emal contractor red book
TRANSCRIPT
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EMAL Contractor EHS Requirements
EMAL CONTRACTORS
EHS REQUIREMENTS
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IMPORTANT SAFETY NOTICE
The electro-magnetic fields generated in the production ofaluminium may cause malfunction of heart pacemakers orother electronic medical implants. Visitors to site fitted withthese types of devices are prohibited from entering theEMAL Industrial Area.
All visitors fitted with hear pacemakers or other electronicmedical implants must inform the EMAL SecurityDepartment on arrival at the main Security Gate.
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INDEX
1. Introduction
2. Disclaimer
3. Contractual Obligations
4. EMAL Core Values
5. EMAL EHS Policy
6. Contractor Site Access & Work Process/ Requirements
7. Safety Violations & Black Point System
8. Incident Communication, reporting and investigation
9. Personal Protective Equipments
10. Permit to Work
11. Lockout & Tagout
12. Working at Height (including portable ladders)
13. Confined Space
14. Mobile Equipment
15. Lifting Equipment
16. Hot Work
17. Signs, Signals & Barricades
18. Abrasive Wheels
19. Electrical Safety20. Excavation, Digging and Perforation
21. Housekeeping & removal of material
22. Cartridge operating fixing tools
23. Grit blasting
24. Working over water
25. Occupational Health
26. Environment
27. Fire Protection
28. Security Arrangements
29. Attachments
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1. INTRODUCTION
This booklet is issued to contractors carrying out work within EMAL. It outlines
Safety Health & Environmental requirements and procedures, which the Contractor
is required to follow when undertaking work.
The booklet is produced primarily for the use of Contractors Management and
supervisory staff who are required to ensure that the safety, Health and
Environmental requirements and procedures are brought to the notice of all
contractors employees and those requirements are and procedures are strictly
followed.
If there is any doubt or misunderstanding about the content of the booklet, the
contractor should consult EMAL Representative for clarification. Where the
contractors require special precautions or more detailed guidance on Safety
procedures, he should discuss this with the EMAL Representative prior to the
commencement of work.
2. DISCLAIMER2.1. This booklet provides summary of EMAL EHS requirements for contractors.
It has been prepared to facilitate EHS implementation by contractors when
working in EMAL, however it does not, in any way, relieve the contractors
from their contractual requirements to comply comprehensively with all
EMAL EHS procedures and standards. Relevant EMAL EHS Standards and
procedures shall be consulted for further details on specific issues.
2.2. The Contractor and the Contractors employees shall conform in all aspects
of their legal duties ad responsibilities as laid down by various U.A.E
Authorities. The following Safety, Health and Environmental requirements
and procedures do not relieve the contractor from his legal or contractual
obligations.
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3. CONTRACTUAL OBLIGATIONS
3.1. The contractor will ensure that all equipment, plant, machinery and
apparatus brought onto or used in EMAL are safe and without risk to health
and safety or the environment and is maintained to an acceptable standard.
All necessary test and examination certificates must be available for
verification at all times.
3.2. EMAL retains the right to stop any operation, activity or erection of plant/
equipment, etc., if it is considered to be detrimental to safety and health of
site personnel or (others). EMAL will not accept any responsibility for all
increased cost arising out of such action.
3.3. The contractor and contractors employees will obey all written or verbal
instructions given by EMALs representative and / or Area PTW Issuing
Authority in respect to Safety & Health of site personnel (or others).
3.4. EMAL retains, the right to remove the Security Clearance of any person not
complying with requirements, or any person in a Supervisory capacity who
permits such non- compliance.
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4. EMAL CORE VALUES
o SAFETY FIRST LAST & ALWAYS
o PROTECTION OF THE ENVIRONMENT
o EVERYTHING CAN BE IMPROVED
o INVESTING IN TODAY FOR TOMORROW
o WE RESPECT INDIVIDUALS AND THEIR DIFFERENCES
It is mandatory for every EMAL employee as well as contractors to comply and
follow the above five EMAL core values in all their activities and work. To help
EMAL realize its vision, we expect that all contractors will embed these core
values in their workforce and activities, resulting in a synergized effort for the
achievement of greater objectives.
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5. ENVIRONMENTAL, HEALTH AND SAFETY POLICY
We at EMAL are committed to continuous improvement and sustainable development.
We believe all accidents are preventable and we will work ceaselessly to ensure that our
business activities cause no harm to employees, contractors, visitors or community members,and have the minimum possible impact on the environment.
We are committed to achieving Environmental, health and Safety excellence through the
implementation of an effective Environmental, Health and safety management system, and more
specifically by:
- Creating a workplace culture where protection of peoples health, safety and the environment
is paramount and this is reflected in the behaviour of all concerned.
- Ensuring all EMALs management systems and procedures reflect current best practice,
specially in the areas of Health, Safety and the Environment.
- Ensuring all employees understand the Health, Safety and Environmental requirements and
impacts of their work, and their obligations in relation to this policy.
- Ensuring that all employees have the skills, knowledge and resources to allow them to work
safely, without impact on their health and the environment.
- Ensuring that all activities under EMALs control comply with this policy and all applicable
statutory requirements.
- Ensuring the environmental, health and safety aspects and impacts of our activities are fully
understood, and managed in accordance with best practices.
- Promoting Environmental, Health and Safety awareness amongst employees, contractors,
visitors, customers and the wider community.
EMAL Policy requires all its employees and contractors to behave consistently with the
requirements of this policy. Specifically:
- All employees area authorized to refuse to perform any act they judge to be unsafe
- No employee may be instructed to perform an unsafe act or work in breach of this policy
- All employees are required to stop any activity that they judge is unsafe or in breach of
EMAL policy.
- No employee shall incur any punishment or suffer any negative consequences as a result of
following this policy.
- No employee or contractor is permitted to act in breach of this policy and any such
occurrences may lead to disciplinary measures being taken against those accountable for
this breach.
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6. CONTRACTOR SITE ACCESS & WORK REQUIREMENTS
6.1. Before hiring
In order to guarantee that the potential tenderers have all information, know all
requirement and site conditions, the purchasing/ supply chain department will
attach to the project/ contract enquiry, the following documentation:
EMALs EHS policy
EMAL EHS Standards
Technical specifications
Other info sent by the contract administrator
H&S Prequalification Questionnaire (HS.SAF.09.F01)
6.1.1. Contractor prequalification
Prequalification is a mandatory requirement for all contractors who wish to
work for EMAL with the exception of the conditions stated for Service
Providers. Contracts can only be awarded by EMAL to pre-qualified
contractors. The H&S Pre-Qualification Questionnaire (HS.SAF.09.F01) is to
be sent with the enquiry documents to all proposed tenderers, if they are not
already pre-qualified.
To be placed on an approved contractor list, a contractor must obtain at least
40% rating in EHS prequalification.
The following categories will be assigned to the contractors based on their
pre-qualification ratings:
Exceed expectations for rating greater than 75%
Acceptable for rating equal to or greater than 40%
Not Acceptable for rating less than 40%
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6.1.2. EHS Standards
Purchasing/ Supply chain department shall send a CD containing all EMAL
EHS Standards to the potential tenderers along with the contract enquiry.
6.1.3. Plant Visit
For big projects or when requested by the project/ contract administrator, all
proposed tenderers shall visit the plant before sending the offer.
6.2. During hiring
Once the Contractor is selected, the purchasing department will request the
contractor to meet following EMAL requirements and submit appropriate
documentation related to the following to EMAL EHS department, at least 15
days prior to the start of the project.
6.2.1. EHS Plan/ Method Statement
EHS Plan to their scope of work comprising of identified hazards and their
control measures in accordance with EMAL standards. Risk Assessments
shall also be submitted along with this EHS Plan.
6.2.2. Contractor Site Representative and EHS RepresentativeThe Contractor shall nominate a Site representative and a EHS
Representative and notify EMAL in writing before start of the project. Prior to
that, CV of Contractor EHS representative shall be shared with EMAL EHS
for review and approval. If required, EMAL can ask for an interview of EHS
representative before approval.
6.2.3. Contractor employee list
The contractor shall submit a complete list of its employees who will work on
EMAL project. Attachment 1 (Form HS.SAF.09.F02) shall be used for this
purpose.
