere falls below the acceptable level. shall be worn by
personnel gauging or inspecting the roof of a nitrogen-
blanketed tank to avoid exposure to nitrogen
5.6.4.11 Nitrogen shall not be used for instrument air.
5.6.4.12 Nitrogen lines shall be connected to instrument air lines only
after carefully analyzing the possibility and hazards of air
entering the nitrogen system and providing appropriate
protections against such possibilities. The change shall undergo
the Management of Change (SHEM-09) review process
5.6.4.13 When purging equipment with nitrogen, it is a good practice to
install a pressure gauge on the nitrogen system and on the
process system to allow the operator to monitor both systems.
5.6.4.14 When purging equipment with nitrogen a pressure relief system
shall be serviceable or installed to relieve the maximum quantity
at or below the design pressure.
5.6.4.15 Nitrogen shall be vented in a safe location such that personnel
are not exposed to low oxygen atmosphere as a result of
venting of nitrogen.
5.6.4.16 Spillage of liquid nitrogen can cause embrittlement of structural
material. Integrity of structural material shall be checked, if
liquid is spilled on it.
5.6.4.17 During turnaround, Nitrogen will be used widely for equipment/
system decontamination and dry-out. Contractor will hire more
personnel for the turnaround who will be new to the Petrokemya
system. It will be impractical to isolate the Nitrogen header.
Risks due to presence & use of Nitrogen must be managed to
ensure a safe turnaround.
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5.6.4.18 During TA, TA Manager will be responsible to control usage of

Nitrogen under strict conditions.
5.6.4.19 After the unit is hydrocarbon free and before allowing confined
space entry permits.
5.6.4.19.1 All Nitrogen valves at Utility Stations on the unit shall
be chained and locked.
5.6.4.19.2 All user lines shall be physically disconnected or
blinded.
5.6.4.19.3 Any need for Nitrogen shall be thoroughly verified,
documented & approved by the Op and TA Managers.
5.6.4.20 Cryogenic gloves and goggles must be worn when handling
liquid Nitrogen, steam lines or manipulating steam lines.
5.6.5 Steam and Hot Condensate handling shall comply with the following
requirements:
5.6.5.1 Area owner ensures the existence of the standard operating
procedure for handling operation activity of purging and
handling of steam system available. This procedure is part of
post qualification as per SHEM-03: Standard Operating and
Maintenance Procedures. The risk of handling steam system is
made known to users, as part of JQP training.
5.6.5.2 Steam is produced in various plants in Petrokemya (e.g
Utilities , Co-Generation, Olefins plants and distributed in
three different types as follows:
5.6.5.2.1 High Pressure (HP) steam at 4700kpa, superheated to
approximately 400°C.
5.6.5.2.2 Medium Pressure (MP) steam at 1200kpa and 220°C.
5.6.5.2.3 Low Pressure (LP) steam at 450kpa and 150°C.
5.6.5.3 Steam can cause burn, pipe hammer, equipment damage,
reduction in volume and can cause high vacuums and damage
to the equipment and thermal expansion. There is hazard of
over-pressurization because of blocked-in condition when the
equipment is full of liquid.
5.6.5.4 The steam lines are audited daily by area operator as routine
checklist and plant audits. Findings shall be reported and
corrected immediately.
5.6.5.5 It must be well understood that sudden application of steam to
cold equipment can cause equipment failure by thermal shock or
water hammer. Steam valves shall be opened slowly to warm
systems to an acceptable temperature and to insure that steam
flow control valves are not allowed to open suddenly.
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5.6.5.6 Appropriate personnel protective equipment shall be provided

