Table of Contents

1.0 INTRODUCTION.......................................................................................................................................5
1.1 HSE Goal..............................................................................................................................................6
1.2 HSE Mission.........................................................................................................................................6
2.0 DUTIES AND RESPONSIBILITIES................................................................................................................6
2.1 The Employers duties includes, but are not limited to:.......................................................................6
2.2 Employees duties includes, but are not limited to:..............................................................................6
3.0 SAFETY POLICIES......................................................................................................................................7
3.1 Company HSE Policy............................................................................................................................7
3.2 Drug and Alcohol Policy.......................................................................................................................8
3.2.1 Objective......................................................................................................................................8
3.2.2 Exceptions of This Policy..............................................................................................................8
3.2.3 Drug and Alcohol Test..................................................................................................................8
3.2.4 Reasons and Observable Cause for Alcohol and Drug Test..............................................................8
3.3 Smoking Policy.....................................................................................................................................9
3.3.1 Objectives of the Policy................................................................................................................9
3.3.2 Where to Smoke..........................................................................................................................9
3.4 Weapons............................................................................................................................................10
3.5 Housekeeping....................................................................................................................................10
3.6 Behavior at Work...............................................................................................................................10
3.7 Incident Reporting/Investigation.......................................................................................................10
3.8 Policy Violation and Disciplinary Action.............................................................................................10
3.8.1 Minor offences/violation...........................................................................................................11
3.8.2 Major offences/violation............................................................................................................11
3.8.3 Minor Offences Punitive Measures............................................................................................12
3.8.4 Major Offences and Punitive Measures.....................................................................................12
3.9 Safety Guidelines and Programs........................................................................................................12
3.9.1 Safety Rules................................................................................................................................12
3.10 HSE Meetings.....................................................................................................................................12
4.0 HSE MANAGEMENT SYSTEM..................................................................................................................13
4.1 Process Safety Management (PSM)...................................................................................................13
4.2 Corporate HSE Management System.................................................................................................14
5.0 FIRE SAFETY MANAGEMENT..................................................................................................................14
5.1 Fire.....................................................................................................................................................14
5.2 Causes of fire.....................................................................................................................................14
 5.3 Precautions........................................................................................................................................15
5.4 Fire extinguisher selection.................................................................................................................15
5.5 Fire extinguisher operation................................................................................................................15
5.6 Fire Prevention/Protection................................................................................................................15
5.7 Welding and Cutting..........................................................................................................................15
5.8 Fire Emergency Handling...................................................................................................................16
5.9 Emergency Response and Drills.........................................................................................................16
6.0 EMPLOYEE SAFETY AND OCCUPATIONAL HEALTH.................................................................................16
6.1 Personal Protective Equipment (PPE)................................................................................................16
6.2 Compulsory Basic PPE’s.....................................................................................................................16
6.3 Injury and First Aid.............................................................................................................................17
7.0 EQUIPMENT SAFETY..............................................................................................................................17
7.1 Electrical Hazards and Requirements................................................................................................17
8.0 WORK AT HEIGHT SAFETY......................................................................................................................17
8.1 Working at Height..............................................................................................................................17
8.2 Scaffolding.........................................................................................................................................18
8.3 Ladder Safety.....................................................................................................................................18
8.4 General Tool Usage Requirement......................................................................................................19
9.0 MACHINE SAFETY...................................................................................................................................19
9.1 Guides for Operation.........................................................................................................................19
9.2 Lifting and Rigging..............................................................................................................................19
10.0 COMPRESSED GAS CYLINDERS...............................................................................................................20
10.1 Storage...............................................................................................................................................20
10.2 Handling and Transportation.............................................................................................................20
10.3 Radiography Safety............................................................................................................................20
11.0 HAZARDOUS SUBSTANCES.....................................................................................................................21
11.2 Industrial Hygiene (IH).......................................................................................................................21
11.3 Hazardous Information (MSDS).........................................................................................................21
11.4 Chemical Handling.............................................................................................................................21
11.5 Laboratory Rules................................................................................................................................22
11.6 Hydrogen Sulphide............................................................................................................................22
11.6.1 Properties and Characteristics...................................................................................................22
11.6.2 Effects of Exposure limits (ppm – Parts per million)...................................................................23
11.7 Protection from H2S...........................................................................................................................23
11.8 Avoiding Exposure to H2S...................................................................................................................23
12.0 CONFINE SPACE.....................................................................................................................................23
12.1 Hazards in Confined Space.................................................................................................................24
 12.2 Possible Control Measures for Work in Confined Spaces..................................................................24
13.0 TRANSPORTATION.................................................................................................................................24
13.1 Traffic Management..........................................................................................................................24
13.2 Vehicle Safety....................................................................................................................................25
13.3 Drivers are to ensure the following:..................................................................................................25
14.0 SAFETY PROCEDURES AND PERMITS.....................................................................................................25
14.1 Lock-out and Tag-out.........................................................................................................................26
14.2 Barricades and Signs..........................................................................................................................26
14.3 Office Safety.......................................................................................................................................26
15.0 ENVIRONMENTAL PROTECTION.............................................................................................................27
15.1 Environmental Regulations and Guidelines.......................................................................................27
15.2 Environmental Preservation..............................................................................................................27
15.3 Environment......................................................................................................................................27
15.5 Environmental Management and Monitoring (EMM).......................................................................27
15.6 Pollution Prevention..........................................................................................................................27
15.7 Waste Management..........................................................................................................................28
15.8 Oil Spill management and Response..................................................................................................28
1.0 INTRODUCTION
Health Safety and Environment is an integral part of OPAC Refineries operation.
The objective of the HSE Department is simply to protect the people, environment, asset and
reputation of the company from harm. This will be achieved through proper and efficient
management of the following;
 Corporate HSE management system (HSEMS) and its elements which covers the safety of all
persons, assets and environment in OPAC including all OPAC work locations.
 Process Safety Management System (PSMS) and its elements with core focus on the safety of
the plant.
 Environmental management system (EMS) with core element of addressing environmental
issues within the operational area including the host communities and the neighboring
communities.
1.1 HSE Goal
Zero harm to the PEAR (People Environment Asset and Reputation)
1.2 HSE Mission
We must ensure to the highest standards for the safe operation of facilities and the protection of
the environment, our people and customers, and the indigenes of host communities.

