Safety Manual - Wallem Shipmanagement LTD. [2011, PDF]

Contents

PREFACE ......................................................................................................................................1
REVISION SHEET...............................................................................................................................1
MANAGEMENTS REVIEW .................................................................................................................1
SIGNATURE CARD.............................................................................................................................1
1 INTRODUCTION :.......................................................................................................................1
1.1 PURPOSE OF MANUAL....................................................................................................1
1.2 CODES AND REGULATIONS...........................................................................................1
1.3 AVAILABILITY OF MANUAL .............................................................................................2
1.4 TRAINING...........................................................................................................................2
1.4.1 DRILL SCHEDULES ..........................................................................................................2
1.5 LOSS TIME INJURY FREQUENCY (LTIF).......................................................................3
1.6 WORK PLANNING & TOOL BOX MEETINGS.................................................................4
1.7 TOOL BOX MEETINGS.....................................................................................................4
1.8 PERMIT TO WORK............................................................................................................5
2. EMERGENCY ORGANISATION :...............................................................................................1
2.1 GENERAL...........................................................................................................................1
2.2 ALLOCATION OF EMERGENCY STATIONS..................................................................1
2.3 LOCAL EMERGENCIES....................................................................................................2
2.4 EMERGENCY STATION SIGNAL.....................................................................................2
2.5 EMERGENCY SQUAD ......................................................................................................2
2.6 COMMAND.........................................................................................................................3
2.7 SPECIAL DUTIES..............................................................................................................3
2.8 SUPPORT SQUAD ............................................................................................................4
2.9 FIRST AID AND PROVISIONS SQUAD ...........................................................................4
2.10 PERSONNEL ON WATCH ................................................................................................4
2.11 WIVES AND SUPERNUMERARIES.................................................................................4
2.12 EMERGENCY HEADQUARTERS (EHQ).........................................................................4
2.13 SUPPLEMENTARY EQUIPMENT STATIONS (SES)......................................................5
2.14 GENERAL EMERGENCY (BOAT) STATIONS ................................................................5
2.15 EMERGENCY ORGANISATION IN PORT......................................................................5
2.16 SAFETY OFFICER.............................................................................................................7
2.17 SAFETY COMMITTEE.......................................................................................................7
2.18 FIRE CONTROL PLANS (SAFETY EQUIPMENT PLANS) .............................................7
2.19 FIRE PATROLS..................................................................................................................7
2.20 EMERGENCY ORGANISATION CHART.........................................................................8
2.21 SAFETY & FIRE PROTECTION WHILST IN SHIPYARD................................................9
3. EMERGENCY EXERCISES & PROCEDURES..........................................................................1
3.1 TRAINING...........................................................................................................................1
3.2 LOCAL EMERGENCY PROCEDURES - GENERAL.......................................................2
3.3 LOCAL EMERGENCY ALARMS - ACTION......................................................................2
3.4 DISCOVERY OF A FIRE ...................................................................................................3
3.5 ACCOMMODATION FIRE.................................................................................................4
3.6 ENGINE ROOM FIRE........................................................................................................4
3.7 GALLEY FAT FIRES..........................................................................................................5
3.8 INCIDENT AT THE MANIFOLD/TANK OVERFLOW (TANKERS)..................................6
3.9 TANK EXPLOSION............................................................................................................6
3.10 PUMPROOM FIRE.............................................................................................................7
3.11 PROTECTION OF THE FIRE-FIGHTERS........................................................................7
3.12 FIXED FIRE EXTINGUISHING SYSTEMS......................................................................8
3.13 MANOVERBOARD ............................................................................................................8
3.14 COLLISION AND GROUNDING........................................................................................9
3.15 HELICOPTER EMERGENCY............................................................................................9
