00.11.

55 - 020

Safety

Safety in the petro-chemical industry

Safety policy, safety regulations and instructions
In this lesson, we will discuss the concept of 'safety policy' and how this could
be implemented.
The Occupational Health and Safety Legislation states that the employer
(general manager) is responsible for safe working conditions for his employees.
However, it is impossible for him to watch everybody. For that reason, safety
districts have been set up. Apart from that department managers and the section
heads are responsible for the employees under their supervision. And of course,
you yourself are responsible for your own safety.
At the end of this lesson, we will discuss general regulations and some specific
regulations that are applied in the Shell manufacturing site in the Netherlands.

Contents of the lesson

1

Safety policy

Safety regulations and instructions

General rules and regulations

The copyright in this material is vested in Shell Global Solutions International B.V., The Hague, The Netherlands and Shell Netherlands Raffinaderij B.V. All rights
reserved. Neither the whole or any part of this document may be reproduced, stored in any retrieval system or transmitted in any form by any means (electronic,
mechanical, reprographic, recording or otherwise) without the prior written consent of the copyright owner.

Safety / 00.11.55 - 020

Lesson
1. Safety policy

- safety policy

A policy is the way of taking action to achieve a pre-determined goal. A

government pursues a policy, and so does the management of a soccer club.
Even in a family, a policy is pursued. With respect to safety, the management of
the petro-chemical company must also pursue a policy, the safety policy. The
aim of this safety policy is to prevent accidents, damage, and losses that can
arise as a result of the activities within the petro-chemical company. The policy
must at least meet all legal guidelines with respect to health and safety.

1.1 Safety policy guidelines

The aim can be achieved by acting as follows:
1. Designing or having others design installations and equipment according to
the proper and therefore safe standards. When doing this, one should take
into account the nature of the process involved.
2. Constructing installations and equipment in a proper and therefore safe way.
3. Operating installations and equipment in a proper and therefore safe manner.
4. Inspecting the installations and equipment thoroughly, thereby keeping them
in a good and therefore safe condition.
5. Maintaining the installations and equipment in a proper and safe way.
6. Keeping the working area in a safe condition
The following points are vital in order to ensure that the above mentioned six
points are acted upon:
1. In the Netherlands that would involve the Staff Council in proceedings
concerning health and safety as laid down in the Legislation regarding Staff
Councils.
2. Improving processes and equipment.
3. Ensuring that all employees have sufficient theoretical knowledge, practical
skills and experience so that they can adequately meet the requirements of
the functions in the organisation.
4. Continue to develop and introduce procedures, regulations and codes of
conduct by training that will promote safe working conditions.
5. Ensuring adequate supervision regarding compliance with the procedures,
regulations, codes of conduct, and instructions.
6. Ensuring that all employees have an opportunity to acquire the knowledge
necessary to prevent accidents and occupational illnesses.
7. Supplying the necessary means to promote safety and to prevent damage to
health.
8. Ensuring that every employee is aware of his individual and collective
responsibilities and that he becomes involved with safety aspects of his daily
routine.
9. Promote the exchange of new information on health and safety. This can be
realised by maintaining close contact with other operating companies in
related industries.
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Question 1
What is the aim of the safety policy?
Question 2
Does one have to involve theStaff Council when taking steps in the field of health
and safety?

1.2 Implementing the safety policy

- employer is
responsible

- safety districts

- supervisor safety
districts

To begin with, the employer is responsible for thehealth, safety, safety policy
and implementation of the safety policy on his industrial site. This is a regulation
laid down by the Occupational Health and Safety legislation.
To ensure that the safety policy is well implemented on a large industrial site,
the managing director can divide the area in safety districts. One should be able
to obtain a map at the Safety Department which shows the whole area divided
into safety districts.
The managing director appoints a supervisor for each safety district. Usually this
will be the departmental manager or the section head, whose main activities are
concentrated in that particular safety district. The supervisor of that district has
amongst others to ensure that everyone in his area complies with:
- The regulations laid down by law;
- The company regulations;
- The instructions concerning occupational health and safety.

- functionally
responsible people

People with functional responsibility are those people such as departmental

managers and section heads, who are in charge of a number of employees.
Because of their position, they are responsible for preventing anything that
might endanger safety or health in the working area. These dangers may arise as
a result of the activities carried out by the employees of their department or
section and/or the quality of their technical advice. In their department or section
they are responsible for the observance of:
- Legal regulations;
- Company regulations;
- Instructions concerning occupational health and safety.