to employees who handle steam hoses, operate steam and hot
condensate valves, or work in close proximity to steam fittings,
piping, etc. Selection of Personnel Protective Equipment shall be
in accordance with SHEM-08.08: Personnel Protective
Equipment.
5.6.5.7 Equipment that is routinely purged with steam shall be
engineered/operated by taking into consideration one of the
hazards of steam, specifically that it condenses to 1/1600th of its
original volume which can cause high vacuum and damage
equipment.
5.6.5.8 Equipment that is heated with steam shall be engineered/
operated by taking into consideration the hazards of over-
pressurization because of blocked-in (isolated) conditions when
the equipment is full of liquid.
5.6.5.9 Appropriate grounding shall be provided to reduce potential for
static charge build-up in steam systems in accordance with
SABIC Engineering Standards E11-S03: Bonding and Grounding
for further details.
5.6.5.10 Steam hoses that are used for purging of flammable or
combustible materials shall be free of visible defects and shall
have an electrical bond.
5.6.5.11 Low-point drains shall be provided to remove initial condensate
from steam lines.
5.6.5.12 Steam/condensate lines shall be insulated/guarded where
exposure to personnel is possible as per the applicable
standards / regulations. In the absence of any applicable
standards / regulations, steam/ condensate lines above 70°C
shall be insulated / guarded where exposure to personnel is
possible.
5.6.5.13 Steam shall not be used on electrical equipment as the moisture
can cause short circuits and internal damage to electrical
equipment.
5.6.6 AIR HANDLING shall comply with the following requirements:
5.6.6.1 Air connection at Utility Stations shall have a distinctive
connection and identified with a permanently mounted sign.
5.6.6.2 Utility air stations shall be installed with an automatic safety
shut-off valve to prevent whipping / swaying of hoses in case of
rupture / failure of hose connected to the station.
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5.6.6.3 Permanent / temporary connections between the air system and

any process system shall only be installed after carefully
analyzing the hazards of air entering into process system and /
or process stream entering into the air system and by providing
appropriate protections against such possibilities. The change
shall go through the Management of Change (SHEM-09) review
process. Air lines connected to process systems shall be
installed with check valves and double block and bleed valves or
as recommended in the Process Hazard Analysis (PHA) study /
Job Safety Analysis (JSA).
5.6.6.4 Tank trucks or other vessels that contain flammable materials
shall not be unloaded by pressuring with compressed air.
5.6.6.5 Under normal circumstances, air shall not be used for pressure
testing. The exception is the Pressure Relief device testing /
calibration and leak testing of instruments in the workshops, for
which air is used. Leak testing of process equipment / piping
with air requires a review by Stationary Engineer to establish
guidelines for maximum pressures to be applied. Use of air for
leak testing equipment prior to start up is not recommended,
except for new start-ups prior to contamination with
flammables. Nitrogen is preferred over air for leak testing.
5.6.6.6 Compressed air shall not be used to provide personnel cooling
or to blow off clothing for cleaning.
5.6.6.7 Air lines/hoses used for cleaning shall be equipped with a
pressure controlling/regulating device limiting pressure to a
maximum of 29 psig. Vacuum cleaning is preferred over air
cleaning.
5.6.6.8 It shall be well understood by all concerned staff employees that
exposure of pyrophoric materials to air can result in ignition.
Such material shall be handled in inert atmosphere or as given
in their SDS. Some of the most commonly encountered
materials include:
a) Phosphorus (white or yellow).
b) Potassium (and most of its salts, such as potassium hydride,
KH).
c) Sodium (highly dependent on moisture content).
d) Aluminum Alkyls (a common catalyst, also called tri-
ethylaluminum).
e) Titanium (if finely divided, such as in shavings from machine
tools).
f) Magnesium (and many of its salts).
g) Hydrazine, H2NNH2.
h) Metal Hydrides.
i) Reduced Catalyst.
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j) Operation management shall ensure that SOP have been