2.0 DUTIES AND RESPONSIBILITIES

2.1 The Employers duties includes, but are not limited to:
 Provision of preventive equipment to give protection against accidents, occupational
diseases, fire hazards, and hazards from the use of equipment and hazardous chemicals.
 The provision and maintenance of plant and system of work that are safe and without risk to
health.
 Arrangement of the workplace to ensure safety and absence of risks to health in connection
with use, handling, storage and transportation of articles and substance.
 Provide at no cost to the worker, occupational health protection and personal protective
clothing and equipment, which are appropriate for the nature of the job.
 Provision of such information, instruction, training and supervision as are necessary to
ensure safety and health of all workers.
 Provision of adequate first aid facilities.
 Display of instructions to prevent fire, and to protect against work hazards.
 Ensure ventilation and cleanliness, with provision of adequate lighting, drinking water and
toilets.
 Disciplinary code for contravening safety provisions.
2.2 Employees duties includes, but are not limited to:
 To corporates with the government and employers in the fulfilment of the obligations placed
on him/her by the HSE policy to secure the occupational safety, health and welfare in the
workplace as defined by this policy.
 To take reasonable care for his/her own health and safety and other persons who may be
affected by his/her acts or omission.
 Use and maintenance of personal protective equipment supplied.
 To comply with the instructions given for their own safety and health and those of others
and with safety and health procedures.
  To use safety and health devices and personal protective equipment correctly and not
render them inoperative.

3.0 SAFETY POLICIES

3.1 Company HSE Policy
HSE POLICY
OPAC refineries believes that managing all of the HSE aspects of her operations is the basis for reaching our
vision to be best in class in Health, Safety and Environmental performance and to be so recognized by our
industry peers and our host communities.
We consider no phase of our operations or administration more important than the safety of our employees.
We will provide and maintain safe working conditions, establish and insist on safe work methods and
practices at all times. Safety protection shall be an integral part of all aspects of our business including design,
procurement, construction, planning, production, administration, sales and transportation. Injuries have no
place in our company.
It is the responsibility of all employees, management and contractors to ensure that all operations are
performed in a safe manner and to comply with all set policies, procedures and guidelines. We aim to resolve
safety problems through prevention.
It is the company objective to ensure the Health, Safety and Environmental programs are reviewed on an
annual basis and updated as required.

Each level of management must reflect an interest in company safety and must set a good example by
complying with company rules for safety protection. Management interest must be vocal, visible and
continuous from top management to departmental heads and supervisors.
Departmental heads and supervisors are responsible for preventing injuries.
Supervisors are responsible for preventing exposures to hazards in their specific work areas.
All employees are expected to take an active interest in the safety process, follow safe practices, participate in
program activities, obey rules and regulations and work in a way that maintains the high safety standards
developed and sanctioned by the company.
Our goal is simple- “Achieving and maintaining incident and injury free operations”.

We are together committed to:

Protects the health and safety of our people, contractor personnel and the general public.
Minimize adverse environmental impacts.
Comply with all applicable HSE laws, relevant legislation, regulation and industry standards.
Continual improvement to drive down HSE impacts of our operations by identifying all HSE risk and impacts
with appropriate controls and steps to improve them.
Ensure that HSE is an integral part of our business decision-making processes at all levels of the company via
the application of proactive, systemic, timely and risk-based approach to HSE.
Provide the necessary training to ensure that all employees and contractors are aware of their roles and
responsibilities regarding safety.
Prevent all injuries and protect the environment in which it operates.
Recognize those who contribute to improve HSE performance.
Conduct regular HSE reviews and audits in order to provide assurance regarding conformance with
requirements.
Act on individual responsibilities basis to operate safely and contribute to the wellbeing of one another.

Signed: Alexander Novikov

 Managing Director, OPAC Refineries

3.2 Drug and Alcohol Policy

OPAC recognizes that employees under the influence of drugs and alcohol whilst at work represent
a serious risk not only to themselves but also to other employees and customers. Therefore, the
following applies;
 Drugs, Alcohol and their Influences are STRICTLY PROHIBITED and in OPAC Refineries.
 It must not be used before and during work.
 Alcohol Test is a routine exercise meant for all employees involved in operation.
 Safe range for Alcohol test is 0.02-0.05 BAC
 Failure to perform test is a violation of this policy and therefore an offence with disciplinary
response.
 An Alcohol test for any employee above the stated range will attract disciplinary action.
 Possession or use, transfer, offer, share, attempt to sell or obtain, or be under the influence
of any drug or similar substance while on duty or on company business, on company premise
including operating company vehicles and plant equipment is strictly prohibited.