6.2.4. MSDS (Material Safety Datasheets)
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The contractor shall provide EMAL a list of all chemicals along with their
MSDSs, which are to be used during the works. Attachment 2 (Form
HS.SAF.09.F03) shall be used for this purpose. Material safety datasheets
(MSDS) shall also be available at the workplace.
The use of particular chemicals must be validated by EMAL Occupational
Health Service.
If additional products are to be brought to site, the contractor shall request for
EMAL approval prior to the mobilization of the product on EMAL premises.
6.2.5. Inventory of all equipments and machines
The contractor shall provide EMAL EHS with a complete list of all equipments
and machines to be used on the project along with relevant documentation.
Attachment 3 (Form HS.SAF.09.F04) shall be used for the purpose. The
documentation shall include a copy of the manufacturer instructions, and shall
be available in the workplace, equipment certification (if applicable) and legal
inspections of all equipments and machines to be used in the project/ contract
(welding machines, power generators, compressed air equipments, etc.).
Quarterly Inspections shall be done on all equipments and machines and an
inspection tag shall be posted in accordance with EMAL Electrical SafetyCode / Portable electrical tools standard.
No explosives shall be allowed on site other than cartridges used in cartridge
operated fixing tools.
EMAL can verify and inspect any equipment, inspection record.
6.2.6. Inventory of all standard free moving mobile equipments.
The contractor shall provide EMAL a complete list of all standard free moving
mobile equipments and their related documentation (Police Registration
document, valid third party certification, latest inspection record, operator
license and operators third party certification etc.) through Attachment 4
(Form HS.SAF.09.F05)
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6.2.7. Fall Prevention PPEs
The contractor shall provide complete list of all fall prevention PPEs to be
used on the project to EMAL. These include harnesses, lanyards, hooks etc.
Attachment 5 (Form HS.SAF.09.F06) shall be used for the purpose.
6.2.8. Lifting Tools (below the hook devices)
The contractor shall provide complete list of all lifting tools to be used on the
project to EMAL EHS. These include Lifting/ rigging tools and accessories like
slings, wire ropes, U-bolts and other such accessories. Attachment 6 (Form
HS.SAF.09.F07) shall be used for the purpose.
6.2.9. EHS Training & Certification
EMAL EHS will provide a Train the Trainer program for contractors. To attend
this Train the Trainer program, the contractor employee/ EHS representative
should have relevant EHS qualification and experience. Once the contractor
EHS representative successfully completes this program, a badge/ certificate
is issued, authorizing the EHS representative from contractor to train and
induct contractor employees for EMAL contract.
Each contractor shall provide relevant training as per the following table priorto the commencement of work as detailed in their EHS specification sheet.
Certificates of these trainings shall be made available to EMAL EHS.
Topic Theoretical
training
Practical
training
TEST Badge
Health & Safety Principles (UAE
Law)1h - - -
Forklifts YES YES YES YES
Cranes YES YES YES YES
Aerial Lifts YES YES YES YES
Loaders YES YES YES YES
Other Standard Mobile
EquipmentsYES YES YES YES
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Topic Theoretical
training
Practical
training
TEST Badge
LOTOV (Lockout & Tagout &
Verification)- AP level- See
LOTOV EMAL Standard
2h - YES -
Confined Space- Authorized
Entrants2h - YES -
Mobile Equipments (general
overview of the EMAL Mobile
Equipment & Pedestrian
requirements)
2h - YES -
Working at Height (If they are
going to use fall prevention
PPEs)
2h 2h YES -
Molten Metal overview (if they
are going to work inside Molten
Metal areas)
2h - YES -
Electrical Safety- Portable
Equipments. (If they are going to
work with portable electrical
equipments).
2h YES -
Heat stress control YES YES
Other training (required by the
Contract/ Project administrator or
HS department).
6.2.10.Medical Check-up Certificates
Each contractor has to submit to the EHS department, Medical check-up
certificates for all its workers in accordance with EMAL medical services
standards. Medical checks shall be done on an annual basis.
6.2.11.Access to the Site
If all documentation is correct and as per EMAL standards, only then the
contractor will receive a Contractor Site Access Permit (Attachment 7 Form
HS.SAF.09.F08) authorizing the contractor to enter EMAL premises.
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The access permit shall be signed by the relevant authorities from different
departments/ areas such as Contract Administrator, EHS department and
Security. EHS will keep a copy of the Access permit and all documentation in
the contractors file.
The following persons shall be required to carry EMAL authorization card in
their possession at all times during their work.
Operators of mobile cranes
Drivers/ operators of mobile plant (mechanically propelled vehicles)
Banksman for mobile cranes and heavy vehicles.
Persons authorized to use cartridge operated fixing tools Fire watchers
Persons authorized to change abrasive wheels
Persons entering into Potline Area
Alcoholic and non-Alcoholic prescription drugs shall not be permitted onto
EMALs premises. Persons suspected to be under the influence of alcohol or
drugs shall not be permitted onto EMALs premises.
6.3. During Work
6.3.1. Method Statements and Task Risk Assessments
A mandatory requirement to receive Permit-To-Work for any task is Method
Statement and Task Risk Assessment for that particular task.
6.3.2. Permit to work
Before starting the work the contractor shall request the Permit to Work. (See
EMAL Permit to Work Standard).
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6.3.3. Pre- Work Briefing
The first day of the work, all workers shall receive a pre-work briefing about
the risk of the area, emergency instructions, environment issues, reminders of
the special permits for special activities (if it is required).
6.3.4. Health & Safety Targets
The EHS department and the Contract/ project administrator will define EHS
targets for each contractor and subcontractor. The targets will be defined
according to the number of people, work durations and type of work.
The compliance level of the EHS targets will be used for the post work
evaluation. The contractor or subcontractor will be required to:
Self- Inspections
Risk Notifications
Job Observations
Toolbox Meetings
Participate in EMAL EHS Meetings and programs
Near Miss communication.
The Contractor shall also report its EHS Statistics every Sunday to the
Contract Administrator and EHS department. These statistics shall include
the following information from the start of the project:
Manhours worked
Number of Self-inspections
Number of Risk notifications raised
Job observations
Incidents including nearmisses
6.3.5. EHS Incidents
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All incidents shall be communicated to EMAL in accordance with EMAL
Incident Management system.
6.4. After the work - Post Work evaluation
After the completion of a project, the EHS department together with the project
owner/ contract administrator and contractor, will review the contractor
performance.
7. SAFETY VIOLATIONS AND BLACK POINT SYSTEM
7.1. General
7.1.1. Any Environment, Health or safety violation detected during the
contractor or subcontractor work execution shall be communicated to the
EHS department according to the EMAL Health & Safety Notification
standard. Once the EHS department receives the notification, it will
classify the violation and will assign the appropriate number of black
points and notify the contractor with a copy to the contract administrator.
7.1.2. The maximum number of black points allowed within a working year is
23, after which the contractor can be blacklisted from EMAL for 2 years,
meaning the contractor will not be allowed any further contract for this
duration.7.1.3. In case a contractor reaches 24 black points within a working year, a
panel will be formed comprising of EHS, Purchasing and relevant
department/s to decide the further course of action for the contractor.
7.1.4. The total number of black points accumulated by the contractor during
a contract shall be kept as a record in purchasing department and will
determine contractors future suitability for EMAL.
7.1.5. For every safety violation issued to the contractor, an action plan will
be required by the contractor to address the root cause of the violation
and rectify it, failing which the grade of safety violation will be raised.
NOTE: More details on safety violations and the process to raise them can be
found in EMAL Safety Notification Standard.
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7.2. Classification of Safety Violations
7.2.1. Low Risk
Minor flaws or faults in the following equipments, conditions
or tools, such as:
o Portable tools
o Welding equipments, power generators, compressed air
equipments, etc
o Portable electrical equipments
o Portable ladders
o Restrooms, warehouse, containers, etc
o Residual containers, not properly identified, etc.
Lack of:
o Housekeeping
o Incident reporting
o Secondary containers for residuals
Smoking in non designated areas
Over speeding for the first time.