developed and used to manage the interaction with these
chemicals.
5.6.6.9 The list of chemicals handled by Operations that may form
peroxides on contact with air shall be known and its hazards well
understood by all concerned. Such material shall be handled in
inert atmosphere or as given in their SDS. Commonly
encountered materials that may form a peroxide when exposed
to air include ethers, nickel carbonyl, acetaldehyde record.
5.6.6.10 The hazards of Flammable materials in air that is enriched with
oxygen because they have a wider flammable range, are easier
to detonate, and can create a more violent explosion than a
flammable material in atmospheric air, shall be well-understood
by all personnel who are involved in such operations.
5.6.6.11 To remove hydrocarbons prior to the introduction of air into a
system and to remove air prior to the introduction of
hydrocarbons into a system, all equipment shall be purged with
water, steam, or another inert material such as nitrogen. After
purging, the vent gas shall be analyzed for the presence of
oxygen.
5.6.6.12 Purging of process equipment with air shall require a thorough
review and, as a general rule, ambient pressure purging of
process equipment from inert to atmospheric conditions shall
continue until complete change to 20.8% oxygen is attained in
the outlet purge stream.
5.6.6.13 Compressed air lines that are in service shall not be subjected to
excessive heat, such as welding, without prior review from Unit
Stationary Engineer.
5.6.6.14 Plant and Instrument air shall not be used for breathing, hands
or body cleaning or drying, cleaning of contaminated clothing,
or cooling the body.
5.6.6.15 Compressed air shall not be used for equipment ventilation.
5.6.6.16 To remove hydrocarbons prior to the introduction of air into a
system and to remove air prior to the introduction of
hydrocarbons into a system, all equipment shall be purged with
water, steam, or another inert material such as nitrogen. After
purging, the vent gas shall be analyzed for the presence of
oxygen.
5.6.7 PIPING and CONNECTIONS:
5.6.7.1 All Utility Nitrogen, Steam and Air piping shall be Labeled or
identified to conform with the Line Identification
5.6.7.2 Dedicated couplings, unique for each service shall be used at
Utility stations. These dedicated couplings shall be tack welded
in place to prevent their removal and the use of an incorrect
coupling.
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5.6.7.3
Pressure testing equipment or pipes using Nitrogen or Air
requires a review by the Stationary section of the technical
division in order to establish guidelines for pressures to be
applied. Use of air for leak testing equipment prior to start up is
not recommended. Steam shall not be used for any pressure or
leak testing.
5.6.7.4 For all other requirements related to hoses, refer to SHEM-
07.07: Hoses Program.
5.7 Manual handling of Materials:
5.7.1 Area owner shall ensure to develop SOP/SMP for manual Safe handling
and lifting.
5.7.2 An ergonomic evaluation shall be carried out on all manual material
handling operations to determine if the job activity shall be redesigned
to reduce the physical and mental stress on the employee.
5.7.3 Advance consideration shall be given to the size, shape, and weight of
materials to be handled and plan the most efficient and safe method to
accomplish the task.
5.7.4 The proper tool shall be provided for the job. Mechanical means shall be
used in lieu of manual lifting where practical. Defective tools and devices
shall not be used or returned to service until repaired.
5.7.5 Employee selection in work assignments shall be matched to the job in
terms of knowledge and physical abilities.
5.7.6 Whenever unusual or hazardous operations are to be performed,
specific safety instructions shall be given that describes how to avoid
injuries prior to performance of the work, and shall warn employees
about possible hazards.
5.7.7 Instructions shall be clear, concise and complete, and terminology shall
be thoroughly explained.
5.7.8 Special efforts shall be taken to prevent hernias and back injuries.
Avoidance of the injuries begins with fitting the job to the worker
(ergonomics) and instruction to the workers in the correct way to do the
work and correction of incorrect behavior. The employee’s first efforts
following safety instruction shall be closely monitored to ensure that
proper lifting methods are used.
5.7.9 Heavy objects shall be pushed and not pulled during transportation.
5.7.10 Personnel shall stand clear of equipment being loaded or unloaded
5.7.11 Correctly-sized carts shall be used for material transportation
5.7.12 Cart wheels shall be chocked when loading or unloading heavy or
cumbersome loads
5.7.13 At least two persons shall perform elevated handling (above head level)
of any piece of equipment that weighs more than 18 kilograms (39.7
pounds).
5.7.14 When two or more persons carry a long object, carry from the same side.
The person in the rear shall give the signals for lifting, carrying or
lowering.
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5.7.15 Never carry an object that prevents you from seeing where you are
going.
5.7.16 Do not throw objects to another person.
5.7.17 Avoid throwing material from elevated positions. If it becomes necessary
to throw material, the area into which material must be thrown shall be
barricaded and guarded to keep persons out.
5.7.18 Keep your hands and fingers out of the ends of pipe or other tubular
materials.
5.7.19 When rolling a drum on its sides push with your hands against the sides
of the drum, never grasp the ends of the barrel or use your feet to push
it.
5.7.20 Use a mechanical aid or get help when you need to upend a full barrel.
5.7.21 Carts shall be driven to the right within Petrokemya facilities.
5.7.22 The aid of second person shall be provided for directing and opening
doors when the size of the load and the size of the cart make this
necessary.
5.7.23 All containers shall be examined for identification and special handling
instructions.
5.7.24 Avoid lifting objects over your head or reaching out to place the object
on a shelf or platform.
5.7.25 Uncrating shall be done with wrecking bars or claw hammers. All
exposed nails shall be removed or bent to prevent injury.
5.7.26 Whenever possible jack handles shall be removed when not in use. Jacks
shall be level and set on firm footing.
5.7.27 Additional planning shall be given to such problems as sharp edges or
shapes of loads, hazardous or fragile material, uneven weight
distribution, and routes of travel while lifting and carrying.
5.7.28 Only Petrokemya approved standard pallets shall be used with “Manual
Forklift Pallet Trucks”. Personnel shall ensure SWL of Manual Forklift
Pallet Trucks supersedes the intended load, pallets stability upon
loading/unloading and transport, and sufficient clearances from all sides
of the pallet against the forks and loading/unloading ground.
5.7.29 Employees shall be made familiar with the selected equipment before
the work begins. Instructions shall be clear, concise and complete, and
terminology shall be thoroughly explained.
5.7.30 Adequate clearances shall be observed so that employees can readily
avoid being struck, caught or pinned between moving loads or material
handling equipment.
5.7.31 Material handling equipment capacities shall be observed. When
transferring loads, care shall be taken to avoid shock loading
5.7.32 The seven (7) basic steps of manual handling (Attachment 4) is
mandatory for everyone working in Petrokemya and shall follow to
prevent an injury.
5.8 NON-POWERED EQUIPMENT FOR MATERIAL HANDLING:
5.8.1 Equipment in this category of material handling shall include, but not
limited to, the following examples:
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5.8.1.1 Pry bars, lever trucks, jacks, rollers, dollies, skids