3.2.1 Objective
The objective of this policy
 Is to ensure that all employees are required to report and remain fit for duty, free of the
negative effects of alcohol and other drugs.
 Ensure that the possession, use, solicitation for or sale of dangerous drugs is kept away
from the company premises.
 Eliminate the risk posed by the abuse of such circumstances

3.2.2 Exceptions of This Policy

Moderate use of alcohol within the safe limits (0.02-0.05 BAC) by personnel is not prohibited during
the following activities:
 Appropriate business and social settings.
 During business trips other than during business meetings.
 During company sponsored or authorized social events during which alcohol is served.

3.2.3 Drug and Alcohol Test

Drug and Alcohol test can be carried out under the following circumstances:
 For-Cause Testing (where there is reason to believe).
 Post-accident/incident testing.
 Random testing.
 As part of a Pre-Employment Medical.
 Periodically.

3.2.4 Reasons and Observable Cause for Alcohol and Drug Test
A decision to cause test will be arrived at following a process of observation, investigation and
where appropriate, an interview with the employee suspected of drug use. Cause testing will occur
where there is a reasonable belief that an employee may be affected by drugs.

OPAC operational locations unless otherwise restricted by law, testing of operation and office-based
personnel may be conducted under the following observable reasons:
  Evidence that the employee may have tampered with a previous drug test.
 Criminal citations, arrests or convictions involving drugs and alcohol.
 Unexplained absenteeism or tardiness.
 Employee admissions regarding drug or alcohol use.
 Any involvement in any work-related accident or near misses.
 The Odor or Smell of Alcohol or Drugs on the employee’s breath or clothes or in an area such
as in a vehicle, office, work area, or restroom immediately controlled or occupied by the em -
ployee.
 There is reason to believe an employee is impaired by or under the influence of a controlled
substance, illegal drugs, legal drugs or alcohol at work.
 Alcohol, alcohol containers, illegal drugs or drug paraphernalia in the employee’s possession
or in an area controlled or occupied by the employee vehicle, office, desk and restroom.
 An employee is found in possession of a controlled substance, an illegal drug, alcohol or drug
paraphernalia or when a controlled substance, an illegal drug, alcohol or drug paraphernalia
is found in the workplace in an area the employee uses or controls such as the employee’s
work area, locker, bag, suitcase, room, vehicle, or other personal property.
 An employee has been injured or caused or contributed to the cause of a job-related acci-
dent or incident that may or may not have resulted in injury to persons or damage to prop -
erty, environmental damage or interruptions to operations.
 An employee is selected for random drug testing or when a decision has been made to test
all employees at a location or in a department.
 Irregular work attendance pattern involving multiple instances of unauthorised absence or
lateness during the preceding 12 months and unexplained or significant deterioration in job
performance.
 Deterioration in personal appearance and unexplained significant changes in behavior., abu-
sive behavior, repeated disregard of safety rules or procedures, insubordination, etc.
 Lack of concentration, easily distracted and aggressive or argumentative including severe ir-
ritability, depression or unpredictable mood changes.
 Cause testing may also occur where there is credible information from another employee or
source that drug or alcohol abuse is occurring.

3.3 Smoking Policy

The non-smoking policy within restricted company premises applies to the use of tobacco products
which includes but not limited to cigarettes, electric cigarette, pipes, cigars, snuffs, chewing of
tobacco, chewing or smoking of marijuana and the likes.
However, there are designated smoking areas which are meant ONLY for smoking legal products.

3.3.1 Objectives of the Policy

 To protect non-smokers from the health impact of the exposure to undesired smoking
habit of others.
 To reduce the risk of fire due to indiscriminate smoking in the workplace.
 To ensure employees compliance to national smoking policy.

3.3.2 Where to Smoke

Smoking is allowed only at the following places:
 At designated smoking points.
 At the residential area.
 In the room if you are the only occupant or if your roommate smokes as well.
To ensure that we reduce the risk of fire in operation area, it is HIGHLY PROHIBITED AND
SANCTIONABLE to smoke in the following places:
 The Gantry.
 The Tank Farm.
 The entire plant area except the smoking point.

3.4 Weapons
Weapons are anything that are designed or used to inflict bodily harm or physical damage to
persons, equipment, buildings etc. These includes but not limited to knifes, guns and explosive
devices and chemicals.

Anything falling in this category is strictly PROHIBITED within OPAC facilities.

There are however some exceptions to this:
 Guns and fire arms allowed for security purposes. However, use within the facility must
be guided.
 Knifes can be allowed for work, when necessary, as in kitchen or other justifiable places.

3.5 Housekeeping
Good housekeeping keeps us safe. Unclean/untidy workplace can cause incidents (injury) resulting
from slips, trips, falls and fire hazards.
Employees Requirements:
 Keep the work area clean and orderly condition.
 Stack all items in the right position.
 Dispose all waste appropriately in the rubbish bin.
 Keep all passageways, stairs, storerooms, offices and work areas clean, unobstructed
and free of trips hazards.
 Return all tools, items and equipment to their appropriate storage locations.
 Prevent combustibles, which can pose a fire risk in the workplace.
 Properly clean up any oil, water or other substances spilled on the floors.

