18002-HSE-MG-023-01 Maintenance Area Management

MAINTENANCE AREA MANAGEMENT
DOCUMENT: 18002-HSE-MG-023-01
405 MW dc SOLAR PV PLANT,SAKAKA- KSA
Owner / Client ACWA POWER
Owner’s Engineering TYPSA
Principal Subcontractor
MAHINDRA SUSTEN
Name & Designation Signature Date Signed
Dibu. MK
Prepared by:
HSE Manager
A u t h o r i z e d b Muneer Nwairan
y: Project Director
Approved by ACWA POWER
1
The latest version of this document is available in electronic format for consultation and document management.
Document: 18002-HSE-MG-023-01
Rev. No. Purpose of Issue Date Issued Remark
0 Initial release for approval 06/06/2019
1 Added Section 4.5 to 4.13 06/07/2019
2
Table of Contents
1. PURPOSE................................................................................................................................................4
2. SCOPE....................................................................................................................................................4
3. GENERAL INFORMATION.......................................................................................................................4
3.1 Glossary of Terms..............................................................................................................................4
3.2 Responsibilities..................................................................................................................................5
3.2.1 General Responsibilities.................................................................................................................5
4. HAZARDS, PRECAUTIONS AND SAFE WORK PRACTICES.........................................................................5
4.1 WELDING, CUTTING AND HEATING HAZARDS:..................................................................................5
4.2 FIRE WATCH PERSONNEL...................................................................................................................7
4.3 PERSONAL PROTECTION....................................................................................................................7
4.4 WELDING WORK CLASSIFICATION AND REQUIREMENTS...................................................................8
4.5 Oil Changes for the Equipment:.......................................................................................................10
4.6 Work environment and facilities......................................................................................................10
4.7 Hazardous manual tasks:.................................................................................................................11
4.8 Working under vehicles/Equipment:...............................................................................................11
4.9 Noise................................................................................................................................................11
4.10 Slips, trips and falls..........................................................................................................................11
4.11 Hazardous substances.....................................................................................................................12
4.12 Waste Disposal:...............................................................................................................................12
4.13 Related Documents.........................................................................................................................12
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1. PURPOSE
The Purpose of this document outlines the principals involved and the precautions to be taken during
maintenance (welding, cutting, grinding and equipment work activities) in MSPL premises. These activities
are considered safe if they are carried out in a controlled manner by complying with the recommended
safety precautions.
Personnel doing welding, cutting and other hot work require a high degree of skill and shall be qualified
for the work they are doing. This document does not replace a welding manual. The qualification of
personnel falls outside the scope of this document
2. SCOPE
This procedure shall apply to all construction, assembly, pre-commissioning, commissioning and start-up
activities throughout the life-cycle/ duration of Sakaka project
All the requirements described in this procedure apply to the Construction, Pre-commissioning,
Commissioning activities performed by the CONTRACTOR and its SUBCONTRACTORS inside CONTRACTOR
fenced areas, if there is an activity that is performed in other contractor or owner areas, however shall be
applicable the other Contractor or Owner’ Procedure. If there is no such procedure, then this procedure
will be of application.
3. GENERAL INFORMATION
3.1 GLOSSARY OF TERMS
Subcontractor: Organization which, submitted the co-ordination of CONTRACTOR, performs construction

and erection, pre-commissioning and commissioning activities for the project.
Site: Areas within the Project fenced area where CONTRACTOR and its SUBCONTRACTORS shall carry out
the works included in the Contract.
Fire Watch: is a person assigned in welding works to cover safety surveillance and response function on
emergency, including first-aid firefighting.
First-Aid Fire Fighting: is a practical training on the use of fire extinguishers, fire hose and couplings, foam
making equipment, operation of plant paging and fire alarm call points, and use of other first-aid
firefighting equipment available in MSPL premises.
Flameproof Tarpaulin Canvass is a cloth (glass fibre based, or silica fibre based) used for welding work
fire protection which does not burn or give off fumes when exposed to heat.
The terminology ‘welding works used in this document refers to welding, cutting and heating activities.
4
3.2 RESPONSIBILITIES
3.2.1 GENERAL RESPONSIBILITIES