3.16 FIRE IN CARGO HOLD ...................................................................................................10
3.17 FIRE IN DECK CARGO ...................................................................................................12
3.18 BUNKERING OIL SPILL ..................................................................................................12
3.19 GENERAL EMERGENCY ALARM - ACTION ...............................................................12
3.20 ABANDON SHIP DRILLS ................................................................................................12
3.21 LOWERING LIFEBOATS ( SIDE LAUNCHING BOATS )..............................................13
3.22 TESTING AND MAINTENANCE OF LIFEBOATS..........................................................14
3.23 TOXIC VAPOUR RELEASE PROCEDURES.................................................................14
3.24 WILLIAMSON TURN DIAGRAM .....................................................................................15
3.25A VESSEL : YEARLY PROGRAMME OF EMERGENCY EXERCISES FOR ALL
SHIPS EXCEPT TANKER *...............................................................................................1
3.25B VESSEL : YEARLY PROGRAMME FOR EMERGENCY EXERCISES FOR ALL
TANKER*1
EMERGENCY DRILL EVALUATION FORM ....................................................................................2
TRAINING RECORDS LOG..............................................................................................................4
RECORD OF TRAINING ON EMERGENCY EQUIPMENT TRAINING .........................................5
4 THEORY OF COMBUSTION : ....................................................................................................1
4.1 GENERAL...........................................................................................................................1
4.2 FLASH POINT AND AUTO IGNITION TEMPERATURES...............................................2
4.3 CLASSIFICATION OF FIRES............................................................................................2
4.4 FLAMMABILITY..................................................................................................................3
4.5 FIRE SPREAD....................................................................................................................3
4.6 EXTINGUISHMENT ...........................................................................................................4
4.7 REMOVAL OF HEAT .........................................................................................................4
4.8 REDUCTION OF OXYGEN ...............................................................................................5
4.9 DRY POWDER...................................................................................................................5
4.10 FOAM..................................................................................................................................5
4.11 FIRE EXTINGUISHING CHART........................................................................................6
5 FIRE PREVENTION AND CONTROL OF IGNITION SOURCES ..............................................1
5.1 GENERAL...........................................................................................................................1
5.2 SMOKING...........................................................................................................................1
5.3 HOT WORK........................................................................................................................1
5.4 FUNNEL SPARKS .............................................................................................................1
5.5 CURRENT ELECTRICITY.................................................................................................2
5.6 STATIC ELECTRICITY......................................................................................................3
5.7 ELECTRICAL STORMS (LIGHTNING).............................................................................3
5.8 INCENDIVE SPARKS........................................................................................................3
5.9 FRICTION...........................................................................................................................4
5.10 SPONTANEOUS COMBUSTION......................................................................................4
5.11 AUTO-IGNITION ................................................................................................................4
5.12 PYROPHORIC IGNITION..................................................................................................4
5.13 SAFE HOUSEKEEPING....................................................................................................4
5.14 GALLEY FIRES..................................................................................................................5
5.15 PAINT STORES .................................................................................................................5
5.16 OXYGEN AND ACETYLENE CYLINDERS......................................................................5
5.17 FIRE PREVENTION - MACHINERY SPACES.................................................................6
5.18 FIRE PREVENTION - ACCOMMODATION, STOREROOMS & GALLEY......................6
5.19 FIRE FIGHTING ON PURE CAR (AND TRUCK) CARRIERS.........................................6
6. STATIC ELECTRICITY : .............................................................................................................1
6.1 GENERAL...........................................................................................................................1
6.2 STATIC ACCUMULATORS...............................................................................................1
6.3 CHARGE SEPARATION....................................................................................................1
6.4 PRECAUTIONS DURING CARGO OPERATIONS..........................................................1
6.5 PIPELINE AND HOSE CLEARANCE................................................................................2
6.6 ELECTRICAL CONTINUITY..............................................................................................2