3.6 Behavior at Work

This is particular to horseplay. Horseplay is any unnecessary act/action or activity in the workplace
which could lead to an incident, loss of production time etc. Horseplay could even be jokes involving
physical contacts, playing/chasing around, reckless/unnecessary use of tools, pranks, etc. All such
activities in these categories are PROHIBITED.

3.7 Incident Reporting/Investigation

Accident and incident investigation is one of the key elements of the Health Safety and Environment
(HSE) Management System. In order to strengthen our system, it is compulsory that all incidents
must be reported for necessarily follow up and investigation.
All incidents including near misses, injuries, fatalities, spills, fire etc. must be reported to the
immediate heads and HSE Department.

3.8 Policy Violation and Disciplinary Action

OPAC Refineries is bound under obligatory requirements to protect her employees from all forms of
injury at work, exposure to hazardous materials and as well protect her assets and environment.
Compliance to safety policies will promote and sustain a safe workplace for all and it is compulsory
that everyone must comply. Violation (negligence or disregard) of these policies and plans poses a
threat to the safe delivery of this core objective and endangers everyone, business operation
including plants and machinery, the environment and as well jeopardize the reputation of the
company. Employee’s violation due to his/her action and inaction having been fully aware of the
consequences is strictly unacceptable, requires correction and possible sanctions.

3.8.1 Minor offences/violation

A conduct which is likely to result in a serious on-the-job injuries or illnesses, death and
damage to equipment.
Examples includes but not limited to the following;
 Failure to use required PPE.
 Failure to follow safe work procedure.
 Engaging in horseplay while at work outside the plant area.
 Smoking in unauthorized places outside the plant.
 Unsafe or reckless disposal of non-hazardous waste within the company’s premises.
 Failure to follow supervisor’s instructions on critical works.
 Engaging in works which one is not trained for.
 Failure to obtain permit to work.
 Not providing Safety Induction to new comers, visitors and contractors.
 Unauthorized assess without permission.
3.8.2 Major offences/violation
A conduct which is likely to result in a serious on-the-job injury, illnesses, death or damage
to equipment. Such action may or may not be in violation of established and known policies.
Examples include but are not limited to the following;
 Acts of physical violence, including fighting within the facility.
 Willful violation of a safety rule, policy, procedure or safe work practice when a
known exposure to a hazard exists. For instance, refusal or failure to vent a system
before hot work, failure to carry out isolation when it is required or stated in the JHA
etc.
 Engaging in horseplay while at work within the plant area, tank farm and gantry.
 Failure to utilize “life critical” safety equipment such as fall protection when a fall haz-
ard exists.
 Disposal of wastes of any kind (generated in the company) outside the company.
 Conducts or unsafe acts that might subject the company to civil or criminal liability.
 Vandalizing or gross negligence in the care of company/client property.
 Possession of or usage of firearms, knives, or any other weapons or explosives within
the company.
 Inactions which could endanger the life of co-workers or damage the plant.
For instance, failure to pass required information/instruction on a particular job,
failure to communicate necessary change to work method etc.
  Failure to obtain permit to work for critical work within the plant area.
 Smoking in unauthorized zone within the plant area.
 Not reporting Near Miss, Property damage and all incidents.
 Engaging in critical works outside stated time in the permit to work.
 Any violation with intention of causing harm or property damage.
 Working in OPAC premises or driving OPAC vehicles under the influence of Alcohol.
This also includes possession of alcohol within during work time alcohol exclusive ar-
eas.
3.8.3 Minor Offences Punitive Measures
First Occasion: Verbal Warning (must be documented as verbal in personnel record)
Second Occasion: Written Warning including deduction of allowances or salary and
suspension without pay.
Third Occasion: Further Disciplinary Actions up to and Including Termination.

3.8.4 Major Offences and Punitive Measures

First Occasion: Written warning including deduction of allowances or salary and suspension
without pay or Termination based on severity.
Second Occasion: Termination of employment.
3.9 Safety Guidelines and Programs
3.9.1 Safety Rules
 Report to work free of Alcohol and Drug Influence.
 Respect all legal requirements.
 Risk Assessment/Job Hazard Analysis for all non-routine jobs must be done.
 Permit to Work obtained before doing non-routine jobs.
 Wear required personal protective equipment at all times.
 All incidents must be reported to Supervisors and HSE Department.
 Horseplay, fighting and harassment is prohibited.
 Unsafe Acts are prohibited.
 Only competent persons should be allowed to work without supervision.
 Do not follow shortcuts. Always follow Safe Work Procedures.
 Response to emergency alarm is compulsory.
 Do not work on energized equipment and parts.
 Communicate identified hazards to responsible persons and HSE.
 Stop work where necessary to address observed hazards.
 Use of phones and cameras in the operation area is prohibited.
 Smoking within plant and other prohibited areas is a serious HSE offence and violations,
Smoke only on designated points.
 Report every observed fire and smoke.
 Open flame is prohibited.
 Fire arms is prohibited in the operation area.
 Continuous monitoring and improvement must be maintained.
3.10 HSE Meetings
As part of sustaining our safety culture, certain meetings are compulsory for the purpose of
reviewing, improving, training and communication of safety information.
These includes:
 Toolbox meetings: a meeting held at least once a week and conducted by a safety
officer attached to the department. It is to discuss safety and other issues related to our
job and compulsory for every member of the department. Deliberate absence without
permission from the departmental head or safety officer is not allowed.
 Safety meetings are held on weekly and monthly basis as it affects departments.
An emergency safety meeting could be summoned when the need arises.
And all persons concerned are required to attend.