The following personnel have responsibilities defined in this procedure:
 MSPL Managers
 MSPL Supervisors
 MSPL Employees
 MSPL Contractors
 MSPL Subcontractors
 MSPL Visitors.
4. HAZARDS, PRECAUTIONS AND SAFE WORK PRACTICES
4.1 WELDING, CUTTING AND HEATING HAZARDS:
Welding, cutting and grinding (herein after referred to as "welding work" for simplicity) activities
involve many hazards as follows;
I. Fire hazard: Open flame, electric arc, molten metal, sparks or hot surfaces igniting
flammable or combustible material.
II. Burn injuries caused by hot surfaces, sparks, slag or flame.
III. Health hazards: eye or skin exposure to ultraviolet (UV) and infrared (IR) radiation;
inhalation of dust, toxic fumes such as oxides of Nitrogen (NOx), Carbon Monoxide
(CO), Ozone, etc. and Oxygen deficiency.
IV. Exposure to ultraviolet rays initially causes a painful and disabling but temporary
form of conjunctivitis commonly known as "Arc eye". Looking directly into a powerful
arc without eye protection can cause permanent eye damage. Ultraviolet affects the
skin like severe sunburn.
V. Infrared radiation has the effect of heating the body tissues on contact. If the
intensity of heat due to infrared is not enough to cause a thermal burn, there is no
further hazard.
VI. Hazards induced from preservative coatings on metal surface: The toxic hazard will
depend on the, type of electrode used, the base metal being welded or cut, and
whether the base metal is coated with flammable or toxic material (zinc, lead, paint,
etc).
VII. Mechanical hazards: unguarded rotating parts, flying particles, high pressure water in
hydro jet cutting, noise.
VIII. Compressed gas hazards
IX. Electric shock
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General Precautions:
I. When practical, objects to be welded, cut or grinded shall be moved to a designated safe location
or, if the object cannot be readily moved, all movable fire hazards in the vicinity shall be taken to
a safe place or otherwise protected (e.g. using flame retardant barricades, covers, blinding, etc).
II. If the object cannot be moved and all the fire hazards cannot be removed, positive means shall be
taken to confine the heat, spark, and slag to protect the unmovable fire hazard, from these.
III. The following welding equipment safety shall be strictly enforced:
 All welding equipment shall be properly maintained and regularly inspected by using a
checklist (i.e. as per operating procedure).
 fire extinguishers (6 kg. DCP) shall be provided with each welding equipment, one to be kept
at the work and the other at the machine. Plant extinguishers shall not be used for this
purpose
 Location of welding equipment and laying of cables should not obstruct regular activities.
 Welding work in a Restricted Area shall be done after obtaining a Hot Work Permit and all
requirements pertaining to hot work shall be enforced such as the Hot Work Risk Assessment
for critical welding jobs in hazardous areas.
 The welder shall not work alone. The welder and helper to be trained on Fire prevention by
MSPL / Contractor HSE Trainers.
 When welding work is carried out in a workshop or any similar location a HOT work Permit to
be obtained.
 Welding work on any tank, vessel or piping shall only be undertaken when it has been
positively isolated from all sources of flammable hazards and established that it is free of
flammable vapours or substances.
 Steps shall be taken to contain and/or quench the sparks. Welded components retain heat for
a period of time after the job is completed. Such components shall be marked hot and kept
cordoned off until sufficiently cooled to avoid burn injury or fire.
 Good housekeeping shall be maintained at work site. The welding work area shall at all times
be kept clean of combustible and flammable material. Used welding rods, grinding discs, etc.
shall be collected and not thrown around.
Enclosure of Welding and Cutting Area:
Welding and cutting works at MSPL premises generally require the protection of equipment and
surrounding area from damage or fire ignition from the hot work activity. This activity includes oxy-fuel
metal cutting, light duty welding, heavy duty welding. The following requirements shall be strictly
enforced
 The welding and cutting area must be totally enclosed, using a flameproof tarpaulin canvass
in a manner to contain sparks, molten metal/splatters, block the view of the welding/cutting
arc from passer-by, and isolate any nearby combustible fuel source from the hot work
activity.
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 Regular checks shall be carried out (by the Work Permit receiver) to determine the condition
of the flameproof tarpaulin canvass (e.g. if charred, ripped, torn, melted areas with holes,
etc.). The canvass shall be replaced when the damage is sufficient enough to potentially
exposed equipment surfaces or whenever molten metal / sparks cannot be totally contained.
4.2 FIRE WATCH PERSONNEL
 Work Permit receiver shall provide properly trained and equipped ‘fire watch’ personnel
for welding and cutting works in running process units, pipe rack or in any product pipe
area. The person assigned as a fire watch shall have no other duties that would distract
from the primary safety surveillance and response function. The fire watch person may
do other safety-related task if the primary fire watch responsibility is not compromised.
 The fire watch personnel equipment and knowledge shall include:
o Understands and capable to recognize hazards.