6.7 TANK WASHING................................................................................................................2
6.8 PORTABLE TANK CLEANING HOSES............................................................................3
6.9 STEAMING OF TANKS .....................................................................................................3
6.10 STATIC ACCUMULATOR OILS........................................................................................3
7. ENTRY INTO ENCLOSED SPACES ..........................................................................................1
7.1 ENERAL..............................................................................................................................1
7.2 RESPONSIBILITY..............................................................................................................1
7.3 OXYGEN DEFICIENCY.....................................................................................................2
7.4 HYDROCARBON GAS ......................................................................................................2
7.5 GAS TESTS FOR ENTRY.................................................................................................2
7.6 VENTILATION AND LIGHTING.........................................................................................3
7.7 PRECAUTIONS DURING ENTRY & ENTRY PROCEDURES........................................3
7.8 ENCLOSED SPACE ENTRY CHECK LIST......................................................................4
7.9 CARGO PUMPROOMS.....................................................................................................5
7.10 OPENING UP EQUIPMENT AND PIPELINES.................................................................5
7.11 ENTRY INTO NON-GAS FREE SPACES ........................................................................5
7.12 CANISTER RESPIRATORS..............................................................................................6
7.13 RESCUE FROM ENCLOSED SPACES ...........................................................................6
7.14 WORK BOATS IN ENCLOSED SPACE ...........................................................................6
7.15 ASSESSMENT OF RISK...................................................................................................7
7.16 HAZARDS RELATED TO SPECIFIC TYPES OF SHIPS OR CARGO ...........................7
8 TOXIC GASES AND OXYGEN DEFICIENCY : ..........................................................................1
8.1 TOXIC GASES ...................................................................................................................1
8.2 THRESHOLD LIMIT VALUES ...........................................................................................1
8.3 HYDROCARBON GASES .................................................................................................1
8.4 HYDROGEN SULPHIDE (H2S).........................................................................................2
8.5 BENZENE AND OTHER AROMATIC HYDROCARBONS ..............................................2
8.5 BENZENE AND OTHER AROMATIC HYDROCARBONS (CONTINUED)....................3
8.5 BENZENE AND OTHER AROMATIC HYDROCARBONS (CONTINUED)....................4
8.6 MERCAPTANS...................................................................................................................4
8.7 OXYGEN DEFICIENCY.....................................................................................................4
8.8 INERT GAS - OXYGEN DEFICIENCY..............................................................................5
8.9 INERT GAS - TOXICITY OF FLUE GAS ..........................................................................5
8.10 TANK ENTRY - INTO GASFREE SPACES OR TANKS PREVIOUSLY INERTED .......5
8.11 TOXIC GAS RELEASE......................................................................................................6
9 GAS DETECTION :-...................................................................................................................1
9.1 GENERAL...........................................................................................................................1
9.2 INSTRUMENTS..................................................................................................................1
9.3 OXYGEN ANALYSERS.....................................................................................................1
9.4 LIMITS OF FLAMMABILITY ..............................................................................................1
9.5 CATALYTIC FILAMENT COMBUSTIBLE GAS INDICATOR ..........................................2
9.6 NON-CATALYTIC HEATED FILAMENT GAS INDICATOR.............................................2
9.7 REFRACTIVE INDEX METER ..........................................................................................2
9.8 INFRA-RED INSTRUMENTS ............................................................................................2
9.9 CHEMICAL TUBE INSTRUMENTS ..................................................................................2
9.10 ELECTRO CHEMICAL SENSOR INSTRUMENTS..........................................................3
9.11 MULTI-GAS INSTRUMENTS ............................................................................................3
9.12 PERSONAL GAS MONITORS ..........................................................................................3
9.13 INSTRUMENT CALIBRATION ..........................................................................................3
9.14 OPERATIONAL TESTING & INSPECTION......................................................................4
9.15 TRAINING ON GAS INSTRUMENTS ...............................................................................4
9.16 FIXED GAS DETECTION SYSTEM..................................................................................4
10 BREATHING AND RESUSCITATION EQUIPMENT :-...............................................................1
10.1 DIFFERENT TYPES OF EQUIPMENT.............................................................................1
10.2 SELF-CONTAINED COMPRESSED AIR BREATHING APPARATUS...........................1
10.3 WORKING DURATION OF C.B.A.....................................................................................1
