SABIC - SHEM
SHEM 00 - Leadership and management system
SHEM 01 - HSE Documentation and control
SHEM 02 - Risk assessment / SAFAR
SHEM 03 - Operating and maintenance procedure
SHEM 04 - Training and competence
SHEM 05 - Third party HSSE requirement
SHEM 06 - Pre-start up HSE review
SHEM 07 - Mechanical integrity
SHEM 08 - Safe work practices
SHEM 09 - Management of change (MOC)
SHEM 10 - Incident investigation, reporting, classification and analysis
SHEM 11 - Emergency planning and response
SHEM 12 - Health and environmental hygiene
SHEM 13 - Environmental standards
SHEM 14 - Security standards
SHEM 15 - Road transport safety
SHEM 16 - Product stewardship
SHEM 08 - SAFE WORK PRACTICES
SHEM 08.01 - General HSSE rules
SHEM 08.02 - Laboratory HSE rules
SHEM 08.03 - Material handling and storage
SHEM 08.04 - Road transportation of materials
SHEM 08.05 - Electrical safety
SHEM 08.06 - Lifting equipment
SHEM 08.07 - Tools handling
SHEM 08.08 - PPEs
SHEM 08.09 - Working at height
SHEM 08.10 - Work permits
SHEM 08.11 - Control / Isolation of hazardous energy including LOTO
SABIC - LIFE SAVING RULES (LSR)
1 - Safe system of work (SSOW)
2 - Confined space entry
3 - Working at height
4 - Lifting operations
5 - Line breaks
6 - Energy isolation
7 - Created openings
8 - Disabling safety
9 - Vehicle safety
10 - Management of change (MOC)
11 - Coronavirus (Covid-19)
SABIC - PERMIT PROCESS OVERVIEW
WORK ORDER - WORK PLAN
1 - Lifting plan
2 - Excavation clearance
3 - LOTO certificate
PARENT - PREPARATION
Hazard assessment and control form / formal JSA
CHILD - EXECUTION
1 - Confined space entry permit
2 - Electrical permit
3 - Excavation permit
4 - General work permit (cold work permit) - Vehicle entry in non-hydro carbon area, Work at
height, Torquing, Flange/Gasket tightening activity, Installing & removal of blinding, Scaffolding
work etc...
5 - Hot work permit (i.e. vehicle entry in hydro carbon area, hydro jetting, sand blasting)
*Note* some time vehicle entry permit required hot work permit and some time required vehicle entry
permit and some time required both its depend on each plant policy with gas test.
6 - HPJ permit (High pressure jetting)
7 - Lifting permit
8 - Radiation work permit
(LMRA) LAST MINUTES OF RISK ASSESSMENT
EXECUTION OF WORK
CLOSE OUT OF WORK
LOTO - LOCKS COLOUR CODING
Red - Owner/Client (Isolator qualified person)
Green - General (LOTO authorized)
Yellow - Personal (LOTO affected person)
Black - LOTO coordinator lock
Blue - Transition lock (indicates temporarily stopped and no one is currently perform work on that
equipment. (e.g. waiting for spare parts)
Critical confined space
Working with an engulfment material that might cause an impairment or delay of an immediate
escape from the confined space.
Vertical Entry more than 1.5 meter into process equipment.
In certain cases, eye contact and visibility of entrants to confined spaces can be hindered due to
the size of the equipment or the configurations. In such cases, additional standby men can be
added with one stationed outside the entry point and the other being inside who can maintain
eye contact with the entrants and the external standby man.
Excavation more than 3 meters & excavation within 15 meters nearby potential toxic or
hydrocarbon process pipelines or water pond.
Excessive temperatures leading to heat stress and unconsciousness.
Confined space work permit packages
Blind list with process equipment to be attached to the LOTO
Marked P&IDs (pipe and instrument drawing)
Approved formal JSA shall be attached to the confined space permit
Rescue plan (incase if critical confined space)
Ventilation plan
Emergency equipment requirement (ready for emergency use at entry point)
Appropriate length of life line
SCBA - 60 minutes positive duration
Air horn and Fire extinguisher
Radio/air horn or other adequate communication device
Formal JSA requirement
Breakdown the job into sequence step
Identify the hazards from activity, surrounding tools and equipment
Conduct risk assessment for each hazards
Recommend risk control measure
List down the responsible person for each recommendation
Ensure JSA recommendation are implemented during site operation and performing the work as
applicable.
JSA shall be reviewed and approved.
JSA should be approved by following person...
Maintenance - technical manager
EHSS Dept. and contractor supervisor
Technical / engineer
Others (senior manager, permit issuer signature)
Rescue plan should be signed and approved by following person...
Fire captain / fire manager / incident commander
Supervisor of permit reciever & issuer
Before start of any critical confined space entry, permit issuer shall notify fire captain / fire
manager / incident commander about any change in the confined space during the time of entry.
Critical lifting
Lifting of radioactive sources means RT equipment.
Any lifting that equal or exceed 75% of the crane's rated capacity within the lif configuration of
the crane.
Tandem lifting and lifting with jib crane.
