HSE-SAF-PLN-00-0001

SAFETY MANUAL
REV. 2.0
11 Aug 09
Safety Orientation Program
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TABLE OF CONTENTS

1. INTRODUCTION ......................................................................................2

2. SCOPE .....................................................................................................2

3. DEFINITIONS ...........................................................................................2

4. REQUIREMENTS .....................................................................................2

5. RESPONSIBILITIES .................................................................................5

6. REFERENCES .........................................................................................6

ATTACHMENTS ..............................................................................................6

APPENDICIES .................................................................................................6

Issue Date Amendment Description Prepared By

Rev.
11-Aug-09 Refer to Appendix R Hemant Kumar
2.0

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SAFETY MANUAL
REV. 2.0
11 Aug 09
Safety Orientation Program
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1. INTRODUCTION

The purpose of this program is to outline the requirements for all personnel entering the Q-
Chem manufacturing facilities to ensure a high level of Safety is maintained at all times.

2. SCOPE

This program applies to all personnel wishing to enter the Q-Chem manufacturing facilities,
which includes administration and process areas.

This Program does not address the process of obtaining security clearances, gate passes
and other necessary permission and approvals to enter the plant. The Safety Orientation
Program begins immediately upon the first-time entry through the front gate.

3. DEFINITIONS

Basic PPE is the common PPE that is required to visit or work in any of the Designated
PPE Areas in the plant.

Contractors are the workers brought to site to visit or work on project specific jobs. This
includes all other workers not fitting the category of Employee.

Employees are the persons referred to as Q-Chem Direct Hire, Secondees and base-load
Contract Employees (permanent contractors)

PPE Designated Areas are areas inside the perimeter fence where, at a minimum,
mandatory PPE is required to be worn at all times as per the PPE Matrix.

Visitor is a person entering the plant for visitation purposes only and may or may not be
visiting at PPE Designated Area term to include both Employees and Contractors.

4. REQUIREMENTS

4.1. Safety Induction Video

4.1.1. All personnel entering the Manufacturing facility for any reason must watch
the Safety Induction Video.

• Entering the facility means anywhere past the security gate or

main reception area.

• An outline of what the Safety Induction Video presents is found in

the Appendix of the Program.

4.1.2. Security Section must issue a card to all contractors and visitors after Safety
Induction Video is completed.

4.2. Hazard Communication (HAZCOM)

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SAFETY MANUAL
REV. 2.0
11 Aug 09
Safety Orientation Program
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4.2.1. Access to processing areas of the plant is tightly controlled and persons
intending to enter process areas must be made aware of the dangers
presented to them by the process streams

4.2.2. General HAZCOM training is required for all persons entering the:

• process areas
• workshop
• laboratory

4.2.3. Exception to the General HAZCOM Training requirement. General

HAZCOM Training and other contractor safety training are not mandatory for
delivery truck drivers or visits meeting the definition of a “formal guided tour.

4.2.4. General HAZCOM Training includes:

• Material Safety Data Sheets (MSDS)

• Chemical Approval Process
• H 2 S and SO 2 Awareness
• Benzene Awareness
• Butadiene Awareness
• Hexavalent Chromium VI Awareness
• Heat Stress (During the Period of 1st May to 15th November)

4.3. Formal Guided Tour

4.3.1. Formal guided tour must meet all of the following criteria:

• 100% escorted by a Q-Chem Employee

• Must be for observation purposes only

Note:
• Observation means not including hot work, general work, confined
space entry, operating equipment or handling chemicals.
• Observation refers to activities which are not covered by a work permit
such as audits, walk downs, plant tours, and similar activities.
• Work supervision, vendor technical support, and other tasks involving
job administration, although not requiring a work permit, are not
included in this definition of “observation”. Contractors and other
third-party personnel involved in these types of activities must comply
with the specific training requirements for their tasks.

4.3.2. General HAZCOM training or any other Contractor Training is not mandatory
for formal guided tours.

4.4. Contractor Safety Training

4.4.1. Contractor Training is dependent on the type of work conducted and the
specific plant location where the work is performed.

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SAFETY MANUAL
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11 Aug 09
Safety Orientation Program
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4.4.2. Designated Site Representatives (DSR) is responsible for determining the

type of training required and consult the Training and Safety Department for
assistance, if required.