10.4 DEMAND TYPE C.B.A.......................................................................................................2
10.5 POSITIVE PRESSURE C.B.A. ..........................................................................................3
10.6 FACE MASKS.....................................................................................................................3
10.7 LOW PRESSURE WARNING ...........................................................................................4
10.8 PRESSURE GAUGE..........................................................................................................5
10.9 AIR LINE CYLINDER PACK..............................................................................................5
10.10 AIR LINE FILTER UNIT (AFU)..........................................................................................5
10.11 ESCAPE BREATHING APPARATUS...............................................................................5
10.12 EMERGENCY LIFE SUPPORT APPARATUS (ELSA)...................................................6
10.13 FILTER RESPIRATORS....................................................................................................6
10.14 RESUSCITATION EQUIPMENT .......................................................................................7
10.15 MAINTENANCE .................................................................................................................7
10.16 CBA WEARER' TEST ........................................................................................................7
10.17 EMERGENCY ESCAPE BREATING DEVICE (EEBD)....................................................8
10.18 TRAINING...........................................................................................................................8
11. HOT WORK PROCEDURES : APPLICABLE TO ALL SHIPS....................................................1
11.1 GENERAL...........................................................................................................................1
11.2 HAZARD APPRECIATION ................................................................................................1
11.3 PRECAUTIONS FOR HOT WORK...................................................................................1
11.4 CONTROL OF HOT WORK FOR ALL SHIPS..................................................................1
11.5 HOT WORK ON PIPELINES.............................................................................................2
11.6 GAS DETECTION DURING HOT WORK.........................................................................2
11.7 HOT WORK WITHIN PORT LIMITS .................................................................................3
11.8 PRECAUTIONS DURING GAS CUTTING AND WELDING............................................3
11.9A HOT WORK FOR ALL SHIPS EXCEPT TANKER ( NON TANKERS )...........................5
11.9B ADDITIONAL REQUIREMENT OF HOT WORK FOR ALL TANKERS(OIL, CHEMICAL
OR GAS).............................................................................................................................6
11.10B.1 ASSESSMENT OF HOT WORK ON TANKER VESSELS AND RESPONSIBILITIES ..7
11.10B.2 HOT WORK IN CARGO TANKS ON TANKERS..............................................................8
11.10B.3 HOT WORK IN CARGO PUMPROOM DURING BALLAST VOYAGE ...........................9
11.10B.4 HOT WORK ON THE CARGO DECK OF TANKERS......................................................9
11.10B.5 HOT WORK ON PIPELINES...........................................................................................10
11.10B.6 GAS DETECTION DURING HOT WORK.......................................................................10
11.11B PRECAUTIONS FOR GRIT BLASTING, MECHANICAL OR HAND TOOLS (TANKER)
..........................................................................................................................................10
11.12B HOT WORK FLOWCHART FOR TANKERS.................................................................11
11.13B HOT WORK GUIDANCE FOR INERTED SHIPS..........................................................12
11.14B HOT WORK GUIDANCE FOR NON - INERTED SHIPS ..............................................13
HOT-WORK PROCEDURES - AWARENESS BRIEFING ..............................................................1
11.15B ..........................................................................................................................................14
12. SAFETY DURING TANKER OPERATIONS :.............................................................................1
12.1 GENERAL...........................................................................................................................1
12.2 FIRE FIGHTING EQUIPMENT..........................................................................................1
12.3 SMOKING REGULATIONS ...............................................................................................1
12.4 DOORS AND WINDOWS..................................................................................................1
12.5 AIR CONDITIONING..........................................................................................................2
12.6 CONTROL OF VAPOURS.................................................................................................2
12.7 FLAME ARRESTORS AND P/V VALVES ........................................................................2
12.8 FORECASTLE SPACES....................................................................................................2
12.9 LOADING............................................................................................................................2
12.10 DISCHARGING ..................................................................................................................3
12.11 BALLASTING AND DE-BALLASTING ..............................................................................3
12.12 SHIP TO SHIP TRANSFER...............................................................................................3
12.13 DECK WATCH ...................................................................................................................3