First non-compliance of PPEs
Other safety violations classified as low risk by the EMAL
EHS department
7.2.2. High Risk
The non compliance of the safety rules, requirements
related to the following:
o Medical aptitudes
o Equipment or personal identification
o Inspection of a fall prevention PPE
o Equipment maintenance
o Lockout and tagout
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o Use of mobile equipments without the proper
certification
o Recurrence of a low risk by the same person
o Over speeding for a second time
Lack of maintenance, inspection or third party certification
related to the following:
o Lifting devices (slings, chains, tools, etc)
o Lifting equipments (Cranes, hoists, etc.)
Other safety violations classified as high risk by the EMAL
EHS department
7.2.3. Very High Risk
Failure to stop work immediately when asked by EMAL
because of high risk for people or equipments
Non compliance of a safety rule, procedure that generates a
high potential for a fatality or disabling injury.
Violating speed limit for a third time.
Soils, water or air contamination.
Work execution without EHS plan approval.
Other safety violations classified as very high risk by the
EMAL EHS department
NOTE: The above lists of unsafe events, conditions or acts for
determining different grades of safety violations, are not exhaustive and
any decision of EMAL EHS in this regard shall be deemed final.
7.3. Table of Black Points
The number of black points given for each grade of violation are detailed in
the following table:
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Type of Violation Number of Black Points
Low Risk Violations
First Notification 1
Second Notification 2
Third Notification 4
High Risk Violations
First Notification 4
Second Notification 6
Third Notification 10
Very High Risk Violations
First Notification 10
Second Notification 14
(NOTE: The decision of EMAL EHS in assigning number of black points to a
violation will be final.)
8. INCIDENT COMMUNICATION, RECORDKEEPING & INVESTIGATION
8.1. All incidents (with or without injury must be communicated, and properly
investigated). The non-reporting of an EHS incident is considered as a
serious fault and disciplinary actions could be taken.
8.2. In case of an incident, the worker or co worker must activate the emergency
response, 2111 or immediately notify to his supervisor. The Senior
Production Person, for the area, shall take immediate control, on arrival at
the scene.
8.3. An immediate investigation (preliminary investigation) shall be conducted by
the supervisor concerned. Attachment 8 (Form HS.SAF.03.F05) will be used
to record the preliminary investigation. The contractor EHS representativewill deliver a copy of the Preliminary Investigation to EMAL Contract
Administrator and EHS Department within 24hours of the incident.
8.4. A formal Incident investigation must be conducted and recorded in the EMAL
Incident Management System for all incidents with injuries.
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8.5. In EMAL The Incidents are Classified in:
Incident Without Injuries
o Near Miss
o Damage Incident
Incident with Injuries
o First Aid
o Medical Treatment
o Restricted Work
o Lost Time Injury
o Fatality
8.6. Incident Reporting Flowchart
NO
Did the employee experience an
injury or illness?
YES
NO
Is the injury or illness work-
related?
Yes
Is the injury or illness a new
case?NO
Update the previously recorded
injury or illness entry if necessary
YES
NO
Does the injury or illness meet
the general recorded criteria or
the application to specific cases?
YES
Do not record the injury
or illnessRecord the injury or illness
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9. PERSONAL PROTECTION EQUIPMENT (PPE)
9.1. General PPE requirements
9.1.1. All PPE must comply with European (EN) or the American National
Standards Institute (ANSI) safety standards.
9.1.2. Contractors shall provide EMAL a list of all the PPEs and their
specifications that will be used for the works for approval.
9.1.3. All PPE shall be of a safe design and construction for the work to be
performed.
9.1.4. There is a need to ensure that people with long hair, protect their hair
from contact with moving parts of tools and machinery. It is forbidden to
work outside of the office with long hair, unless it has been tied up out of
the way.
9.1.5. It is forbidden to work outside of the offices wearing jewellery in the
form of bracelets, necklaces and earrings. These must be removed prior
to going out onto the site.
9.2. Provision and suitability of PPE
9.2.1. The company shall issue safety equipment free of charge to
employees, dependant on the nature of their work.
9.2.2. Visitors to site shall be informed of PPE requirements before visiting
site.
9.2.3. The company will take into consideration the health of people wearing
PPE and its ergonomic effects. Employees should inform the company if
they start to have difficulty wearing any of their PPE due to health
reasons.
9.3. Compatibility
9.3.1. The PPE selected must fit the individual properly.
9.3.2. If more than one item of PPE is being worn, the different items of PPE
must be compatible with each other to ensure the risks are still being
adequately controlled.
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9.4. Assessment and identification of site and task PPE requirements
There are various ways in which site and task PPE requirements will be
identified and these are as follows:
9.4.1. Mandatory site PPE (outside of offices in designated areas)
All personnel entering designated PPE areas will be required to wear
the following items of PPE:
Hard hat
Safety glasses
Protective clothing/overalls. In Hot Work areas, flame retardant
garments certified with the EN 531:1995 level D2 is required.
Safety boots with methatarsal protection
9.4.2. PPE identified by mandatory signage
There are areas on site that will require you to wear additional PPE
when entering specified zones, for example hearing protection zones
or respiratory protection zones. These will be identified by mandatory
(blue and white) signage.
9.4.3. PPE identified by risk assessmentCertain tasks, for example working with substances, will require the
wearing of additional PPE. This additional PPE requirement will have
been identified by risk assessment and the information passed to
employees by supervisors or contract administrators.
10. PERMIT TO WORK (PTW)
Permit to work (PTW) will be required for all construction, modification,
maintenance, or inspection. Works that do not require PTW must be approved by
the department head and by the Safety Department. In such cases, the
Department is required to list the work and maintain proper record. All contractor
jobs will require a PTW.
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10.1. Issuing Authority (IA)
A competent person possessing the necessary experience, and technical
knowledge, appointed in writing by EMAL to issue, and cancel permits to work
within the terms of their authorization. An Issuing Authority will be always an
EMAL employee.
10.2.Receiving Authority (RA)
10.2.1. A contractor competent person possessing the necessary experience,
and technical knowledge, appointed in writing by EMAL to receive and
clear PTW.
10.2.2. For contractors, a letter shall be submitted by all contracting
companies stating competency of persons supervising all on-site
activities. Each supervisors letter shall be kept on file by EMAL EHS
Department who will ensure that the list of Receiving Authorities on the
EHS Homepage on EMAL intranet is updated.
10.2.3. The EHS department shall conduct a test for all contractor supervisors
applying to receive permits at EMAL. This shall be done prior to any
entry of the contractor supervisors name on the Safety Homepage onEMAL intranet.
10.2.4. In the event of a contractor coming to site for the purpose of
consulting, attending to a breakdown or doing an ad-hoc, once off task,
the contractor will only be allowed to work under EMAL supervision.
10.2.5. The Contractor Receiving Authority is responsible:
that the authorized employees comply with all requirements indicated
in the PTW.
Is responsible to lead and prepare the Pre-work check list.
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10.3.Permit to Work Process
10.3.1. The PTW has one sheet and all permits will be numbered. The PTW
sheet has three paper copies (white, yellow and pink).
10.3.2. The PTW will be completed by the issuing authority. Once the PTW is
completed the issuing authority and the receiving authority will sign the
PTW. The issuing authority will keep the original of the PTW (white copy)
and he will give the other two copies (yellow & pink) to the receiving
authority.
10.3.3. Before the commencement of any work under a PTW, the content and
work hazards and countermeasures (Pre- work check list Attachment 9
Form HS.SAF.01.F02) will be explained to the working party.
10.3.4. The receiving authority will give the pink copy of the PTW to a
competent person. This copy must be in the workplace.
10.3.5. Once the job is completed the CP will give back the pink copy to the
RA. The receiving authority will give back the two copies (yellow & pink)
to the issuing authority and he will sign the white copy of the PTW in theclearance box. The issuing authority will sign the PTW cancellation box
in the original paper (white)
10.3.6. A PTW will be valid until clearance and cancellation. A PTW once
issued, will be retained in the custody of the Receiving Authority, until
Clearance.
10.3.7. Receiving authority shall ensure the changes in the surroundings and
other environmental conditions at the work place. The responsibility of
checking the isolation status rests with isolating/issuing authority till the
PTW is cancelled. Where the Receiving Authority changes, then a
Transfer record must be completed. See Attachment 10.