- own responsibility

All employees are held responsible for their own health and safety as well as that
of the other employees, by:
1. Becoming acquainted with, and acting according to company regulations
and instructions in the area of health and safety.
2. Using prescribed personal safety devices.
3. Working safely.
4. Taking care that no dangerous situations arise in the work place.
5. Informing the supervisory staff of potentially dangerous situations with
respect to health and safety.
6. Contributing to increased safety in their own work situation.
7. Actively participate in discussions on policy aspects that are of general
importance to health and safety.
8. Supporting all activities initiated by the company to improve health and
safety in the work area.
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5820-020-001-H

Figure 1
Implementation of the safety policy at the Shell Manufacturing Site in the Netherlands

- supervisory staff

Note that this site has combined chemicals and refining activities and hence the
presence of a RM (refinery manager) and a CM (chemicals manager) reporting
to the site manager or Managing Director.
Furthermore, it is necessary that at every level in the organisation s, the
supervisory staff check the safety precautions taken when work is being carried
out. This can be achieved by:
- giving the necessary orders/commands;
- taking the necessary steps;
- supplying the necessary means;
- supervising adequately.
Departments and services that are in general directly or indirectly involved with
the implementation of the safety policy are the Safety department and very
importantly the contractors working at the site.

- preventive
healthcare

- safety policy

Safety department
This department performs tasks in the area of preventive occupational healthcare
and the working environment in the work area. The department can inspect the
aspects of personal occupational health and occupational hygiene. It can report
its findings to the functionally responsible supervisor and, if necessary, to the
management.
Furthermore, the Safety department is responsible for encouraging, advising and
assisting the preparation and implementation of the safety policy. The
department can carry out safety inspections in the work area. It can report its
findings to the functionally responsible supervisor, and, if necessary, to the
management.

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Contractors
Contractors at work on the site are responsible for the safety policy within their
own company. In addition to this, they are obliged to make sure that their
activities cause no danger or dangerous situations to the site. Agreements to that
effect should be part of the work contract.
Question 3
According to the Occupational Health and Safety Legislations, who is
responsible for the safety policy to begin with?
Question 4
Are you yourself responsible for safety at work?

2. Safety regulations and instructions

- objective

The objective of the safety regulations and instructions is to ensure the safety of
individuals, installations, work areas etc.

- various kinds of
regulations and
instructions

With respect to safety, there are various kinds of regulations and instructions for
different situations and activities:
1. Regulations on activities and working environment so-called General
regulations.
2. Regulations regarding the use of electrical equipment.
3. Regulations regarding fire and explosion risks.
4. Regulations regarding personal safety equipment.
5. Regulations regarding clothing and hygiene.
6. Traffic regulations.
7. Instructions regarding the actions to be taken in case of injuries, fire, utility
alarm, gas alarm, situations of unforeseen incidents or damage.
The safety regulations and instructions mentioned above are valid for all
individuals on:
1. All male and female employees.
2. Third parties, i.e. non-company employees, carrying out activities at the
site.
3. Every visitor of the site, plants or workshops. This includes, for example
labour inspectors.
4. Anyone involved in activities off the site but under the direction and
supervision of the company's personnel.

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3. General rules and regulations

In this section, we will discuss general rules and regulations that can be of
importance. The employee should be conversant with these regulations and
know what they mean when he starts working.