o Have appropriate functional fire extinguishing equipment readily available.
o Trained and certified in the equipment’s use and first-aid firefighting. Respective
MSPL / Contractor’s HSE representatives shall train and certify the fire watch.
o Familiar with facilities for sounding an alarm in the event of a fire.
o Capable to communicate effectively with the workforce.
 The fire watch personnel should understand his duties which include the following:
o Shall continuously monitor and watches for fires in all exposed areas.
o Shall remain within 8 meters radius of work vicinity during welding / cutting until
relieved by another fire watch.
o Shall maintain assigned suppression equipment within proximity
o Shall be aware on the location and how to activate the nearest fire alarm.
o Shall activate the fire alarm when available equipment is not enough to suppress
minor fire.
o Shall try to extinguish a fire only when obviously within the capacity of the
available equipment.
o Shall maintain a watch for at least ½ hour after completion of welding and cutting
works until the area has been inspected and found to be free of leaks and ignition
sources (fires, hot spots or smouldering materials).
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4.3 PERSONAL PROTECTION
Respiratory Protection:
 The Local exhaust hoods shall be provided in welding shops or indoor enclosures. Local
exhaust should be achieved by means of movable hood placed as near as possible to the
welding job and provided with an air flow rate sufficient to maintain a velocity of 100 fpm
(ft./minute) at the point of welding in the direction of the hood. General ventilation can
be achieved by providing mechanical ventilation at a minimum rate of 2000 cfm (cu. ft./
minute) of air per welder, or four air changes per hour, whichever is greater.
 Where gases, dust and fumes cannot be maintained below TLV or for any other reason,
welders shall wear canister/cartridge mask suitable for fumes.
Eye Protection:
 Goggles or shields fitted with correct filter lens shall be used during welding and cutting
operations to protect the eyes from light and ultraviolet / infra-red radiation.
 During welding eye protection shall be used by welder and his helper.
 Welder's Goggles shall be used when grinding, chipping, de-slagging and during gas
welding Arc welder shall wear welder's shield. Safety glasses without side shield shall not
be worn in any case.
Protective Clothing and other PPE:
 Fire retardant coveralls/apron shall be worn by welders and fabricators. These protective
clothing shall be kept free of oil and grease and shall have the sleeves and collars kept
buttoned up for protection against ultraviolet and infrared radiation.
4.4 WELDING WORK CLASSIFICATION AND REQUIREMENTS
Gas Welding and Cutting:
 Gas welding and cutting operations utilize the heat of the flame obtained from the
combustion of a fuel gas with oxygen. Oxygen is normally supplied in cylinders containing
244 cu. feet of oxygen at a pressure of 2200 psig at 70ºF. Acetylene is supplied in
cylinders and dissolved in acetone over a porous material at a pressure of 250 psig at
70ºF. Acetylene cylinders normally contain 300 cu. ft. of acetylene. Acetylene is explosive
in a concentration range of 2% to 82% in air and therefore requires careful handling.
 Refer to Compressed Gas Cylinders Safe Work Practices for the safety precautions related
to storage, handling and use of cylinders and its fittings (regulators, gauges and hoses).
 Acetylene gas becomes unstable at pressures above 15 psig and therefore acetylene
regulator pressure shall not be allowed to exceed 15 psig.
 All cylinders shall be kept vertical and secured either in a cylinder trolley or floor support
or lashed to a fixed support. Cylinders shall not be located in any enclosed space where
8
welding or cutting job is taking place. Oxygen and acetylene cylinders shall be kept at
least 15 ft. away from the blowtorch or any other source of ignition.
 Flash back arrestors and hose check valves shall be fitted to both oxygen and fuel gas
regulators (see Appendix-B).
 Spark lighters shall be used to light torches. Matches and smoldering rags shall not be
used.
 Cylinders shall not be transported with the regulators and hose attached, except on a
purpose made trolley.
 Oxygen and acetylene hoses shall be of different colors or otherwise identified and
distinguished from each other. Maroon is generally used for acetylene and black for
oxygen.
 The blowtorch when lighted shall not be placed on or near cylinders, regulators and
hoses. Before changing the torch, shut-off the gas at the pressure reducing regulators
(not by crimping the hose).
 When extinguishing the flame, shut-off the acetylene first by closing the torch control
valve. Only exception to this is when a backfire occurs in the mixing chamber where
oxygen to be shut off first to stop burning internally.
 The blowtorch and hose, when not in use, shall not be left unattended in any confined
space even for short period, e.g., lunch break. Torch shall be taken out or alternatively,
oxygen and acetylene connections shall be disconnected from the cylinders located
outside confined space. Closing of cylinder valves shall not be treated as disconnection.
 Cylinder valve wrench should be left in place on the cylinder when in use.
Electric Arc Welding and Cutting:
 Engine of welding machine shall be stopped during refuelling. Guards of rotating parts
shall be kept in place. Welding machine shall be kept 15 meters away from sources of
flammable hazards. Exhaust shall not be allowed to enter confined spaces. It shall be
provided with reflective sticker or warning light if left by roadside during dark hours.
 All welding leads and returns shall consist of flexible tough rubber covered cables, robust
enough to withstand normal treatment over rough ground and pedestrian traffic. Where
feasible, cables should be additionally protected by stringing overhead or by using cable
covers.
 The insulation of cables, electrode holders, plugs and sockets shall be regularly inspected
for visible damage and discarded if necessary. If cables are to be joined together for
additional length, proper cable connectors shall be used ensuring that no live conductor
is exposed.
 Testing of the welding rod should be done using a testing plate and not by arcing on the
existing structure or piping.
 Electrode holders shall not be placed on the ground when not in use, Instead, it should be
hanged or secured to prevent sparking. Cooling hot electrode holders by dipping in water
shall be prohibited.
 The cable shall have adequate current carrying capacity to meet the job requirement.
 Welding return lead shall be provided from the neutral terminal of each phase of an arc
welding transformer, or the negative terminal of a DC Generator to the work piece.
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 When more than two welders are using the same welding machine, the polarity of each
welding lead and return shall be the same.
 When welding work is not in progress, even for a short period, the power source of the
welding circuit shall be disconnected.
4.5 OIL CHANGES FOR THE EQUIPMENT:
 Oil Changes to be done only after ensuring that the oil containment systems (Drip trays)
are present.
 Spill kits to be available in the work area.
4.6 WORK ENVIRONMENT AND FACILITIES
 Ensure tools and equipment are safe to use and are maintained and regularly serviced.
 Supply workers with appropriate safety gear, where necessary.
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 Provide facilities for workers (e.g. toilets, drinking water, washing and dining areas,
shelter).
 Provide and maintain a physical work environment free of health and safety risks (e.g.
workspace, lighting, ventilation).
 Ensure workers do not eat food in the workshop area.
4.7 HAZARDOUS MANUAL TASKS:
 Bending, stretching and reaching movements, static lifting and positioning tasks – either
with high, sudden, repeated or sustained force – can lead to stress on the body, muscle
strain, overexertion and injuries.
 Carrying out work at the limit of reach or in awkward postures away from the body’s
centre of gravity requires muscles to work harder. When these postures are held for too
long, muscular or spinal injuries can occur.
 Look at reducing heavy lifting or working in sustained or awkward postures by using
mechanical aids and devices.
 If equipment exists to help reduce the risk of body stressing, it should be use like
compressed air, hoists, cranes and lifting hooks, bead breakers and body undersides to
get under vehicles
4.8 WORKING UNDER VEHICLES/EQUIPMENT:

 Associated risks include poor lighting, cramped working conditions, awkward or sustained
postures, hot engine parts and hazardous substances (e.g. fuels, fluids).
 Ensure that Adequate lighting is provided, especially lead lights
 Risks from awkward and sustained working positions are identified and controlled
 Powered tools are provided, where appropriate
 Operating instructions are displayed (where required)
 Appropriate PPE is provided and used (e.g. eye and hand protection)
 Workers are trained in the correct use and care of PPE
4.9 NOISE
 Unwanted or damaging sounds may cause noise induced hearing loss or tinnitus (ringing
in the ears). It may also cause other health effects such as stress, hypersensitivity to
noise, and increased blood pressure and heart rate.
 Keep noise levels below the exposure standard of 85dB(A) in an 8-hour day so that critical
situations can still be communicated despite noise
 Provide personal protective equipment (PPE) that is:
• suitable for the nature of the work and the hazard (e.g. earmuffs, ear plugs)
• comfortable to wear, and of a suitable size and fit
4.10 SLIPS, TRIPS AND FALLS
 Slips, trips and falls are the second most common cause of workplace injury, after
hazardous manual tasks. Some common hazards arise from:
• type and stability of floor or ground surfaces (e.g. uneven or broken concrete,
sloping ground)
• slippery floor surfaces (e.g. from water, spilled fluid, oil)
• equipment, boxes and materials blocking walkways
• stairs or steps
11
• carrying things that obscure the view ahead