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10.3.8. If during the work execution, changes are experienced in the work
conditions, the PTW will be cancelled until the normal condition will be
restored. If the PTW is cancelled, then a new PTW will be needed. The
PTW could be suspended and re-issued using the transfer procedure.
10.4.Pre- Work Check List
A Pre-Work Check List will be required for all jobs even when permit to work is
not required. See Attachment 9. The contractor receiving authority and the
contractor workers will complete the Pre-Work check list before starting the work.
The contractor receiving authority will sign the pre-work check list, with the sign
the receiving authority is confirming that the hazards and countermeasures were
explained and understood to the workers.
11. LOCKOUT, TAGOUT & VERIFY (LOTOV)
The EMAL Lockout, Tagout & Verification Program, describe the requirements to
guarantee a Zero Energy state for all Construction, Inspection or Maintenance
Jobs. It must be remembered that for certain tasks, it may not be possible to
guarantee zero energy. These jobs must be inventoried and the work procedure
approved by the HS department and Department Manager.
11.1. Isolating Authority (IsA)
A EMAL competent person designated by the owner of the area, with the
necessary experience, and technical knowledge for isolating equipment and for
implementing a tag out and lockout procedure.
11.2.Authorized Person (AP)
11.2.1. A EMAL or contractor competent person with sufficient technical
knowledge and practical experience who has been approved to carry out
a task on Plant or Apparatus that has been previously isolated by an
Isolating Authority (IsA)
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11.2.2. All EMAL and contractor employees with the exception of the
administrative personal must receive specific training about the energy
control program to assure the program is properly understood.
11.2.3. Refresher training will be required every two years or before if the
program changes or if it is considered because of increasing number of
incidents, violations or other reasons.
11.3. LOTOV Tags & Locks
The necessary elements for an equipment/ facility isolation are:
o Safety tags (Isolation tags, Personal and
Verification/Identification tags)
o Safety Locks (Isolation Locks and Personal Locks)
11.3.1.LOTOV Tags
Only tags are acceptable where no physical means of locking isolation
devices exists. The safety tag has three main purposes:
Isolation tag (red) Indicates that the energy isolation devices or
verification device are in the safe position. For example, supply
valve is closed, vent valve is open, etc
Equipment Identification and 0 energy verification tag
(yellow). Indicates the piece of equipment or equipment to be
worked on and confirms that the energy isolation devices were
verified and the equipment is at zero energy. If it has not been
possible to verify the equipment, then a verification tag should still
be attached for identification, but this should be noted on the tag.
In these cases the tag will be yellow with brand red diagonalstripes.
Personal Tags (blue) Indicates that there are people working on
the equipment out of service because of construction, inspection or
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maintenance. The personal tags are exclusively for personal use
and nobody could attach a personal tag of other employee.
The manipulation of a personal tag of another employee will be considered a
serious safety violation and disciplinary actions could be taken. The
contractor personal tags will be identified with the word CONTRACTOR in
print letters.
A safety tag is as restrictive as a safety lock.
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11.3.2.LOTOV locks
The purpose of the locks is to hold energy isolation device in the safe position
to prevent unexpected activation of an energy source, unexpected start-up or
unexpected release of stored energy. The locks are classified by colours and
with different means
Personal Lock (Blue)
IsolationLock (Red)
All locks shall be one key locks
11.4. Isolation Process
11.4.1. Isolations must be referenced in the Permit to work.
11.4.2. The Operations Team, use normal stop procedures to shut down the
Plant or Apparatus and release the Plant or Apparatus for Work.
11.4.3. An IsA will isolate (de-energize, tag out and lockout) the equipment. At
same time will verify the absence of energy and will attach the
equipment identification and 0 energy verification tag in the equipment or
piece of equipment to manipulate.
11.4.4. The IsA will introduce the keys of the isolation locks inside the key
safe and will close the Key safe with the control key. A Identification Tag
stating the Plant or Apparatus will be affixed to the Key Safe
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11.4.5. The IsA will sign the tag out and lockout procedure/Isolation Certificate
to confirm that the equipment isolation has been completed.
11.4.6. The Issuing Authority (IA) will attach one of the Key safe Keys to the
PTW, and will issue this key along with the PTW
11.4.7. The IA will also issue the completed LOTOV procedure/Isolation
Certificate to the Receiving Authority (RA).
11.4.8. The Receiving Authority will introduce the yellow copy of the PTW and
the key of the group box inside a card safe in the workplace or other
suitable location (workshop). They will close the card safe with their
Personal Lock and Tag. Each member of the working party shall also
secure the PTW/Key safe Key in the Card safe with a personal tag and
lock.
11.4.9. The personal tags could only be removed by the owner of the tags
when:
o The work is completed
o At the end of the shift
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o Other job is assigned or the person leaves the job before the
job is completed
11.4.10. Before starting to work, the receiving authority and each
member of the crew shall verify that the equipment/ facility is isolated
according to the LOTOV procedure.
NOTE: If a work in group isolation equipment continues for more than one shift,
the responsibility of the group isolation will be done by a Permit to Work
transference (see EMAL PTW Procedure HS.SAF.01).
11.4.11. The tags and locks removal will be according with this
sequence:
Each person will remove their personal tag and lock from the card
safe.
The RA will remove their personal tag and lock from the card safe and
will return the PTW to an Issuing Authority. The RA shall then sign the
white original copy of the PTW as work clearance.
The RA will give the yellow and pink copy of the PTW and the key of
the Key safe to the IA. The IA shall sign the PTW cancellation.
Once all of the Key safe Keys have been returned and all related
permits cancelled, the IA shall release the group tags and locks from
the Key safe and then remove the Isolation Locks from the energy
isolation devices and restart the equipment. The Plant or Apparatus
will then be returned to the Operations Team for safe return to service.
12. WORKING AT HEIGHTS
Fall control shall be required for personnel exposed to heights greater than 1.8m or
more and at lower heights if potentially hazardous situation exist.
All employees must take a three-step systematic approach to protect them from fall.
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The first step is to assess the workplace and the work itself. Fall hazard shall be
eliminated wherever possible by changing the sequence of the job, by working
from ground level or by the use of special tools, equipments.
The second step also requires assessing the workplace and work processes. If
fall hazard can not be completely eliminated during the first step, management
must take a proactive approach to the prevention of fall by improving the
workplace (collective protection). Early installation of stairs, guardrails, scaffolds,
and travel restriction systems can ensure a safe work environment.
The third step is to use fall arresting equipment. Use fall arresting equipment,
however, only after determining that potential fall cannot be eliminated by
changing work procedures or workplace or collective protection can not be used.
Equipment such harnesses, lanyards, shock absorbers, fall arresters, lifelines,anchorages and safety nets can reduce the risk of injury if a fall occurs.
12.1.Training
12.1.1. All contractor employees with the exception of the administrative staff
shall receive specific training about the working at height program to
ensure that the program is properly understood
12.1.2.Maintenance People or Those People Who Work At Heights: For
these people, refresher training will be required every two years or
before if the program changes or if it is considered because of increasing
number of incidents, violations or other reasons. The training shall be
documented and shall include the following topics/contents:
Use, visual inspection, and maintenance of fall arrest systems;
Practical training in the use of fall prevention equipments.
Must demonstrate competency in initial training
12.2.Scaffolds
12.2.1. Personal working on tubular or other scaffolds shall use a fall arrest
system unless the scaffold complies with the fall prevention system
requirements described in the Scaffolding EMAL Scaffolding standard.
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12.2.2. Scaffolds shall be erected and used in compliance with the EMAL
scaffolding standard and under the supervision of a competent person in
scaffold erection.
12.2.3. Before use the scaffold, the user must check the scafftag to verify that
the scaffold was inspected and the scafftag signed by a competent
scaffold inspector within seven days before the day of use.
12.2.4. A scaffold visual inspection shall be conducted by the user before
each use. If for any reason a user considers a scaffold to be unsafe he
shall immediately contact his supervisor. The supervisor shall
immediately remove the Scafftag and place barrier tape through the
lower rungs of the 1st access ladder. The supervisor shall then notify
the Scaffolding Supervisor.