Lift over live services/pipeline.
Hot or pressure tapping - is the method of connecting to piping or pressure vessels without removing
of pipe or vessel from service. This means that a pipe or tank continue to be in operation whilst
maintainence or modification are being done to it.
Isolation or Positive isolation - means to provide a safe environment for performing maintenance,
repair or replacement operations on process facilities by disconnecting or separating the energy sources,
to protect the people and equipment. Isolation can apply by following ways.....
Types of isolation
Mechanical/Process isolation
Physical disconnection - removal of a spool piecses or pipe section by using blind flange.
Blinding/Blanking - different types of blinding like spade & spacer, spectacle blind, blind flange
etc...)
Double block & bleed (bleed means vent & drain) - shutting two isolation valves and opening a
bleed valve.
Double block - If double block with bleed isolation is not possible, double block isolation only
could be acceptable with the required precautions, if backed (samarthan) by the risk
assessment.
Single block & bleed - used only when there is no possible alternative and the risk is acceptable.
Electrical isolation - LOTO - electrical, valve, telecommunication, energy sources include
mechanical, hydraulic, pneumatic (air), chemical, thermal, radioactive, gravity etc...
LOTO - is a safety procedure used in industry to ensure that dangerous machines are properly shut off
and not able to be start up again prior to the completion of maintenance or repair work.
LOTO process
Step 1 - Preparation for LOTO
Step 2 - Securing LOTO
Step 3 - Try out and verification (start the job)
Step 4 - LOTO removal
Some important points about LOTO
LOTO coordinator shall be operation supervisor or operation specialist level or above. Appointed
and approved by concern department sr. manager. LOTO coordinator should be obtained LOTO
training. Responsible for LOTO record used in LOTO certification control sheet. Responsible for
the LOTO program for their area (e.g. site, unit, plant). Manage the keys in the LOTO coordinator
cabinet in such a way that no unauthorized persons can obtain any key.
LOTO specific procedure shall be developed by owner expert person or engineer and approved
by owner sr. manager.
LOTO affected person - maintenance, operation, contractor etc...
LOTO devices shall only be placed and removed by LOTO authorized employees which will
defined by management system. They may be sr. operator, lead operator, operation supervisor
or above. Nominated by concerned department sr. manager. In case of absence of that
authorized person, LOTO device(s) shall be removed by another LOTO authorized person after
approval of area owner supervisor.
LOTO device(s) can remain in place for the duration of the work period. But must be verified at
the beginning of each subsequent shift.
Prior to removal of LOTO, authorized persons shall ensure work area is inspected, nonessential
items have been removed and everybody is safely positioned or removed.
If an energy-isolating device is not capable of being locked out, the owner shall conduct a formal
JSA and action shall include steps to utilize a Tag-Out only system.
Basic LOTO principle - One lock, one key, one tag & one person (1-1-1-1).
If LOTO key missing, report immediately & formally to owner, LOTO coordinator, executer
supervisor, department sr. Manager and operation sr. Manager. After that some varification
process will be happen by sr. manager (LOTO person) and LOTO coordinator then lock cutting
form filled by LOTO coordinator then lock will be cut with all safety precaution.
Everythings (means each and every datails) related from LOTO should be record or register in
LOTO log book or control sheet.
LOTO certificate is only an authorization for LOTO/equipment isolation; but to perform the job
work permit is required.
In LOTO - There are following details mentain in TAG, equipment locked by... Name... Date
& Time.... Dept. ... Expected completion date... etc...
LOTO tools - LOTO lockbox, lockout stations, cables, chains, multi-lock hasps.
Below diagram will help to understand the mechanical isolation...
Process isolation by physical disconnection in combination with [1] double block and bleed [2]
single block and bleed
Process isolation by a spade in combination with [1] double block and bleed [2] single block and
bleed
*Note* Spade have always one hole for lifting/shifting. Spacer have always two hole one for
lifting/shifting and other (small hole) for symbol of spacer. Spectacle blind use upto 25kg. above that use
of spade and spacer. Above 16" diameter spade and spacer use.
Mechanical/Process isolation summary______
MECHANICAL/PROCESS ISOLATION SUMMARY
No. Types of work/case Types of process material Minimum type of isolation
Blind and/or physical
Confined space entry Any material
1 disconnection
Hydrocarbon or other
Blind and/or physical
hazardous material (e.g.
disconnection
toxic, acidic, caustic)
Other material (non-hazards)
Mech. Hot activity (Pressure > 2kg/cm2 or temp. Double block and bleed
2 (welding, grinding, > 50*C)
burning etc…) Single isolation is accepted as
Other material (non-hazards) minimum isolation (if other
(pressure < 2kg/cm2 or isolation is practical & all
temp. < 50*C) available drain and vent
connections are opened).
Double block and bleed. If not
applicable/practical then
single valve isolation is
Hydrocarbon or other
accepted with approval of the
hazardous material (e.g.
concerned Sr. Manger, as long
toxic, acidic, caustic)
as all available drain and vent
connections are opened and
no sign of passing observed.