3.1 General rules

Irrespective of the activities the employee performs, he should always comply
with the following general rules.
You have already met several of these rules in the previous lesson.
1. Before carrying out any activities, permission (permit) must be obtained
from the plant/department where these activities are to take place.
2. Smoking is prohibited on site, the plants and the workshops with the
exception of those areas where there is valid written permission, signed by
the Safety Supervisor. This permission states the times that smoking is
allowed and you must comply with this regulation.
3. If you want to enter a plant for any reason, you should always first check in
with the supervisor in charge. When leaving the plant you must check out. If
you work in the evening or late at night, ensure the work area and the roads
leading to it are well lit.
4. Loose loading platform grids, gaps in the loading platforms and gaps in the
loading platform railings should be well secured, both during the day and at
night. Indicate their presence with the necessary danger signs (notices, tape,
red lights and so on).
5. Do not carry out any jobs that are not your responsibility unless your
supervisor tells you to.
6. If you are in doubt about possible consequences of certain actions, you
should always ask your supervisor for advice.
7. Never obstruct fire fighting and safety equipment such as fire hydrants, red
lockers, yellow lockers, water basins and emergency showers. They should
be freely accessible at all times. Ensure the plant gates and the exits of the
tank farms are also unobstructed.
8. Connections to the utility networks, i.e. tool air, steam and electricity, can
only be made at points indicated by the supervisor or his representative.
9. In case of thunderstorms, ensure you are not located on the roofs of tanks,
columns, in chimneys, on high platforms or on flaring installations.
10. The use of water from the fire water system to clean tools or for other
cleaning purposes is forbidden. In exceptional circumstances, the company
fire brigade can give permission for hosing down equipment.
11. Hoses and other materials stored in the fire fighting equipment lockers (red
lockers) can only be used to extinguish fires.
12. It is forbidden to make permanent connections to the drinking water mains.
For temporary open hose connections on existing valves and taps, approval
must be obtained from the supervisor in charge or his representative.
13. Air reserved for equipment, hose-connected facemasks, and breathing hoods
cannot be used for other purposes.

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14. If you work in elevated places, be sure to use good climbing equipment and
proper scaffolding. Do not use toolboxes, cable reels and the like as
scaffolding. Do not use barrels as scaffolding or as benches.
15. It is forbidden to throw materials from a height without permission.
16. Removing or switching off safety devices is forbidden.
17. Installations and equipment can only be started after all safety devices are
installed.
18. Try to avoid places where people are working overhead. In unavoidable
circumstances, take the necessary precautions and be extra alert.
Question 5
Are you allowed to smoke at the sites?
Question 6
When can you start up equipment?

3.2

Regulations for using electrical equipment

Using electrical equipment involves risks. That is why you should comply with
the following regulations:
1. Electrical equipment can only be put into operation with the permission of
the supervisor responsible for that equipment.
2. Electrical installations and equipment have to be in a good condition.
3. Only qualified personnel can perform repairs and work on electrical
installations and equipment. If there is a malfunction, notify the responsible
department as soon as possible.
4. Electrically powered tools should be suitable for a safe AC-current of 50V
maximum. Deviations from this regulation can under special conditions
only be accepted with written permission from the responsible department.
5. 220V double insulated tools can be used outside enclosed spaces without the
permission of the department.
Question 7
Who is allowed to repair electrical installations?

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3.3 Regulations concerning fire and explosion hazards

The effects of a fire or an explosion can be enormous. Therefore the following
regulations for the prevention of fires and explosions should be complied with:
1. At the site, plants or workshops it is forbidden to carry personal torches,
portable radios cameras with batteries or other electrical equipment. They
can cause an explosion if there is a gas leakage.
Remark: at the site, plants or workshops it is forbidden to take pictures or
movies. This is only allowed with written permission from the supervisor of
the department involved (this with regards to explosions and industrial
espionage.)
2. Do not leave any combustible materials in plants, workshops, tank farms or
pipe trenches. Deposit combustible materials such as wood, rope, paper etc.
in appropriate waste disposal bins. These bins will be picked up and
removed by the responsible department.
3. Spilled oil or chemicals have to be removed immediately. Both can be
dangerous in many ways.
4. Take care that your work area is always clean and tidy both during work
time and when you leave.
5. Do not keep drums, gas cylinders and loading carts longer on the premises
than strictly necessary. At the end of every working day, they should be
taken outside the plant. Gas cylinders and drums are not allowed to be
placed inside sheds and buildings.
6. Do not use types of oil that are lighter than gas oil for cleaning purposes. Do
not clean your hands with substances such as kerosene because they remove
the fat from your skin. Use regular soap or other prescribed means.
7. If your clothes become soaked with combustible or poisonous liquids, take
the clothes off as soon as possible to prevent combustion or from becoming
contaminated. Wash yourself thoroughly with lots of hot water and some
soap, and put on clean clothes. Clean clothes can be obtained and
contaminated clothing should be handed over to the relevant departments.
8. It is strictly forbidden to ventilate with oxygen because this considerably
increases fire hazards. If necessary, use a safety fan.
9. Rags soaked with oil or chemicals should be taken away in drums. Ensure
that filled bottles, tins, etc. are clearly labelled describing the contents.