12.3.Fall Arrest Equipment
12.3.1. The full body harness will meet ANSI (American National Standards
Institute) or EN (European Norms) standards. Safety belts are
prohibited.
12.3.2. A visual inspection shall be conducted by the user before each use of
fall arrest equipment.
12.3.3. Every quarter, a document inspection by a competent person shall beperformed on fall arrest equipment. Health and Safety Department will
nominate the competent persons for fall arrest equipment inspection.
12.3.4. Fall arrest equipment inspected and rejected for further use shall be
destroyed to prevent further use and inspection record shall be updated
to include the method of disposition.
12.3.5. The inspector shall complete the inspection record (Attachment 11
Form HS.SAF.04.F03) and forward a copy of the completed form to the
department EHS coordinator and another copy to the Health and Safety
department.
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12.4.General Practices
12.4.1. Workers must avoid climbing on equipment such as pumps,
exchangers, valve and wheels, transformers, electric motors, handrails,
structures, or any other facilities not specifically designed for climbing
12.4.2. Climbing on conduit, cable trays, or other similar equipment is not
permitted.
12.4.3. Climbing of vertical beams is not permitted.
12.4.4. Workers must not climb a ladder while another is above or below on
the same ladder.
12.4.5. Personnel performing jobs from an aerial lift, scissor lift or basket shall
use a fall arrest system attached to the basket.
12.4.6. Climbing onto the middle rail, top rail or working from the outside of the
basket is prohibited while the person is attached to the aerial lift, scissor
lift or basket anchorage point.
12.4.7. All work on flatbed trailers higher than 1.8m must be performed with
full fall protection such as - safety nets, fall arrest systems, or full
guardrail protection.
12.4.8. All work on flatbed trailers lower than 1.8m height shall be preferably
performed with full fall protection, if this is not possible anyone whoaccesses the flatbed trailer must be required to wear a hardhat with
chinstrap.
12.4.9. Climbing on top of a trailer load without fall protection is still prohibited.
12.5.Working at roof
Working at roofs require a Fall Protection Plan (HS.SAF.04.F02) and roof work
access permit.
12.6.Ladders
12.6.1. Portable manufactured ladders shall bear identification indicating that
they meet the appropriate ladder construction requirements of ANSI
(American National Standards Institute) or EN (European Norms)
standards.
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12.6.2. The use of metallic ladders is forbidden inside the Reduction
department, for electrical works or at proximity of live lines. For these
works a wooden or fiber glass ladders shall be used.
12.6.3. Portable single ladders shall not be used to jump heights greater than
3.5m.
12.6.4. Portable single ladders shall not be longer than 5m.
12.6.5. Ladders shall not be placed in front of doors opening toward the ladder
unless the door is blocked upon, locked, or guarded.
12.6.6. When ascending or descending, the climber must face the ladder and
must keep three points of contact. Tools should be carried on a waist
belt, in a shoulder bag or raised and lowered on a rope to ensure a
person climbing up/down a ladder maintains an adequate grip on the
ladder.
12.6.7. Ladders shall extend 1m above where a person can gain access at the
top of the ladder.
12.6.8. Ladders shall be placed at a gradient of not less than 1:4 (i.e. one
meter out horizontal for every four meters of height) and not greater that
1:6.
12.6.9. A portable ladder shall not be used by more than one person at the
same time.12.6.10. All portable ladders shall be equipped with shoes.
12.6.11. A portable ladder shall not be used as working surface. As
exception and when not possible to use a working platform, a scaffold or
an aerial lift, the next requirements must be considered:
12.6.12. When persons feet are positioned above 1.8m the employee
shall use a fall-prevention/arrest system.
12.6.13. Every three months a component person from the department
should inspect and maintain a list of all ladders in their charge and
record date of inspection and defects noted. See Attachment 12 (Form
HS.SAF.05.01 - Portable Ladder Inspection and Identification List).
Ladders adequate for using will be identified with a color code of the
quarter as follows:
1st
Q 2nd
Q 3rd Q 4th Q
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13. CONFINED SPACES
13.1.Definition
Means a space that:
- is large enough and so configured that an employee can bodily enter and
perform assigned work; and
- Has limited or restricted means for entry or exit (for example, tanks, vessels,
silos, storage bins, hoppers, vaults, and pits are spaces that may have limited
means of entry.); and
- Is not designed for continuous employee occupancy.
13.2.Confined Space Entry Permit
13.2.1. A Confined Spaced Entry Permit shall be required to entry in any
Confined Space.
13.2.2. Confined spaces shall be classified Class A or Class B confined
spaces. All the confined spaces entrances shall be identified with a sign
reading DANGER- PERMIT REQUIRED CONFINED SPACE, DO NOT
ENTER
13.2.3. The confined space entry permit is described in Attachment 13 (Form
HS.SAF.06.F01 - Confined space entry permit) and shall include:
All personnel in confined spaces and attendant will carry
portable lighting.
at least one attendant outside the permit space into which entry
is authorized for the duration of entry operations
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If hot works are done inside a confined space this one must be
reclassified as Class A confined Space. Hot work permit will
also be necessary and EMAL Hot Work standard shall be
followed.
Either double insulated or ground fault circuit interrupter
protected electrical tools and low current, low voltage (24 volt
maximum) lighting systems shall be used in damp or metallic
hazardous confined spaces.
Electrical and pneumatic tools shall be selected to eliminate
sparks and other hazards as required by the conditions of the
confined space.
Gas cylinders should not be used with in a confined space.
Should there be condition arises where gas cylinders have to
be used inside the confined spaces, special precautions are to
be taken and it shall be approved by H & S Department. At no
circumstances, CO2 fire extinguisher shall be taken into the
confined space.
Internal combustion engines should never be used inside
confined space.
13.3.Confined Space Training
13.3.1. Confined Space training for contractors shall be of two types:
o Level 0: All contractor employees must receive a general overview of
the EMAL Confined Space program.
o Level 1: All contractor authorized entrants and attendants shall
receive a specific training of the EMAL confined space program.
13.3.2. This training will be refreshed every two years. Each contractor must
have an updated list of all authorized entrants and attendants. The
certification shall contain each employee's name, the signatures or
initials of the trainers, and the dates of training.
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13.3.3. The training shall establish employee proficiency in the duties required
by this document and shall introduce examples of new or revised
procedures.
13.3.4. Additional to this training, all authorized employees and attendants
shall receive a specific pre-work meeting for the specific confined space,
before entering. This information will be provided by the confined space
issuing authority. This pre-work meeting is valid for six months in the
class B confined spaces and only for each work in the class A confined
spaces.
13.4.Duties of Authorized Entrants
The employer shall ensure that all authorized entrants:
13.4.1. Know the hazards that may be faced during entry, including
information on the mode, signs or symptoms, and consequences of the
exposure
13.4.2. Properly use equipment as required.
13.4.3. Communicate with the attendant as necessary to enable the attendant
to monitor entrant status and to enable the attendant to alert entrants of
the need to evacuate the space as required by this document;
13.4.4. Alert the attendant whenever:
The entrant recognizes any warning sign or symptom of
exposure to a dangerous situation, or
The entrant detects a prohibited condition; and
13.4.5. Exit from the permit space as quickly as possible whenever:
An order to evacuate is given by the attendant or the entry
supervisor,
The entrant recognizes any warning sign or symptom of
exposure to a dangerous situation,
The entrant detects a prohibited condition, or
An evacuation alarm is activated.
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13.5.Duties of Attendants.
The employer shall ensure that each attendant:
13.5.1. Knows the hazards that may be faced during entry, including
information on the mode, signs or symptoms, and consequences of the
exposure;
13.5.2. Is aware of possible behavioural effects of hazard exposure in
authorized entrants;
13.5.3. Continuously maintains an accurate count of authorized entrants in the
permit space. See Attachment 14 (Form No HS.SAF.06.F04 - Confined
space entry/exit record).