Plant Warnings

PPE REQUIRED

4.0 HSE MANAGEMENT SYSTEM

4.1 Process Safety Management (PSM)
Our plant operations are governed by our compliance to the provisions of the elements of the
Process Safety Management System which are:
 Process Safety Information
 Process Hazard Analysis
 Operating Procedure
  Mechanical Integrity
 Pre-Startup Safety Review
 Management of Change
 Employee Participation
 Contractors
 Process Safety Management Training
 Emergency Planning and Procedure
 Incident Investigation
 Hot Work Permits
 Compliance Audits
 Trade Secret Protection

4.2 Corporate HSE Management System

OPAC’s Corporate HSE Management System focusing on all company operations includes 17 components
essential for its operations:
 Responsibility, accountability and authority for health, safety and environmental (HSE).
 HSE targets, objectives and policy.
 Personnel training, awareness and competence.
 Employee’s communication, participation and community involvement.
 Hazard identification, risk assessment and control.
 Incident/near miss investigation and reporting.
 Planned HSE inspections.
 Management of change.
 Contractors and visitor’s safety.
 Permit to work systems.
 Crisis and emergency management.
 Industrial hygiene and laboratory safety.
 Health and fitness for work.
 Environmental effects and waste management.
 Personal protection equipment (PPE).
 Audits, assessment and review.
 Performance measurement and continuous improvement.

5.0 FIRE SAFETY MANAGEMENT

5.1 Fire
Fire hazard includes burns, property damage and fatality. A fire must have three
things to ignite and maintain combustion: Fuel, Heat, Oxygen.
The “Fire Triangle” identifies these three components of any fire:
 Fuel paper, wood, flammable gas, energized electrical equipment, etc...
 Energy (heat), sufficient to support combustion.
 Often referred to as the ignition source.
 Oxidizer (air)
Prevention is based on eliminating or minimizing one of the components of the “Fire Triangle”.

5.2 Causes of fire

 Hot work, welding and cutting.
  Poor housekeeping.
 Spontaneous ignition.
 Chemical spill and gas leakage.

5.3 Precautions
 Safe work practices.
 Avoid leakages and spillage.
 Restrict the fire at initial stage.
 Know the location of fire extinguishers.
 Know the emergency exits.
 Periodic fire drills conducted.

5.4 Fire extinguisher selection

 Water type: used on solid fire, paper, cloth, wood, etc.
Cannot be used on electrical fire.
 Liquid Foam type: used for flammable liquids, oil, petrol etc.
Cannot be used on electrical fire.
 DCP (Dry Chemical Powder): good for all fires.
 Co2 (carbon Dioxide): good for most fires including electrical.
Not effective in open spaces.

5.5 Fire extinguisher operation

P-Pull the pin.
A-Aim at the base of fire.
S-Squeeze the handle.
S-Sweep side to side at the base of the fire.

5.6 Fire Prevention/Protection

Bearing in mind that a refinery and hydrocarbon storage facility is a high-risk operation and prone to
fire incidents, we strive to prevent every act of omission or commission that could result to a fire;
 Do not leave a flammable liquid exposed in a container
 Our products are not to be found outside their storage locations in the company
premises except approved for usage by appropriate authority and must be done in a
safe manner.
 Combustible materials must be kept close to storage facilitates.
For example, a greased rag.
 Lighters, match sticks and their likes are prohibited from storage facilities.
 Respect our no smoking and open flame plant rules and all others.

5.7 Welding and Cutting

 Inspect all leads, grounds, clamps, welding machines, hoses, gauges, torches and
cylinders before use.
 All work must have a separate and adequate ground connection.
 Be sure all fittings, couplings and connections are tight.
 Avoid breathing fumes. Use local exhaust or a respirator.
 No welding or burning must be done on a closed vessel or tank.
  Each welder is responsible for containing sparks and slags and removing combustibles
to prevent fire.
 Hoses and welding leads should not be run through doorways or wall openings.
 Do not leave the rod in the electrode holder when you lay it down.
 An approved welding helmet shall be worn.
 Never do electric welding from a metal ladder.
 Do not exceed 15psi on the torch side of the gauge when using acetylene.
 When lighting a torch, open fuel gas valve on the torch before opening the oxygen
valve.
 Use an approved spark lighter, do not use matches to light a torch.
 Approved cutting goggles must be worn. Use at least No.3 filter.
 Keep oil and grease away from oxygen regulators, hoses and fittings.
 Flash back arrestors shall be fitted to avoid reverse flow of flame in gas cutting torch.
 Prior to replacing a blowpipe, regulator or pressure gauge, the gas cylinders must be
isolated.

5.8 Fire Emergency Handling

In case of fire, the following should be done:
 Quickly alert the fire fighters and everyone around by all possible means
 Remove all flammables and combustibles as quick and as safe as possible
 Use the extinguishers at the initial stage if you trained to do so and as safe as possible.
Do not fight a fire before alerting others and do not take unnecessary risk.
 Evacuate immediately if unable to curtail the fire.

5.9 Emergency Response and Drills

As part of our emergency preparedness, drills are conducted frequently to instill the culture of
active and prompt response during emergency situations.
Therefore, whenever the fire alarm is sounded:
 Leave your work location to the Emergency Assembly Point or Muster point.
 Help others in need without putting yourself at risk.
 Participate in head count and give useful information as may be needed.