12.14 MOORINGS AND ACCESS...............................................................................................4
12.15 TOWING OFF WIRES OF FIRE WIRES...........................................................................4
12.16 SLOP TANKS.....................................................................................................................4
12.17 COW NOTICE ....................................................................................................................5
13. INERT GAS :................................................................................................................................1
13.1 GENERAL..........................................................................................................................1
13.2 RESPONSIBILITY.............................................................................................................1
13.3 SYSTEM MANUAL............................................................................................................1
13.4 INERTING BEFORE LOADING........................................................................................1
13.5 LOADING...........................................................................................................................1
13.6 ON PASSAGE...................................................................................................................2
13.7 DISCHARGE .....................................................................................................................2
13.8 CRUDE OIL WASHING AND TANK CLEANING ............................................................2
13.9 GAS FREEING..................................................................................................................2
13.10 INERT GAS SAFETY CONTROLS..................................................................................2
13.11 SAFETY CHECKS WHEN PLANT IS SHUT DOWN .......................................................3
13.12 SYSTEM TEST SCHEDULE .............................................................................................3
13.13 MAINTENANCE PROGRAM .............................................................................................3
13.14 EXCHANGE OF TANK ATMOSPHERE. ..........................................................................3
13.15 COMPOSITION AND QUALITY OF INERT GAS.............................................................4
13.16 INERT GAS SYSTEM FAILURE ......................................................................................4
13.17 STATIC ELECTRICITY PRECAUTIONS..........................................................................5
13.18 INDIVIDUAL TANK PRESSURE MONITORING AND ALARM SYSTEMS ....................5
13.19 FLAMMABILITY DIAGRAM ...............................................................................................7
14. DRY BULK CARGOES - SAFETY CONSIDERATIONS.............................................................1
14.1 GENERAL SAFETY...........................................................................................................1
14.2 SAFETY DURING CARGO OPERATIONS......................................................................1
14.3 COAL ..................................................................................................................................2
14.4 DIRECT REDUCED IRON (DRI).......................................................................................4
14.5 SWARF...............................................................................................................................6
14.6 SULPHUR...........................................................................................................................7
14.7 ASBESTOS ORE ...............................................................................................................7
14.8 TAPIOCA ............................................................................................................................8
14.9 GRAIN.................................................................................................................................8
14.10 CEMENT IN BULK .............................................................................................................9
14.11 POLLUTION PREVENTION AFTER DISCHARGING......................................................9
15. PERSONAL SAFETY :................................................................................................................1
15.1 SLIPS, TRIPS AND FALLS................................................................................................1
15.2 STAIRS AND WALKWAYS................................................................................................2
15.3 HANDLING LINES..............................................................................................................2
15.4 HEARING AND EYE PROTECTION.................................................................................3
15.5 PORTABLE LADDERS......................................................................................................4
15.6 WORKING ALOFT OR OVERSIDE ..................................................................................5
15.7 HANDLING CAUSTICS, ACIDS & OTHER HAZARDOUS MATERIALS........................5
15.7.1 STOWAGE OF CHEMICALS ............................................................................................6
15.8 LIFTING EQUIPMENTS.....................................................................................................6
15.8.1 SAFETY WHILE LIFTING ITEMS......................................................................................6
15.8.2 SAFETY PROCEDURES FOR LIFTING OPERATIONS.................................................7
15.9 SAFETY WHILE OPERATING POWER TOOLS ...........................................................10
15.10 SAFETY WITH USE OF GALLEY EQUIPMENT............................................................10
16. HEALTH HAZARDS ASSOCIATED WITH CHEMICAL CARGOES:- ........................................1
16.1 GENERAL...........................................................................................................................1
16.2 POISONS............................................................................................................................1