5.8.1.2 Chain falls, come-alongs, cable pullers, wheel hoists
5.8.1.3 Hand trucks and wheel barrows
5.8.2 Trained personnel with approved SMP shall handle all Non-powered
equipments.
5.8.3 Material handling equipment inspections:
5.8.3.1 Inspection shall be carried out of all material handling equipment
in this category for defects prior to use. Defective equipment shall
be removed from service immediately, and tagged.
5.8.3.2 All material handling equipment such as: Pry bars, lever trucks,
jacks, rollers, dollies, skids shall be inspected by a competent
person from SCW as per SHEM-08.07: Tools Handling. Chain falls,
come-alongs, cable pullers, wheel hoists shall be thoroughly
examined and inspected every six months by Mobile Equipment
as per SHEM-08.06: Lifting Equipment, proof load tested and
certified before first being put in service. But at an interval not
exceeding four years. The safe working load and the date of last
test shall be marked on the equipment.
5.8.3.3 Inspection documentation shall be maintained till the next
inspection with respective department.
5.8.3.4 TUV third party, which is a certified company, is conducting
periodic inspections for lifting equipment. This report will be filed
with inspection document controller as per SHEM-08.06: Lifting
Equipment.
5.8.4 The list of non-power tools is available with Petrokemya tool room, which
are inspected, certified and yearly color coded as per SHEM-08.07: Tools
Handling.
5.8.5 Tool room and workshop supervisor maintains the lifting equipment due
for inspection for load testing & verification.
6. LEGAL AND REGULATORY REQUIREMENTS
All the local, regional, national and international regulation requirements applicable
to this management system, and to which Petrokemya subscribes, have been
identified and determined in accordance with Compliance, Assessments and
Evaluation Management System (OMS-232), and incorporated into the management
system or otherwise referenced in Section 10.
The legal/regulatory requirements applicable to this management system are
provided below:
 SAF-02 Environmental, Health and Safety Management, HCIS, Ver 2.0, 2017
 SAF-06 Plant Layout, Spacing and Access, HCIS, Ver 2.0, 2017
 SAF-15 Private Industrial Fleet Vehicle Filling Stations, HCIS, Ver 2.0, 2017
 SAF-23 Flammable/Combustible Liquids in Portable Containers, HCIS, Ver 2.0,
2017
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 SAF-24 Hazardous Materials in Portable Containers, HCIS, Ver 2.0, 2017
7. CONTROL OF RECORD
The following records are identified and described in the record control requirements
pertaining to this Management system in accordance with Documentation & Control
of Records Management system (OMS-234).
S. Owner Dept./Section Retention

Records Location
No. (Position) Period
Initial Inspection Check Planning & Materials
List For Receiving Management Warehouse
1 1 year
Compressed Gas Department/ Material record file
Cylinders Manager
Planning & Materials
Plant Inspection Checklist Management
2 for Compressed Gas Warehouse/ECM 1 year
Department/ Material
Cylinders
Manager
Plant Inspection Checklist
for Compressed Gas ECM/record file
Concerned Department/
3 Cylinders received at at the 1 year
Department Sr. Manager
locations other than department
warehouse
4 SHEM-08.03 hard copy OMS EL/SEL Record file at EL 3 year
ECM/Record file
5 SHEM-08.03 soft copy OMS EL/SEL 3 year
at EL
ECM/record file
SMP/SOP for material Concerned Department/
6 at the 3 year
handling Department Sr. Manager
department
ECM/record file
Concerned Department/
7 Annual KPI reports at the 1 year
Department Sr. Manager
department
Table 4 Control of Records
8. COMPETENCY
The following competency matrix is developed based on Petrokemya Organization