13.5.4. Remains outside the permit space during entry operations until
relieved by another attendant;
13.5.5. Communicates with authorized entrants as necessary to monitor
entrant status and to alert entrants of the need to evacuate the space
under described in this document;
13.5.6. Monitors activities inside and outside the space to determine if it is
safe for entrants to remain in the space and orders the authorizedentrants to evacuate the permit space immediately under any of the
following conditions;
o If the attendant detects a prohibited condition;
o If the attendant detects the behavioral effects of hazard exposure in
an authorized entrant;
o If the attendant detects a situation outside the space that could
endanger the authorized entrants; or
o If the attendant cannot effectively and safely perform all the duties
required for his position.
13.5.7. Summon rescue and other emergency services as soon as the
attendant determines that authorized entrants may need assistance to
escape from permit space hazards;
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13.5.8. Takes the following actions when unauthorized persons approach or
enter a permit space while entry is underway:
Warn the unauthorized persons that they must stay away from the
permit space;
Advise the unauthorized persons that they must exit immediately if
they have entered the permit space; and
Inform the authorized entrants and the entry supervisor if
unauthorized persons have entered the permit space;
13.5.9. Performs non-entry rescues as specified by rescue procedure
13.5.10. Performs no duties that might interfere with the attendant's
primary duty to monitor and protect the authorized entrants.
14. MOBILE EQUIPMENTS
The Industrial Free Moving Mobile Equipments are classified in:
14.1.Standard Free Moving Mobile equipments
Are operator controlled mobile equipment not constrained by Fixed rails and can
include gasoline, propane, diesel, or electrically powered used for labor activities
as, forklifts, aerial lifts, trucks, buggies, sweepers.
All standard Free Moving Mobile Equipment must be identified with:
- Mobile Equipment number (according to the EMAL identification code). This
identification must be painted or engraved in the Mobile Equipment and must
be visible from 20m distance. The recommended dimensions for the
identification are 21 x 30 cm.
NOTE: If the Mobile Equipment has official plate number, this identification
eliminates the previous requirement.
- SWL (Safe Working Load)
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.
14.2.Auxiliary Free Moving Mobile Equipments
These are Industrial Free Moving mobile equipments used to transport people
and equipment around site such as cars, 4x4, pick-ups and buses. The auxiliaryFree Moving Mobile Equipments do not have to comply with the 100% of the
requirements specified in this procedure (pre- use check list, audible backwards
signal) but must be identified with Department, Contractor Company or a visible
visitor vehicle pass.
The Auxiliary Free Moving Mobile Equipment is not allowed to be driven inside
the production buildings.
The use of two wheels mobile equipment is forbidden inside EMAL site. This
includes motorcycles and pedal cycles.
14.3.Free moving mobile equipment operators
14.3.1. The free moving mobile equipment operators shall pass the mobile
equipment medical evaluation. Moreover the driving license of every
driver should be checked prior to imparting of the training as per UAE
law (HS.SAF.13.A02).The driving license should be of the appropriate
category as the training category being imparted.
14.3.2. All Auxiliary Free moving mobile equipment operators shall be
required to provide a valid official UAE driving license for the class of
vehicle.
14.3.3. The Training for Standard free moving Mobile Equipment, shall
include:
- Theoretical trainingo EMAL Mobile Equipment Program
o General Safety rules and operating procedures
o Equipment controls and safe work instructions.
o Specific Mobile Equipment Instructions, including the manufacturer
indications.
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o Concepts about working with loads
- Practical training deployed by a competent person who has free
moving mobile equipment knowledge, training and experience.
Practical training shall include:
o Mobile Equipment driving, steering and maneuvering
o Vehicle pre operation check- list
o Load Manipulation, stacking and un stacking
o Vehicle stability
o They have to pass a written test and an accreditation will be given
to each authorized operator.
14.4.General Training
All contractor employees who do not drive Mobile Equipments and work in areas
where mobile equipment movement exists, will receive the same theoretical
training that is required for the Free Moving Mobile Equipment operators.
14.5.Mobile Equipment Certification
14.5.1. An EMAL Authorization Certificate to drive shall be issued to eachEMAL Mobile Equipment Operator which states Name, Employee
Number, department, class of vehicle, plant area, and validity.
14.5.2. The EMAL Authorization Certificate for Standard Free Moving Mobile
Equipment shall be issued by the Training department after confirming
that the employees have the medical aptitude and have passed the
theorical and practical training.
14.5.3. The EMAL Authorization Certificate for Auxiliary Free Moving Mobile
Equipment shall be issued by the Security department after confirming
that the employees have a valid UAE Driving License.
14.5.4. The Certificates shall then be forwarded to the H&S Department, and
a new ID badge will be issued indication that the employee is authorized
to drive on site, and category of vehicle.
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Photo
DriverCertification
Badge
Name
ID
Deptt
M.E
Driver CertificationBadge
Type of M.ETraining
(Next date)
Training
(Last date)
Photo
DriverCertification
Badge
Name
ID
Deptt
M.E
Driver CertificationBadge
Type of M.ETraining
(Next date)
Training
(Last date)
Note: Driver Certification Badge
14.6.Preventive Maintenance
14.6.1. Each contractor company will develop a preventive maintenance
program for all free moving mobile equipment according to the Original
Equipment Manufacturer (OEM) requirements and local legislation.
14.6.2. Mobile Equipment involved in incident shall not be repaired until
incident report is submitted to EMAL EHS department.
14.6.3. After every Preventive Maintenance, the contractor will fix a sticker in
the mobile equipment indicating the mobile equipment hours, km or date
for the next scheduled preventive maintenance.
14.7.Pre use inspections, Check List
14.7.1. A pre use inspection shall be performed on free moving mobile
equipment before each shift that the equipment is to be used to assure
that the following parts, equipment, and accessories are in safe
operating condition and free of apparent damage that could cause failure
while in use.
14.7.2. The pre use inspection will be divided in minor and major findings.
14.7.3. If a Major finding is detected the mobile equipment shall be
immediately locked out and tagged out according to the EMAL lockout &
tagout procedure. If Minor findings are identified, then it will be written in
the check list and communicated to the department mobile equipment
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responsible in order to include the equipment in the maintenance
program.
14.7.4. Major finding are considered all items that could affect the safety of the
Mobile equipment operator and/ or to the safety of the pedestrians, e.g.
seatbelt, flashing lights, brakes etc.
14.7.5. Pre use inspection records are to remain with the free moving mobile
equipment for the entire shift. Pre- use inspection records shall be
verified by each operator using the free moving mobile equipment. Pre
use inspection records shall be kept by the department mobile
equipment responsible for a minimum of three months.
14.8.Other Requirements
14.8.1. Do not block recognized gangways and access ways unless a clear,
safe diversion has been provided.
14.8.2. Only authorized routes must be used to and from work sites.
Contractors vehicles are not allowed to cross the Hot Metal Roads.
14.8.3. No road shall be closed off without written approval from EMAL. A
request for road closures shall be made at least 48 hours before the
closure is required. EMAL Representative shall send a copy of the
approved request to EMAL Security prior to closure of the road.14.8.4. All free moving mobile equipments and auxiliary equipments must be
equipped with seat belt. The number of passengers carried in company
vehicles will be determined by the fixed seating provided.
14.8.5. As general rule, if the mobile equipment is equipped with a closed
cabinet, the use of hardhat and safety glasses are not required.
14.8.6. The speed limits inside plant area are as follows:
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Outside
Buildings
Inside
Buildings
Auxiliary Free Moving Mobile Equipments:
Buses, trucks, cars30 10
Standard Free Moving Industrial Equipments
(forklifts, aerial lifts, )20 10
14.8.7. All vehicles should give prioritization to the Fire Brigade mobile
equipments or ambulances
14.8.8.Over speeding violations will be communicated according to EMAL
Safety Notification Standards. Moreover following steps would be taken
in case of a violation:
On first notification the operator/user would not be allowed to
operate/drive inside EMAL premises for 1 month in12 months.
On second notification the operator/user would not be allowed to
operate/drive inside EMAL premises for 3 months in 12 months
On third notification the operator/user would not be allowed to
operate/drive inside EMAL premises for 6 months in 12 months
and would have to pass through the mobile equipment training.
14.8.9.REVERSING WARNING: All free moving mobile equipment and any
associated towed equipment having obstructed rear vision shall be fitted
with an audible and or visible reverse warning system.