4.4.3. The DSR must inform the Training Department well in advance so the
courses can be scheduled accordingly.

• DSR shall consult the Training Department for scheduling applicable

contractor safety training at least one week in advance or it may result in
significant delays to the job.

4.5. New Employees

4.5.1. It is the relevant Department’s responsibility to ensure new employees are

scheduled for training and complete the safety training within the acceptable
timeframe.

 Employees shall complete all required training as per New Employee

Orientation (NEO) / General Orientation Training (GOT) program before
they start work on the process areas.

4.6. Required Safety Training

All the Required Safety Training detailed in the Global Training Matrix (Refer
Attachment 1).

4.7. Safety Certification Training

4.7.1. Conducting certain jobs on the plant site requires workers to achieve a
minimum level of training to be “authorized” or certified.

4.7.2. Permit Issuer Certification (Employee Only)

• PTW
• LOTO
• Blinding (Production only)
• Confined Space
• Gas Detection
• Fire Extinguisher

4.7.3. Lead Worker Certification (Employee)

• PTW
• LOTO
• Blinding (Production only)
• Confined Space
• Fire Extinguisher
• English interview with Safety Representative (Contractors only)

4.8. Training

4.8.1. All required safety training is taken through Instructor led training in the
classroom or on Computer Based Training (CBT) or a combination of both.
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• Refresher training is issued through TRAQS as per Global Training

Matrix.

4.8.2. All Contractor Safety Training is valid for 1 year only.

4.8.3. Training Department must issue Training Cards (proof of training) for workers
requiring Safety Certification.

• For workers on-site for less than 30 days – paper copies of training
records are acceptable.

• Training Cards must be printed for workers on-site for greater than 30
days.

4.8.4. The Training Department is responsible for maintaining all training records
and status of training for all employees and contractors.

5. RESPONSIBILITIES

5.1. Employee

5.1.1. Complete all the Required Safety Training.

5.2. Contractor

5.2.1. Must attend the required training identified in the Contractor Safety Training
Request Form (AD-TRN-SFM-00-0010) filled by DSR.

• Competency exams are required for all safety training courses.

5.3. Q-Chem Designated Site Representative (DSR)

5.3.1. Every Visitor and Contractor has a Q-Chem Designated Site Representative
who is ultimately responsible to ensure the Safety Training of each contractor
meets the minimum requirements of this program.

5.3.2. Must notify Training Department one week in advance for required Contractor
Safety Training.

5.4. Training Department

5.4.1. Schedule and carryout the required Safety Training.

5.4.2. Issue proof of training to all personnel attending safety training.

• Issue Training Cards to Employees and Contractors as required

5.5. Security Section

5.5.1. Maintains the Safety Induction Video Cards in sufficient quantity to provide
new contractors and visitors upon completion of Safety Induction Video.

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5.6 Safety Department

• Owner of this Safety Orientation Program and must audit contents of the
program periodically.

6. REFERENCES

None

ATTACHMENTS

Attachment 1 - Global Training Matrix

APPENDICIES

Appendix 1 – Q-Chem Safety Orientation Video Outline

Appendix R - Revision History

Appendix 1 - Q-Chem Safety Induction Video Outline

• Tenets of Operation (Three Guiding Principles)

• Overview of the Q-Chem processing facilities

• General discussion on the hazards present in the processing facilities.

• Access control system general description

• Restricted Access to the Process Areas

• Site smoking policy and Designated Smoking Areas

• Site traffic rules and speed limits

• Control of sources of ignition

• Incident reporting procedure (Injury, Property Damage, Fire, Chemical / Solid Spills,
Gas Release)

• Plant Alarm System – including zone descriptions, pull stations and strobes, Evacuate
and All-Clear)

• Emergency response plans for processing areas

• Emergency response plans for the administration areas

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SAFETY MANUAL
REV. 2.0
11 Aug 09
Safety Orientation Program
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Appendix R: Revision History

Rev. Issue Date Amendment Description

Prepared By
2.0 11-Aug-09 General review and changes in the formal guided tour criteria. Hemant Kum
1.0 1-Mar-06 This revision removes the Security Site Access process and is re-
include only Safety Orientation / Induction and address the minimu Jarvis Olsen
requirements for entry into the process areas.
0 1-Oct-02 First Release

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