3.4 Regulations concerning means of personal protection

It is (still) not possible to design processes and equipment in such a way that
they will never cause any danger. In certain cases, the hazards are known and
you should use personal means of protection. For this, the following regulations
apply.
1. The personal means of protection you need to safely carry out your activities
are at your disposal at no cost.
2. For certain activities using the means of protection at your disposal can be
made compulsory. As an example: at the Shell site in the Netherlands in all
plants, in tank farms, newly- built buildings and in all departments where
this is indicated by signs, you must wear a safety hat and safety goggles.
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5820-020-002-S

Protect yourself at work

Figure 2

3. Everybody who works near very noisy equipment, such as venting steam
pipes and compressor houses must use ear protection. To this end, there are
special earplugs and caps. If you do not protect your ears, permanent
reduction of hearing will result quite quickly. Cards indicating noise levels
can be made for every plant.
4. In all plants and workshops you should wear safety goggles and/or
protective glasses. Signs will advise you where you have to wear these.
Wearing contact lenses is allowed in plants, workshops and laboratories. If
you wear contact lenses, you would be well advised to register with the
Safety department.
5. Occasionally you will have to use special personal safety equipment such as
breathing apparatus. Make sure you know exactly how to use these.
6. If you have long hair long, use a hair net. And if you wear a beard, protect it
with a beard net. If you wear your hair loose, it can block your view at a
critical moment, or it can be caught by moving equipment parts and be
pulled out. If you wear a beard, it is possible that a gas mask or a
compressed air mask will not seal properly. That is why beards are not
permitted for the staff of the fire brigade and operational departments.

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Figure 3
Ear plugs and caps

Figure 4
Safety glasses

Figure 5
Breathing apparatus

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5820-020-006-S

Figure 6
Personal protection is vitally important

3.5 Regulations concerning clothing and hygiene

- little soap

Sometimes clothing can be dangerous without you being aware of it. Please
ensure the following clothing and hygiene regulations are adhered to:
1. Keep your work clothes in good condition and keep them tucked in while
working. Clothes that are too loose or hang loose, and belts are potentially
dangerous. This is particularly the case if you are working near moving
equipment parts and/or electrical equipment.
2. Do not continue to wear clothes that are soaked with oil or chemicals. Take
the clothes off as soon as possible and change into clean ones. If the oil or
the chemicals have penetrated as far as your skin, wash yourself thoroughly
with lots of warm water and a little soap.
3. If you come into contact with oil or chemicals, wash your hands and face
thoroughly with lots of warm water and a little soap, especially before you
start eating, smoking, or before you go home.
4. It is forbidden to wash hands and clothes with inflammable products, i.e.
petrol and organic solvents (they remove the fat from your skin).
5. When working do not wear rings or chains that can become caught or
snagged.
6. Never carry pointed or sharp tools in the pockets of your work clothes. If
you fall or bend over, you may be injured.

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5820-020-007-S

Figure 7
Clothing regulations

3.6 Regulations concerning traffic

It is for a good reason that traffic on public highways is bound by certain
regulations. These same regulations should apply to the site.
1. Within the, the rules of the Road Traffic Regulations and the Road Traffic
Act apply. These regulations can be supplemented for instance by the
following stipulations: a. The speed limit at the site is 40 km/h, unless a
lower speed limit is indicated. b. If it is dark, motor vehicles should turn on
their low beam.
2. In case of hazard from gasses, employees of the installation concerned will
close off the roads by means of permanently set up barriers or stop signs
with flashing signals, and report this to the security department. Pedestrians
are also strictly forbidden to go beyond barriers or stop signs with flashing
signals.
3. If traffic is to be obstructed because of guy ropes, excavation work, tools,
cranes and the like, either above or on the road, a sufficient number of
warning signals should be placed in position, both during the day and at
night time. The necessary barriers, signs and red lights should be made
available through e.g. the security department, and have to be handed in as
soon as possible after use.

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Figure 8
Area with a 30 km/h speed limit

5820-020-009-S

Figure 9
An obstructed road? Always warn people!