6.0 EMPLOYEE SAFETY AND OCCUPATIONAL HEALTH

6.1 Personal Protective Equipment (PPE)
As a last line of defense after all others in the hierarchy of hazard control, OPAC Refineries therefore
recognizes the need for personal protective equipment. In compliance with both local and
international regulations, OPAC Refineries as the employer has the responsibility of providing the
required PPE for all employees directly engaged in her operations.
It is also a legal requirement that employees must comply with use of PPE.
Every contractor engaged by OPAC Refineries must as well comply with this policy of compulsory
PPE use.

6.2 Compulsory Basic PPE’s

 Hardhat for head protection.
 Safety Shoe for foot protection.
 Coverall for body protection.
 Eye google/face mask for eye/face protection.
 Respirators for nose protection.
  Earmuff/Earplug for ear protection.
 Hand gloves for hand protection.
For non-routine works please contact the HSE Department for PPE selection and guide for use.

6.3 Injury and First Aid

An injured person is expected to quickly contact the first aiders/HSE Department for immediate
attention and further actions. However, it is also expected that all workers should know the location
off all first aid boxes. It is the right of any injured worker to receive care before been reassigned to
work.
Occupational Illness should be as well reported to immediate heads and onward to the HSE
Department.

7.0 EQUIPMENT SAFETY

7.1 Electrical Hazards and Requirements
The requirements for carrying out electrical works in OPAC are pre conditions which must be
satisfied before work is done. The following rules should be adhered to when doing any electrical
work:
 Follow required safe work procedure.
 Prevent all possible contact with electric current.
 Do not use outlets or cords that have exposed wiring.
 Do not use power tools with the guards removed.
 Do not block access to circuit breakers or fuse boxes.
 Do not carry out any electrical work when it is raining.
 Ensure proper isolation, lockout and tag-out and de-energization of energized parts.
 Do not use conductive or uninsulated tool for electrical works.
 Do not do any work you are not trained for.
 Ensure the use of appropriate PPE.
 Check for electrical lines when working overhead.
 Do not used aluminum or steel ladder.
 Always use a circuit breaker or fuse with the appropriate current rating.
 Do not touch a person or electrical apparatus in the event of an electrical accident.
Always disconnect the current first.

8.0 WORK AT HEIGHT SAFETY

8.1 Working at Height
 All work at height is properly planned and organised.
 Those involved in work at height are trained and competent.
 The location where work at height to be safe always.
 Equipment for work at height is appropriately inspected and controlled.
 The risks from fragile surfaces are properly controlled.
 The risks from falling objects are properly controlled.
 use an existing place or means of access.
 Use the most suitable way of working.
 Select the most suitable equipment.
 All work at height takes account of weather conditions that could endanger health and
safety.
 Just remember a risk assessment is to be written to control the hazards.
8.2 Scaffolding
Scaffoldings are commonly used for working at height and there is a potential risk for the scaffolder
(person working on a scaffold) to fall from an incomplete scaffold during the erection and
dismantling of a scaffold.
 Every scaffold that is available for use needs to be able to prevent employees falling.
Guardrails, toe boards and similar barriers should be provided.
 Any scaffold must be designed, erected, altered and dismantled by competent people
under the direct supervision of competent supervisor.
 Complete scaffold shall be inspected each week thereafter and immediately after
alteration or relocation.
 After each inspection, a competent person shall fill out and place a tag on the scaffold.
 Ensure that materials used during construction cannot fall to the ground.
 Working platform should be wide enough to allow people to pass safely and use any
equipment or material necessary for their work
 Any ladder used in conjunction with scaffolding must be in good condition, of sufficient
strength and securely located.
 A scaffold collapse can involve multiple fatalities. Scaffold must be based on a firm level
foundation capable of supporting the weight of the scaffold and the loads likely to be
placed on it.
 Check the scaffold components for any defects.
 Do not use damaged scaffold components.
 Scaffolding tag procedure to be followed to know the status of the scaffold. Green Tag is
Safe to Use. Red Tag is not safe to use.
 Any damage to scaffolds, false work, or other supporting structures shall be
immediately reported to your supervisor and repaired before use.

8.3 Ladder Safety

The following requirements apply to the use of ladders:
 Avoid the use of ladders made of conductive materials especially if the job to use it for
is electrical.
 Use a ladder that can sustain at least four times the maximum intended load.
 Ladders must be tagged safe for use and inspected for possible defects before
proceeding with it.

However, other instructions from the HSE Department pertaining to ladder safety should be
followed.
8.4 General Tool Usage Requirement
 Keep all tools in good condition.
 Inspect couplings, hoses, and hose connections of pneumatic tools each time you use
them. Make sure they are in good condition, properly attached and secured.
 Always use the right tool for the job.
 Ensure that guards are in place for tools designed to have guards.
 Return all tools to the appropriate place after work
 Only use tools you are trained to use.
 Wear the right PPE for the tool used.

9.0 MACHINE SAFETY

9.1 Guides for Operation
 Ensure the work area is free of hazards before proceeding to work.
 Complete and necessary functional checks to ensure machine fitness and this must be
done before starting the machine. This is operator’s responsibilities.
 All equipment deficiencies must be reported promptly to the appropriate maintenance
team.
 Only competent persons are allowed to operate machines.
 Cranes or hydras shall not be used to carry loads above their rated capacity.