Structure in accordance with Training & Competencies Management system (OMS-
131). The matrix identifies the key skills and knowledge required to successfully
Rev. # ( 0 ) Date Mar, 2021
Page 32 of 35
implement this Management system. These competencies are mapped to critical

functional roles within the organization structure.
Senior Managers
Management
Department
EHSS Senior
SHEM-08.03
Office Based
Contractors
Maintenance
Type
Employees
Employees
Operations
Employees
Operation
Competency
Manager
EL/SEL
SMT
Hazardous material handling
D D A D D D A D D
expectations
Hazardous material storage
P P A D D D D D D
requirements
Table Error! No text of specified style in document. Competency Matrix
Competency Types: Core Leadership Functional

Proficiency Levels: D Developing P Proficient A Advanced
9. CONTINUAL IMPROVEMENT:
To promote continual improvement in the application of this management system, the

below key performance indicators (KPI) are defined to assess the performance in line
with Performance Management system (OMS-211). In addition, attachment 6 can be
utilized to assess the implementation of this management system requirements.
Reference KPI Frequency Rhythm

OMS-211 SHEM-08.03 Compliance Annually OMS Committee Meeting
(%)
Incident due to Annually
OMS-211 deficiencies of SHEM- OMS Committee Meeting
08.03
Table 6 KPI
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Page 33 of 35
 Continual Improvement Process
Figure 1 Continual improvement living process
10. REFERENCE AND IMPORTANT LINKS:
10.1 References
• SAF-02 Environmental, Health and Safety Management, HCIS, Ver 2.0,
2017
• SAF-06 Plant Layout, Spacing and Access, HCIS, Ver 2.0, 2017
• SAF-15 Private Industrial Fleet Vehicle Filling Stations, HCIS, Ver 2.0, 2017
• SAF-23 Flammable/Combustible Liquids in Portable Containers, HCIS,
Ver 2.0, 2017
• SAF-24 Hazardous Materials in Portable Containers, HCIS, Ver 2.0, 2017
 External Standards and Publications
 BS 341-2
 DIN 477-6
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Page 34 of 35
 NFPA 55
 NFPA 30 section 7.2 Requirements (revision 2018)
 NFPA 704
 National Institute for Occupational Safety and Health (NIOSH) standard
 OSHA 29 CFR 1910.101
 OSHA 29 CFR 1910.106
 OSHA 29 CFR 1910.176
 OSHA 29 CFR 1910.1200
 SABIC Engineering Standards E11-S03 Bonding and Grounding
 Underwriters Laboratories (UL)-Listed Container standard
10.2 Linkage with Other OMS
Input Interface / link Output
OMS-111 Leadership commitment and culture. SHEM-08.03
OMS-122 Objective setting and Sub-element Leader responsibilities. SHEM-08.03

Formation of relevant (sub-) committees and periodic
meetings.
OMS-131 Request for identification and communication of the SHEM-08.03
necessary training requirements relating to this OMS
standard.
OMS-211 To promote continual improvement in the application of SHEM-08.03
this management system, the below key performance
indicators (KPI) are defined to assess the performance in
line with Performance Management system (OMS-211).
OMS-231 Management system development guidelines. SHEM-08.03
Clarification, variance and exemption process to be
followed.
OMS-232 Compliance assessment expectations. SHEM-08.03
OMS-234 Documentation and record keeping requirements. SHEM-08.03
SHEM-08 Minimum expectations for the Sub-element Leader on SHEM-08.03

updates, action follow up, communication and reporting.
SHEM-08.08 PPE requirements. SHEM-08.03