4. Only park passenger cars in the indicated spaces. Never park a vehicle in
front of (a). fire hydrants; (b). lockers for fire extinguishing materials (red
lockers); (c). lockers for gas protection materials (yellow lockers); (d). water
basins and emergency showers; (e). plant entrances, tank farm entrances etc.
(f). fire brigade garage.
5. Always park bicycles and mopeds in the appropriate racks or reserved
locations.
6. Do not jump on or off moving vehicles intended for the transportation of
passengers.
7. Using tractors, cranes, forklift trucks etc. for transport of passengers is not
allowed.
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8. Do not walk or drive off the roads within the site, except for locations where
you have your own activities or you have to supervise activities.
9. It is forbidden to transport passengers on the carrier of bicycles or mopeds.
10. Whenever possible, use gangways, stairs and platforms. Do not walk
unnecessarily on pipelines, steel constructions etc.
11. It is forbidden to transport products that are more volatile than gas oil (flash
point lower than 65 degrees Celsius) in open drums.
12. Cranes, cars etc. are not allowed to be parked in the area of plants that are in
operation. This is only allowed when the section supervisor or his deputy
has issued a permit.

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Summary
A policy is a way of taking action to achieve a predetermined goal. With respect
to safety, the management of a petro-chemical company should pursue a policy
called the safety policy.
The safety policy is achieved by paying attention to the safety of installations
and equipment during development, construction, operation, inspection and
maintenance. The working area should also receive due attention.
In the Netherlands legislation has decreed that the employer is responsible for
the safety policy. To achieve his goal, the employer has created a number of
safety districts controlled by subordinates. The functionally responsible people
are responsible for the safety of the employees they supervise. Of course, every
employee is responsible for his own safety, and he should not endanger the
safety of others.
With regard to safety for a large number of situations and activities, there are
various kinds of regulations and instructions:
1. Regulations concerning activities and working area, the so called the
General Rules.
2. Regulations concerning the use of electrical equipment.
3. Regulations concerning fire and explosion hazards.
4. Regulations concerning means of personal protection.
5. Regulations concerning clothing and hygiene.
6. Regulations concerning traffic.
7. Instructions on how to act in situations such as injuries, fire, utility alarm,
gas alarm, instances of unforeseen, uncommon incidents and damage.
You have been made aware of the first six of these regulations and instructions
in this lesson.
The safety regulations and instructions mentioned are valid for all people on a
petro-chemical industrial site:
1. All male and female site employees.
2. Third parties involved in activities at the site, or its plants and workshops.
3. Every visitor to the site, plants or workshops. This includes, for example
labour inspectors.
4. Anybody involved in activities off the site who are supervised by company
employees.

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Test
Exercises
Do not send in your answers for correction
1. List the six ways in which a petro-chemical company can attain its safety
goals.
2. Are you allowed to use 220V double insulated tools outside an enclosed
space without the permission of the responsible department?
3. You want to carry out activities in a plant. What do you need before you
proceed?
4. You are on the roof of a tank, and you notice there is going to be a
thunderstorm. Can you stay where you are?
5. You are near a venting steam pipe. What do you have to wear?

Answers to the questions in the lesson

1. The aim of having a company safety policy is to avoid accidents, damage
and losses that can be caused by the activities of the company.
2. Yes. The Staff Council has to be involved in steps in the field of health and
safety, as laid down by the Legislation regarding Staff Councils.
3. According to Dutch legislation, the employer is in first instance responsible
for the safety policy.
4. You are also responsible for the safety. You cannot endanger yourself or
others.
5. Smoking is not allowed on site.
6. You can only start equipment once all security devices have been installed.
7. Only qualified personnel can carry out repairs on electrical installations.

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Answers to the exercises

1. They try to achieve their objective by acting as follows:
a. Designing or having others design installations and equipment according
to the proper and therefore safe standards. When doing this, one should
also take into account the nature of the process involved.
b. Constructing installations and equipment in a proper and therefore safe
way.
c. Operating installations and equipment in a proper and therefore safe
manner.
d. Inspecting the installations and equipment thoroughly, thereby keeping
them in a good and therefore safe condition.
e. Maintaining the installations and equipment in a proper and therefore
safe way.
f. Keeping the working area in a safe condition.
2. You may use 220V double insulated tools outside an enclosed space without
the permission of the responsible department.
3. You will need a permit to carry out activities in a plant.
4. In case of a thunderstorm, you should not stay on a tank roof.
5. If you are near a venting steam pipe, you have to wear ear protection, i.e.
special ear-plugs or caps.

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