Double block and bleed. If not
applicable/practical then
3 Non-mech. Activity single valve isolation is
Other material (non-hazards)
accepted with approval of the
(pressure > 1.9 bar(g) or
concerned Sr. Manger, as long
temp. > 50*C)
as all available drain and vent
connections are opened and
no sign of passing observed.
Single isolation is accepted as
Other material (non-hazards) minimum isolation (if other
(pressure < 1.98 bar(g) or isolation is practical & all
temp. < 50*C) available drain and vent
connections are opened)
If above isolation methods cannot be strictly followed and implemented, then you shall
conduct risk assessment for all such cases and obtain SAFER approval.
Equipment valves isolation shall include an attachment of P&ID drawing copy with all
valves marked and numbered what to be opened and what to be closed. Equipment
isolation shall be reviewed and approved by lead operator and supervisor level for
confined space entry isolation.
Equipment Isolation shall be the nearest isolation valve to the equipment.
Some important points about LOTO
LOTO coordinator shall be operation supervisor or operation specialist level or above. Appointed
and approved by concern department sr. manager. LOTO coordinator should be obtained LOTO
training. Responsible for LOTO record used in LOTO certification control sheet. Responsible for
the LOTO program for their area (e.g. site, unit, plant). Manage the keys in the LOTO coordinator
cabinet in such a way that no unauthorized persons can obtain any key.
LOTO specific procedure shall be developed by owner expert person or engineer and approved
by owner sr. manager.
LOTO affected person - maintenance, operation, contractor etc...
LOTO devices shall only be placed and removed by LOTO authorized employees which will
defined by management system. They may be sr. operator, lead operator, operation supervisor
or above. Nominated by concerned department sr. manager. In case of absence of that
authorized person, LOTO device(s) shall be removed by another LOTO authorized person after
approval of area owner supervisor.
LOTO device(s) can remain in place for the duration of the work period. But must be verified at
the beginning of each subsequent shift.
Prior to removal of LOTO, authorized persons shall ensure work area is inspected, nonessential
items have been removed and everybody is safely positioned or removed.
If an energy-isolating device is not capable of being locked out, the owner shall conduct a formal
JSA and action shall include steps to utilize a Tag-Out only system.
Basic LOTO principle - One lock, one key, one tag & one person (1-1-1-1).
If LOTO key missing, report immediately & formally to owner, LOTO coordinator, executer
supervisor, department sr. Manager and operation sr. Manager. After that some varification
process will be happen by sr. manager (LOTO person) and LOTO coordinator then lock cutting
form filled by LOTO coordinator then lock will be cut with all safety precaution.
Everythings (means each and every datails) related from LOTO should be record or register in
LOTO log book or control sheet.
LOTO certificate is only an authorization for LOTO/equipment isolation; but to perform the job
work permit is required.
In LOTO - There are following details mentain in TAG, equipment locked by... Name...
Date & Time.... Dept. ... Expected completion date... etc...
LOTO tools - LOTO lockbox, lockout stations, cables, chains, multi-lock hasps.
Line break - means opening (for maintainence, cleaning etc...) of a pipe, line, or other part of a process
that contains material capable of causing injury by temperature, pressure or chemical properties to
people & environment. Before line break a hazard/risk assessment shall be made by knowledgeable
persons with all necessary steps as indicated below shall be considered/documented...
Reason for line break, include LOTO specific procedure and try to achieve zero-energy state.
Methods to barricade area to reduce exposure potential while system is (being) open.
Consider immediate SDS control measures if something wrong.
Test safety shower in the area, obtain and wear the appropriate PPE and ensure its condition is
suitable for use.
Clean up any spillage immediately and assign a qualified operator to be standby during line
break to act in case of emergency.
Created opening - any open area such as (12" in least dimension) open grating, open manhole, open
floor, more than 8" deep excavation opening, peet etc.. consider as created opening.
SABIC Paspsort Contents...
EHSS critical rules...
Don't smoke outside smoking designated area.
While driving wear seat belt and don't cross speed limit.
Work with valid work permit if required.
Obtain authorization before overriding or disabling safety critical equipment.
Obtain authorization before entering a confined space.
Protect your self against fall when working at height.
Don't remove / alter gratings without permission.
Don't operate any heavy mobile equipment without proper authorization (crane, forklift, vaccum
truck, man lift).
Don't work on a red tagged scaffolding.
Don't walk under a suspended load.
Verify isolation before work starts and use life protecting equipment.
No intervention model for any key / critical safety rules.
Follow MOC procedure.
EHSS training record - provided by SABIC (Topic, Date, Location, Trainer & Signature with SABIC
Stamp).
Interview result / record (SABIC or SABIC affiliate name, Interviewer name & position, Interview
result, Employee trade, Date of interview, Signature of interviewer & SABIC stamp).
On first page employee personal information.
Awards and recognitions page also there in last by SABIC or SABIC affiliate.
Following gas found in Sabtank plant...
Butadene, Propane, Hyxen, Ateyien
*Note*
RA in JSA number 4 - residual risk
L severity - C 3 always
If residual risk is minor - C 3 (then senior manager approval required for JSA).