SHEM-08.09 Minimum requirements regarding climbing and access to SHEM-08.03
elevated locations.
SHEM-09 Management of Change (MOC) process to be followed in SHEM-08.03
case of changes.
Rev. # ( 0 ) Date Mar, 2021
Page 35 of 35
SHEM-10 Identification of Class A, B and C incidents related to safe SHEM-08.03

work practices.
SHEM-03 Standard Operating & Maintenance Procedures SHEM-08.03
SHEM-08.10 (OMS-316.10/SHEM-08.10: Work Permits) describes in SHEM-08.03

detail the requirement and risk involved with confined
space entry, nitrogen and toxic gases.
SHEM-08.07 All material handling equipment such as: Pry bars, lever SHEM-08.03
trucks, jacks, rollers, dollies, skids shall be inspected by a
competent person from SCW as per OMS-316.07/SHEM-
08.07
SHEM-07.07 For all other requirements related to hoses, refer to OMS- SHEM-08.03
315.07/SHEM-07.07
SHEM-08.06 TUV third party, which is a certified company, is conducting SHEM-08.03
periodic inspections for lifting equipment. This report will
be filed with inspection document controller as per OMS-
316.06/SHEM-08.06
SHEM-03.01 SOP guidelines SHEM-08.03
SHEM-03.02 SMP guidelines SHEM-08.03
Table 7 Linkage with Other OMS
11. ATTACHMENTS
- Attachment 1 Color Codes for Compressed Gas Cylinders.

- Attachment 2 Plant Inspection Checklist for Compressed Gas Cylinders
- Attachment 3 Initial Inspection Check List For Receiving Compressed Gas
Cylinders
- Attachment 4 Manual Handling (7) basic steps
- Attachment 5 Guidelines to report eSHEM for rejection of cylinder
- Attachment 6 Implementation Assessment Checklist
Attachment 1 Attachment 2 Attachment 3 Attachment 4 Attachment 5
Attachment 6

SHEM-08.03 Material Handling1

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Classification: Internal Use

Operation Management System SHEM No. SHEM-08.03

Rev. # ( 0 ) Date Mar, 2021

Material Handling & Storage Next Review Date Feb, 2024

3. GLOSSARY, FORMULAE & DEFINITIONS

4. ROLES AND RESPONSIBILITIES

6. LEGAL AND REGULATORY REQUIREMENT

10. REFERENCE AND IMPORTANT LINKS

Operation Management System SHEM No. SHEM-08.03

Rev. # ( 0 ) Date Mar, 2021

Material Handling & Storage Next Review Date Feb, 2024

3. GLOSSARY, FORMULAE & DEFINITIONS:

It is a colorless, tasteless and flammable gas. The OSHA

Operation Management System SHEM No. SHEM-08.03

Rev. # ( 0 ) Date Mar, 2021

Material Handling & Storage Next Review Date Feb, 2024

HiPo High Potential

JQP Job Qualification Program

JSA Job Safety Analysis

Operation Management System SHEM No. SHEM-08.03

Rev. # ( 0 ) Date Mar, 2021

Material Handling & Storage Next Review Date Feb, 2024

MSDS/SDS Material Safety Data Sheet/ Safety Data Sheet

NFPA National Fire Protection Association, USA

NIOSH National Institute for Occupational Safety and Health, USA

OMS Operations Management System.

Operation Management System SHEM No. SHEM-08.03

Rev. # ( 0 ) Date Mar, 2021

Material Handling & Storage Next Review Date Feb, 2024

PHA Process Hazard Analysis

PSDS Product Safety Data Sheet

QAD Quality Assurance Department

Operation Management System SHEM No. SHEM-08.03

Rev. # ( 0 ) Date Mar, 2021

Material Handling & Storage Next Review Date Feb, 2024

A material safety data sheet (SDS), safety data sheet (SDS), or

SMP Standard Maintenance Procedure

SMT Site Management Team (Director) and President.

SOP Standard Operating Procedure

Test certificate A document signed by an authorized person containing the

Operation Management System SHEM No. SHEM-08.03

Rev. # ( 0 ) Date Mar, 2021

Material Handling & Storage Next Review Date Feb, 2024

TWA Time-weighted Average

UEL Upper Explosive Limit

Operation Management System SHEM No. SHEM-08.03

Rev. # ( 0 ) Date Mar, 2021

Material Handling & Storage Next Review Date Feb, 2024

4. ROLES AND RESPONSIBILITIES

The following positions are assigned to the following responsibility to ensure

R: Responsible A: Accountable C: Consulted I: Informed

Office Based staff

Operation Management System SHEM No. SHEM-08.03

Rev. # ( 0 ) Date Mar, 2021

Material Handling & Storage Next Review Date Feb, 2024

Office Based staff

Operation Management System SHEM No. SHEM-08.03

Rev. # ( 0 ) Date Mar, 2021

Material Handling & Storage Next Review Date Feb, 2024

Office Based staff

Follow Work Permit &

Operation Management System SHEM No. SHEM-08.03