16.3 CARGOES HAVING SKIN CONTACT HAZARDS...........................................................1
16.4 CARGOES HAVING INHALATION HAZARDS ................................................................2
16.5 INGESTION HAZARDS .....................................................................................................2
16.6 CORROSIVE CARGOES ..................................................................................................2
17.0 SAFETY WHILE WORKING ON SYSTEMS...............................................................................1
17.1 GENERAL...........................................................................................................................1
17.2 LOCK OUT /TAG OUT SYSTEM.......................................................................................1
17.3 STEAM SYSTEMS.............................................................................................................3
17.4 HYDRAULIC AND PNEUMATIC EQUIPMENT................................................................3
17.5 HIGH PRESSURE (HP) HYDRO-BLASTING EQUIPMENT............................................3
17.6 ELECTRICAL WORK.........................................................................................................5
ELECTRICAL WORK SAFETY FLOW CHART ...............................................................................8
18. HELICOPTER OPERATIONS :...................................................................................................1
18.1 GENERAL...........................................................................................................................1
18.2 OPERATIONAL INSTRUCTIONS.....................................................................................1
19. CHECKLISTS..............................................................................................................................1
CHECK LIST NO. 1.1 : ENCLOSED SPACE ENTRY PERMIT & CHECK LIST
(REFERENCE SECTION 7.8)...........................................................................................1
CHECK LIST NO.1.2 : PUMPROOM ENTRY PERMIT & CHECK LIST.......................................1
CHECK LIST NO.1.3 : CARGO COMPRESSOR ROOM ENTRY PERMIT & CHECK LIST........1
CHECK LIST NO. 2.1 : PERMIT TO WORK – ELECTRICAL INSTALLATIONS.........................1
CHECK LIST NO. 2.1A......................................................................................................................2
PERMIT TO WORK – ELECTRICAL WORK ON MSB AND ESB...................................................2
CHECK LIST NO. 2.1B PERMIT TO WORK – HIGH VOLTAGE EQUIPMENT...........................3
CHECK LIST NO. 2.1C......................................................................................................................4
CHECK LIST NO. 2.2 : PERMIT TO WORK – ALOFT AND/OR OVERSIDE...............................1
CHECK LIST NO. 2.3 : PERMIT TO WORK – PIPELINES & PRESSURE VESSELS ..................1
CHECK LIST NO.3.1 : HOT WORK PERMIT - TANKERS ( FOR HAZARDOUS AREAS)
(REFERENCE CHAPTER 11 & ISGOTT CHAPTER 9.4 & 9.8.13).................................1
ADDENDUM TO CHECKLIST NO.3.1 (19.3.1.1) HOT WORK PERMIT – TANKERS...................1
CHECK LIST NO.3.2 : ADDITIONAL HOT WORK PERMIT FOR ENCLOSED SPACETANKERS
& OBOS ...........................................................................................................1
CHECK LIST NO.3.3 : HOT WORK OFFICE APPROVAL INFORMATION SHEET - TANKERS
( FOR HAZARDOUS AREAS)...........................................................................................1
CHECK LIST NO.3.4: HOT WORK PERMIT - NON BULK OIL CARRIERS (REFERENCE
CHAPTER 11 )...................................................................................................................1
CHECK LIST NO.3.5 : HOT WORK PERMIT - FOR ENGINE ROOM (REFERENCE CHAPTER
11/ ISGOTT CHAPTER 9.4 & 9.8.13)...............................................................................1
CHECK LIST NO.4.1 : SHIP/SHORE SAFETY CHECK LIST NO. 4 (REF. ISGOTT 26.3.3) .......1
CHECK LIST NO.4.2 : BUNKERING OPERATIONS.......................................................................1
CHECK LIST NO.5 : SHIP/SHORE SAFETY CHECKLIST FOR LOADING OR UNLOADING
DRY BULK CARGO CARRIERS.......................................................................................1
GUIDELINES FOR COMPLETION OF THE SHIP/SHORE SAFETY CHECKLIST FOR
LOADING OR UNLOADING DRY BULK CARGO CARRIERS.......................................3
CHECK LIST NO.6: BEFORE DIVER'S UNDERWATER INSPECTION OR/AND WORK...........1
CHECK LIST NO.7 : SAFETY CHECK LIST FOR PAINTING* IN ENCLOSED SPACES............1
CHECK LIST NO.8 : SAFETY CHECK LIST FOR HYDROBLASTING .........................................1
CHECK LIST NO. 9: ISOLATION PERMIT ( LOCK OUT – TAG OUT OR LOTO ).......................1
EMERGENCY SQUAD DUTY CARD..................................................................................................1
GENERAL ( FOR ALL EMERGENCY SQUAD MEMBERS) : PREPARATION FOR ENTRY BY
FIRE FIGHTERS ..........................................................................................................1
NO. 1. OF THE EMERGENCY SQUAD..............................................................................................1
NO. 2. OF THE EMERGENCY SQUAD..............................................................................................2
NO. 3. OF THE EMERGENCY SQUAD..............................................................................................3
NO. 4. OF THE EMERGENCY SQUAD..............................................................................................4
NO. 5 OF THE EMERGENCY SQUAD...............................................................................................5
SUPPORT SQUAD DUTY CARD .......................................................................................................1
NO. 1. OF THE SUPPORT SQUAD....................................................................................................1
SUPPORT SQUAD DUTY CARD .......................................................................................................2
NO. 2. OF THE SUPPORT SQUAD....................................................................................................2