14.8.10. Splash guards: shall be required on all free moving mobile
equipment potentially exposed to molten substance splashes or in the
area of potential molten substance splashes such as free moving mobile
equipment used to charge, skim or carry molten splashes. Splash
guards shall be designed and installed to keep molten substances from
entering the cab or splashing the operator.
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14.8.11. CABS All vehicles with cabs shall be equipped with
windshields and powered wipers. Cracked and broken glass shall be
replaced.
14.8.12. WARNING LIGHTS All free moving mobile equipments shall
use flashing lights. If an Industrial Mobile Equipment does not have
flashing light, the use of a waning flag will be required
14.8.13. ROPS & FOPS All industrial mobile equipment shall be
provided with ROPS and FOPS. Any exception must be approved by the
Maintenance Senior Manager and HS Senior manager.
14.8.14. Parking
Auxiliary mobile equipment will always be parked in reversing
position. Before any startup the auxiliary equipment driver shall
have to sound the horn.
Parking violations would also be notified as per EMAL Safety
Notification standard and the same criterion as for over speeding
violation will be used.
14.9.Operational Guidelines
14.9.1. In darkness auxiliary mobile equipment operators should use hazard
lights while they stop at any instant and should be extra careful while
maneuvering.
14.9.2. The use of mobile phones whilst operating any mobile equipment shall
be prohibited. The use of a hands free device whilst operating Auxiliary
Free Moving Mobile Equipment shall be permitted.
14.9.3. No person shall be allowed to stand or pass under the elevated portion
of any standard free moving mobile equipment, whether loaded or
empty.
14.9.4. When standard free moving mobile equipment is left unattended, load
engaging means shall be fully lowered, controls shall be neutralized,
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power shall be shut off, and brakes set. Wheels shall be blocked if the
mobile equipment is parked on an incline.
14.9.5. Mobile equipment is unattended when the operator is 5m or more
away from the vehicle which remains in his view or whenever the
operator leaves the vehicle and it is not in his view.
14.9.6. When the operator of mobile equipment is dismounted and within 5m
of the mobile equipment still in his view, the load engaging means shall
be fully lowered, controls neutralized, and the brakes set to prevent
movement.
14.9.7. A safe distance shall be maintained from the edge of ramps or
platforms while on any elevated dock, or platform or freight car.
14.9.8. The safety distance shall be at least 1.8m from parallel edges or
ramps
14.9.9. The safety distance shall be at least 3.1m in front of edges or ramps.
14.9.10. Brakes shall be set and wheel blocks shall be in place to
prevent movement of trucks, trailers while loading or unloading.
14.9.11. Fire aisles, access to stairways, and fire equipment shall be
kept clear.
14.10. Travelling
14.10.1. All traffic regulations shall be observed. A safe distance shallbe maintained approximately three mobile equipment lengths from the
mobile equipment ahead.
14.10.2. The right of way shall be yielded to ambulances, fire trucks, or
other vehicles in emergency situations.
14.10.3. The driver shall be required to slow down and sound the horn
at cross aisles and other locations where vision is obstructed.
14.10.4. The driver shall be required to look in the direction of, and keep
a clear view of the path travel.
14.10.5. Grades shall be ascended or descended slowly
14.10.6. When ascending or descending grades in excess of 10
percent, loaded mobile equipment shall be driven with the load upgrade.
On all grades the load and load engaging means shall be tilted back if
applicable, and raised only as far as necessary to clear the road surface.
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14.10.7. Stunt diving and horseplay shall not be permitted
14.10.8. Speed, the hand steering wheel shall be turned at a moderate,
even rate.
14.11. Mobile Equipment and Pedestrian Segregation
Mobile Equipment and Pedestrian Segregation is a system to identify, develop
and implement mobile equipment only and pedestrian only ways to reduce the
chances of injury and address potential interferences. The segregation is color
coded for easy recognition in the Inside areas and the Outside areas.
The mobile equipment and pedestrian segregation in Inside areas and Outside
areas would be color coded as per the specifications given in the EMAL
Standard forMobile Equipment.
14.11.1. Inside Areas
1.0 m
Safe Pedestrian Walkway:without potentialinterferences with mobile equipment or
protected against the mobile equipment withphysical barriers
Solid Green RAL 6025 1.0 m
Safe Pedestrian Walkway:without potentialinterferences with mobile equipment or
protected against the mobile equipment withphysical barriers
Solid Green RAL 6025
1.0 mSolid Green RAL 6025
Safe Pedestrian Walkway and cautionmarking to segregate shared mobile
equipment area. Fo r crossing instructions
employees have to follow EMAL Mobile
Equipment Standard
Yellow lin e (RA L 102 3) with b lac k ( RAL 90 17)stripes at 45 degrees
0.2 m
1.0 mSolid Green RAL 6025
Safe Pedestrian Walkway and cautionmarking to segregate shared mobile
equipment area. Fo r crossing instructions
employees have to follow EMAL Mobile
Equipment Standard
Yellow lin e (RA L 102 3) with b lac k ( RAL 90 17)stripes at 45 degrees
0.2 m
Red line (RAL 3020)
1.0 mSolid Green RAL 6025
Safe Pedestrian Walkway and Red line to
segregate from mobile equipment area.
Physical barriers along with warning signs
would be placed as per the risk assessment
0.2 mRed (RAL 9017)Red line (RAL 3020)
1.0 mSolid Green RAL 6025
Safe Pedestrian Walkway and Red line to
segregate from mobile equipment area.
Physical barriers along with warning signs
would be placed as per the risk assessment
0.2 m
1.0 mSolid Green RAL 6025
Safe Pedestrian Walkway and Red line to
segregate from mobile equipment area.
Physical barriers along with warning signs
would be placed as per the risk assessment
0.2 mRed (RAL 9017)
Yel lo w (RA L 10 23) & R ed (R AL 90 17)
Safe Pedestrian Crosswalk between twopedestrian walkways through shared
m obile equipment area.
0.2 m 0.2 m
Yel lo w (RA L 10 23) & R ed (R AL 90 17)
Safe Pedestrian Crosswalk between twopedestrian walkways through shared
m obile equipment area.
0.2 m 0.2 m
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Y ello w (R AL 10 23) & R ed (R AL 901 7)
Safe Pedestr ian C rosswalk between twopedestrian walkways through shared
mobile equipment area.
0.2 m 0.2 m
Inward opening crossing
gates as per r iskassessmen t
Y ello w (R AL 10 23) & R ed (R AL 901 7)
Safe Pedestr ian C rosswalk between twopedestrian walkways through shared
mobile equipment area.
0.2 m 0.2 m
Inward opening crossing
gates as per r iskassessmen t
14.11.2. Outside Areas
1.0 m
Safe Pedestrian Walkway made of tough tiles
in outside area adjacent to the mobileequipment travel way
1.0 m
Safe Pedestrian Walkway made of tough tiles
in outside area adjacent to the mobileequipment travel way
Pedestrian Crosswalk outside with whitemarkings
Road
Pedestrian Crosswalk outside with whitemarkings
Road
Bicycleway
Road
Outside mob ile equipment area with a bicycle
way and adjacent pedestrian only walkway
1.0 m 1.0 m
Bicycleway
Road
Outside mob ile equipment area with a bicycle
way and adjacent pedestrian only walkway
1.0 m 1.0 m
Warning/Cautious area for hazardousactivities that involve pedestrians and mobile
equipment at the same place at any giventime
Warning/Cautious area for hazardousactivities that involve pedestrians and mobile
equipment at the same place at any giventime
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15. LIFTING EQUIPMENTS
15.1. Lifting equipment classification
The lifting equipments are divided in two main categories. In each category
different subcategories can be identified with different inspection requirements.
- Lifting gear
o Chain Sling, wire rope sling, Fiber rope slings and synthetic webbing
slings.
o Hooks, shackles , rings, eye bolts and swivels etc.
o Special purpose lifting equipment
o Lifting Beam/spreader Beams
o Beam Clamp and Plate clamps.