• poor lighting
• inadequate or improper footwear
• incorrect use of ladders
• falling or moving objects.
4.11 HAZARDOUS SUBSTANCES
 Hazardous substances include paints, solvents, lead, powders, lacquers, paint removers,
resins, battery acid, used oils, adhesives, degreasers, surface preparation products, rust
converters and removers, and dusts.
 Hazardous chemicals are substances and mixtures that can be a health hazard if not
handled or stored correctly.
 Dusts primarily arise from cutting, grinding and sanding. They have a direct route of
exposure to the lung and intestinal tract and can be an irritant to eyes and the skin.
 Short-term (acute) health effects from hazardous substances and chemicals may include
contact dermatitis, burns to the skin and eyes, vomiting and diarrhoea, irritation to the
nose/lungs/throat, headache and occupational asthma. Long-term (chronic) effects
include lung cancer, chronic dermatitis, chronic obstructive airway disease, and damage
to the reproductive system, kidneys and liver.
 Use suitable for the nature of the work and the hazard (e.g. gloves, masks, goggles, face
shields, respirators).
 used or worn by workers who have been trained in its use and care
4.12 WASTE DISPOSAL:

 All the wastes generated during the maintenance works are to be segregated and
disposed as the guidelines mentioned in the waste management plan.
4.13 RELATED DOCUMENTS
- 18002-HSE-CL-011e-00 Hot Work Checklist

- 18002-HSE-FO-007d-00 Training Attendance list
- 18002-HSE-FO-011l-00 Compressed Gas cylinder inspection
- 18002-HSE-FO-011n-00 Welding machine & PPE Inspection
- 18002-HSE-FO-027a-00 WELDING MACHINE REGISTER
- 18002-HSE-FO-027b-00 Compressed Gas cylinder Register
- 18002-HSE-FO-017a_00 PTW Template
12

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MAINTENANCE AREA MANAGEMENT

Owner / Client ACWA POWER

Owner’s Engineering TYPSA

Name & Designation Signature Date Signed

Approved by ACWA POWER

Rev. No. Purpose of Issue Date Issued Remark

0 Initial release for approval 06/06/2019

1 Added Section 4.5 to 4.13 06/07/2019

3.1 GLOSSARY OF TERMS

Subcontractor: Organization which, submitted the co-ordination of CONTRACTOR, performs construction

3.2.1 GENERAL RESPONSIBILITIES

4. HAZARDS, PRECAUTIONS AND SAFE WORK PRACTICES

4.1 WELDING, CUTTING AND HEATING HAZARDS:

Enclosure of Welding and Cutting Area:

4.2 FIRE WATCH PERSONNEL

 The fire watch personnel equipment and knowledge shall include:

o Understands and capable to recognize hazards.

4.3 PERSONAL PROTECTION

Protective Clothing and other PPE:

4.4 WELDING WORK CLASSIFICATION AND REQUIREMENTS

Gas Welding and Cutting:

Electric Arc Welding and Cutting:

4.5 OIL CHANGES FOR THE EQUIPMENT:

4.6 WORK ENVIRONMENT AND FACILITIES

4.8 WORKING UNDER VEHICLES/EQUIPMENT:

• carrying things that obscure the view ahead

4.12 WASTE DISPOSAL:

4.13 RELATED DOCUMENTS

- 18002-HSE-CL-011e-00 Hot Work Checklist

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