9.2 Lifting and Rigging

 All lifting equipment should have a valid third-party inspection certificate and color
coded.
 Personnel are prohibited from riding on the lifting block, load or headache ball of any
hoisting device.
 All operators must have a valid operator license in lifting operations.
 The weight to be lifted must be determined before hoisting the lifting ropes.
  All hoisting and rigging equipment must be used in accordance with manufacturer’s
specifications and operating requirements.
 Inspect all hoisting and rigging ropes and ensure their fitness for the particular load to
be lifted.
 A rigger must be visible to the operator from any position.
 Never stand or allow anyone to stand or walk under suspended load.
 Operators must remain in the cab if there is a suspended load.
 Never tie knots in slings or shorten by wrapping them around crane hooks or by using a
nut or bolt.
 All the lifting operations must be stopped during heavy wind condition
 Never puts sharp ends in wire ropes. Always protects slings from sharp corners by
padding.
 Lifting hooks shall have a safety latch attached and be in good working order.
 Check that all parts of the load are safely slung.
 Never stand under suspended load.
 Only authorized riggers should give signals.
 Use only the correct signals and make sure that operator understand clearly.
 Ground conditions must be checked for suitability prior to tracking a mobile crane.
 Outriggers (where fitted) must be fully extended on stationary lifts.
 Lifting tackles must be freely available for regular inspection.

10.0 COMPRESSED GAS CYLINDERS

10.1 Storage
 Cylinders should not be stored under direct sunlight and near hot work areas.
 Cylinder to be stored safe, secure and in vertical upright position.
 Full and empty cylinders to be marked and stored separately.
 Store cylinders in well ventilated areas and with protective caps.
 Oxygen cylinders should be stored 5 meters away from other cylinders.

10.2 Handling and Transportation

 Cylinders should not be rolled horizontally and it should be rolled at its base.
 Cylinders should be secured in vertical upright position while transportation.
 Cylinders to be fitted with valve caps or hood.
 Use cylinder trolley for carrying cylinders.
 Do not strike an arc on cylinders.
 Do not lift with slings or by protective cap.
 Lift to upper levels with approved cages only.

10.3 Radiography Safety

 All work carried out using radioactive equipment must be supervised by an authorized
person.
 Training given to authorized persons contains all necessary rules and regulations and
should be fully understood and adhered to at all times.
 Radioactive material must be stored and transported in approved leak proof container.
 All the personnel working in radiography area must wear personal radiation monitor,
protection suit, film badge and dosimeter.
  Radiography area to be barricaded and only authorized personnel must be allowed to
work.
 Radiography work to be planned during day time only and on off days or during off work
time.
 Radiation dose outside barricaded area must not exceed 0.25mrems/hour.

11.0 HAZARDOUS SUBSTANCES

11.2 Industrial Hygiene (IH)
The objective of the Industrial Hygiene is the prevention of worker exposures to harmful agents in
the workplace. Key elements are anticipation, recognition, evaluation, and control of workplace
health hazards. Having this at the back of our mind, our process and operations are strictly
monitored to ensure employees work under a comfortable condition by designing our operation to
reduce stress impact, reduce environmental impacts within our premises and our surrounding
environment. All kinds of control (engineering, administrative and safe work practice) are employed
to control potential health and environmental hazards.

11.3 Hazardous Information (MSDS)

The Material Safety Data Sheet contains all information of all chemical materials and substances
used in OPAC Refineries. They are available in the laboratory, and all places where chemicals and
materials are used. They are to be consulted for safe handling, storage, disposal and first aid
purposes. Our Chemical Hygiene Plan (CHP) provides practicable guide to the use of chemicals.
The entire operations of OPAC Refinery are centered on the refining of crude oil which is a
hazardous substance to produce the following; Naphtha, Fuel Oil, Diesel and Kerosene which are all
hazardous in the following sense:
 They are all highly flammable liquids and can be extinguished using Dry Chemical
Powder (DCP) or CO2, alcohol resistant foam or other foam chemical agents.
 Poisonous gases are produced during their combustion.
 Contact with eye and skin can cause irritation and burns. If in contact with skin wash off
quickly with plenty of water and soap. If in contact with eyes locate the eye wash and
flush with plenty of water for at least 15 minutes. Remove contact lenses if used.
 Cause irritation in the nose, throat and lungs, headache, dizziness and discomfort when
ingested or inhaled from prolonged exposure. If ingested, seek medical attention
immediately.
 Reacts violently with oxidizing agents (like Perchlorates, Peroxides, Permanganates,
Chlorates, Nitrates, Chlorine, Bromine and Fluorine) and Nitric Acid.

11.4 Chemical Handling

Toxic chemicals in the form of solids, liquids, gases, mists, dust, fumes and vapors may cause
problems by inhalation, by absorption (through direct contact with the skin), or by ingestion (eating
or drinking).