- Lifting Appliances
In EMAL the lifting appliances are classified according to the different
inspection requirements in the following categories.
o Fixed Lifting Equipments
o Electric overhead travelling cranes
o Special Purpose Lifting Equipmentso Molten Aluminium and Bath Crucibles
o Mobile Cranes & HIAB
o Forklifts
o Anode Elevators
o Furnace Door Lifting Equipment
o Powered Access Platforms
o Vehicle Lifts in Garage
o Passenger Lift
Contractors have to submit a list of all free moving mobile equipments including
lifting equipments as well as a separate list of lifting gears i.e. below the hook
devices 15 days prior to the contractors mobilization.
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NOTE: This is a mandatory requirement to obtain Contractor Site Access permit.
For more details, EMAL Contractor Management Standard shall be consulted.
15.2. Inspection Requirements:
15.2.1. Lifting Appliances:
All Contractor lifting appliances need to be inspected by EMAL Inspection
Services before being allowed entry into EMALs premises. It is
contractors responsibility to inform and schedule inspection of its lifting
appliances with the Inspection Service & EHS department of EMAL.
Following documents shall be submitted with the request for inspection,
by the contractor, at least 4 days prior to the expected mobilization date of
the lifting appliance:
- Valid 3rd
Party certificate
- Valid Police registration Document
- Valid Insurance Details.
- Valid Operators Driving License/ 3rd
party training & Certification.
- Manufacturers manual and certificates.
After the mobilization, the continuing inspection requirements for in-house
and 3rd
party inspections will be the same for contractors as detailed in
EMAL Lifting Equipment Standard.
15.2.2. Lifting Gears:
For lifting gears or below the hook devices, the contractor shall submit a
complete list (as detailed in EMAL Contractor Management Standard) with
necessary test certificates, manufacturers certificates and 3rd
party
inspection certificates before the lifting gears are mobilized on site. All
contractor lifting gears shall be identifiable with a unique serial ID.
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Once mobilized, the on-going inspection requirements of in-house and
third party inspections are as detailed in the next table.
Lifting
Equipment
Third Party
Inspection
Internal Inspection by
EMAL Inspection
Services
Visual
Inspection
by user
Lifting gear Every 6 months Every 6 months Before use
Fixed Lifting
Equipment
Every 12 months Every 6 months Before use
Special Purpose
Lifting
equipments
Every 6 months Every 6 months Before use
Mobile Cranes &
HIABs
Every year NDT every year on
crane hooks
Before use
Forklifts Every year Before use
Every 6 monthsPower access
platforms Load test every
year
Before use
15.3. Lifting gear safety Rules:
15.3.1. Slings, which are damaged or defective, shall be immediately returned
to the inspection services department, who after marking the sling will
destroy it.
15.3.2. Slings shall not be shortened with knots or bolts.
15.3.3. Slings legs shall not be kinked.
15.3.4. Slings shall be securely attached to their loads.
15.3.5. Employees shall keep clear of loads about to be lifted and of
suspended loads.
15.3.6. Slings shall be padded or protected from sharp edges of load.
15.3.7. Hands and fingers shall not be placed between the sling and load at
any time.
15.3.8. Sling should not be pulled from under a load when the load is resting
on the sling.
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15.3.9. Slings must be stored on suitable racks, shelves or hooks off the
ground and in clean, dry areas.
15.4. Safety Rules for Lifting Appliances (cranes, EOTC, hoists)
15.4.1. The rated load of the crane shall be plainly marked on each side of the
crane, and if the crane has more than one hoisting unit, each hoist shall
have its rated load marked on it or its load block, and this marking shall
be clearly legible from the ground or floor. The rated load marking color
shall be yellow background with black letters.
15.4.2. Only designated and certified personnel shall be permitted to operate
a crane. All crane operators shall possess valid third party certification.
15.4.3. Sheave grooves shall be smooth and free from surface defects that
could cause rope damage.
15.4.4. No less than two wraps of rope shall remain on the drum when the
hook is in its extreme low position.
15.4.5. Rope end shall be anchored by a clamp securely attached to the
drum, or by a socket arrangement approved by the crane or rope
manufacturer.
15.4.6. Rope clips attached with U-bolts on the dead or short end of the rope.
15.4.7. When a newly installed rope has been in operation for an hour, theoperation shall be stopped and all nuts on the clip bolts shall be re-
aligned.
15.4.8. Hooks shall meet the manufacturers recommendations and shall not
be overloaded. The hook shall conform to the cranes rated load
capacity.
15.4.9. A preventative maintenance program shall be established and
conducted as per the schedule.
15.4.10. All functional operating mechanism, air and hydraulic systems,
chains, rope slings, hooks, limit switches and other lifting equipment
shall be visually inspected on daily basis prior to each use. A check list
shall be completed. See Attachment V.
15.4.11. A thorough inspection of all ropes shall be made at least once
every six months by the inspection services department.
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15.4.12. The hoist rope shall be free from kinks or twists and shall not
be wrapped around the load.
15.4.13. The load shall be well secured and properly balanced in the
sling or lifting device before it is lifted and/ or after it is lifted just a few
inches.
15.4.14. The operator shall not leave his/ her position at the controls
while the load is suspended.
15.4.15. The operator will not be allowed to use mobile phone when the
crane is in operation.
15.4.16. At the beginning of each operators shift, the upper limit switch
of each hoist shall be tried out under no load.
15.4.17. For mobile cranes, a load chart must be posted in a
conspicuous position, easily visible to the operator.
15.4.18. All hooks must be equipped with a safety latch to prevent
accidental disconnection of the load.
15.4.19. For mobile cranes, when a load is being lifted, the area equal to
the boom radius of the crane will be barricaded and un-authorized
personnel will not be allowed inside that radius.
16. HOT WORKAny work which generates spark, flame and/or heat. Hot work includes, but is not
limited to, welding, cutting, burning, grinding, and any related heat-producing jobs
that could ignite combustible materials or flammable atmospheres.
A Hot Work Permit shall be issued for all cutting, burning, welding and grinding work
preformed outside of designated safe work areas which has the potential to promote
ignition.
16.1. Designated Hot Work Area:
Specific area designed or approved for hot work, such as maintenance shop or a
detached outside location that is of non-combustible or fire-resistive construction,
essentially free of combustible and flammable contents and suitably segregated
from adjacent areas.
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16.2. Non - designated Hot Work Area:
Areas where there is a presence/potential for presence of explosive atmospheres
(mixtures of flammable gases, vapours, liquids, or dusts with air), or situations
where explosive atmospheres that may develop inside uncleaned or improperly
prepared tanks or equipment which have previously contained such materials, or
areas where accumulation of combustible dusts may develop or any equipment
which are part of the plant or areas near the storage of large quantities of
exposed, readily ignitable materials such as baled paper, or cotton.
Area which is adjacent to fuel gas or fuel oil systems or fuel oil systems.
16.3. Other areas:
Areas which are neither classified as designated hot work area nor as non
designated hot work area. When a hot work has to be carried out in these areas,
check list to be completed. If fire hazards are found whilst completing check list,
then hot work permit shall be obtained.
16.4. Hot work receiving Authority:
An EMAL or contractor competent person possessing necessary experience andknowledge and appointed in writing by EMAL to receive hot work permits.
16.5. Hot Work Training
16.5.1. Level 0: General Overview
All EMAL and contractor employees should receive a general overview of
the EMAL Hot work procedure
16.5.2. Level 1: Hot work operators
All EMAL and contractor authorized hot work operators and fire watchers
shall receive a specific training of the EMAL hot work procedure.
This training will be refresher every two years. Each department must
have an updated list of all authorized hot work operators and fire
watchers. The certification shall contain each employee's name, the
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signatures or initials of the trainers, and the dates of training. See
attachment II.
16.6. Hot Work Permit
16.6.1. Hot Work Permits will be required in non-designated areas. Hot
Work permit has an original and one copy (yellow) for the receiving
authority, see attachment 15 (Hot Work Permit Form No.
HS.SAF.14.F01). The permit (Yellow copy) must be posted at the
location of the work being performed.
16.6.2. If hot work has to be carried out in a location which is neither a
designated hot Work area nor a non-designated hot work area,
then the hot work operator/Maintenance personnel responsible for
the activity shall complete a hot work check List. See attachment 16
(Form No. HS.SAF.14.F04 Hot Work Checklist).
16.6.3. While completing the check list, if any fire hazards are identified
in the vicinity of proposed hot work area, then hot work permit shall