The following rules apply for safe handling of chemicals:

 All chemical must be properly labeled and stored.
 Always read and follow the instruction on the Material Safety Data Sheets (MSDS) and
labels of all chemicals that you work with.
 MSDS must be present for any chemical stored or used within company facilities. It
should be kept in a well-marked location and it must be accessible to employees at all
times.
  Each employee must review the MSDS for a particular chemical before working with
that chemical.
 If required by the MSDS, employees must wear proper eye, face, hand and body
protection.
 Always review emergency first aid procedures before use.
 An employee exposed to hydrocarbon, hydrogen sulfide or other chemicals, gas or
vapor should report the incident to their supervisor immediately after the emergency
procedures listed in the MSDS sheet have been followed. Further treatment of chemical
injuries and illnesses should be left to a physician.
 Do not eat, drink, smoke or chew in areas where chemicals are present.
 Wash hands or other areas of exposed skin after using chemicals.
 Never siphon liquid chemicals by mouth suction from tanks or containers. Always use a
pump.
 Chemical containers should never be stored in direct sunlight as dangerous gas pressure
can build up rupturing the container.
 Employees involved in operations that require the handling of chemicals must know the
location and operation of eye showers and eye wash stations.
 Flush eyewash stations and showers before handling chemicals to ensure proper
operation and clean water in an emergency.
 Empty containers shall be disposed of in a safe and environmentally friendly manner.
 Around any area where large quantities and frequent usage of toxic chemicals occur,
post warning signs identifying the chemicals and their use.
 Employees, when handling chemicals, they are unsure about or unfamiliar with shall
seek the advice of their supervisor and or Safety Officer.

11.5 Laboratory Rules

 Know locations of laboratory safety showers, eye wash stations and fire extinguishers.
 Avoid skin and eye contact with all chemicals.
 Assume that all chemicals of unknown toxicity are highly toxic.
 No horseplay will be tolerated.
 Avoid distracting or startling persons working in the laboratory.
 No cell phone or ear phone usage in the active portion of the laboratories, or during
experimental operations. Do not taste or intentionally sniff chemicals.
 Do not eat, chew and drink in the laboratory.
 Use the appropriate PPEs in the laboratory.

11.6 Hydrogen Sulphide

Hydrogen sulphide (H2S) is deadly especially when you don’t understand and respect its danger.
H2S is a naturally occurring gas by the decomposition of plant and animal materials.

11.6.1 Properties and Characteristics

 Toxic gas.
 Not visible.
 Rotten egg smell.
 Heavier than air.
 Soluble in water.
 Highly flammable.
  When burn emits SO2.

11.6.2 Effects of Exposure limits (ppm – Parts per million)

 Up to 100ppm you will experience rotten-egg smell, burning eyes and respiratory tract
irritation.
 If 100ppm prolonged, you will lose your sense of smell, headache, dizziness and
coughing.
 At 100 to 300ppm will cause drowsiness, severe eye and throat irritation, respiratory
difficulty due to fluid in lungs.
 From 300 to 600ppm will cause loss of reasoning and balance and eventual
unconsciousness
 Exposure above 600ppm will cause immediate death.
 Permissible Exposure Limit (PEL) is 10ppm: Employee can work under this exposure, 8
hours for 5 days a week.
 Short Term Exposure Limit (STEL) is 15ppm: Exposure not more than 15minutes.
 H2S can be detected using air monitoring systems like Multi gas detectors and personal
monitors.
 Mechanical ventilation using fans and blowers and gas test to be done before entering
into confined space. If you suspect H2S evacuate the area immediately.

11.7 Protection from H2S

When you are in the area where H2S is the potential hazard, you must wear approved personal
protective and respiratory protective equipment.
Two common types of PPE are:
 Self-contained breathing apparatus (SCBA).
 Supplied air breathing apparatus.

11.8 Avoiding Exposure to H2S

 Know how to use air monitoring devices.
 Ensure adequate ventilation within area of exposure.
 Be wind conscious.
 In case of H2S emergency, hold your breath.
 Put on your breathing apparatus.
 Proceed to your assembly area.
 Do not attempt to rescue anyone alone. Always proceed in pairs.
 Protect yourself first. Do not become another victim.

12.0 CONFINE SPACE

Confined space is an enclosed or partially enclosed space that:
 Is not primarily designed or intended for human occupancy.
 Has a restricted entrance or exit by way of location, size or means.
Can represent a risk for the health and safety of anyone who enters, due to one or more of the following
factors:
 its design, construction, location or atmosphere.
 the materials or substances in it.
 work activities being carried out in it or the mechanical, process and safety hazards
present.
  Confined spaces can be below or above ground.
 Confined spaces can be found in almost any workplace.

Confined spaces include: silos, vats, hoppers, utility vaults, tanks, sewers, pipes, access shafts, truck
or rail tank cars.
Ditches and trenches may also be a confined space when access or egress is limited.

12.1 Hazards in Confined Space

 Poor air quality like oxygen deficient or enriched atmosphere and toxic gas.
 Chemical exposures due to skin contact or ingestion as well as inhalation of 'bad' air.
 Flammable atmosphere.
 Process-related hazards such as residual chemicals, release of contents of a supply line.
 Safety hazards such as moving parts of equipment, structural hazards, entanglement,
slips and falls.
 Temperature extremes including atmospheric and surface.
 Shifting or collapse of bulk material.
 Barrier failure resulting in a flood or release of free-flowing solid.
 Uncontrolled energy including electrical shock.
 Radiation, Noise, Visibility and Biological hazards.

12.2 Possible Control Measures for Work in Confined Spaces

 Identification of the authorized and competent person.
 Risk assessment.
 Isolation procedures.
 Atmospheric testing and the need for air purging.
 Portable electrical equipment.
 Lighting and ventilation.
 Access and egress.
 Requirement for a stand-by person and identification.
 Emergency equipment, rescue procedures and first aid facilities.
 Signs and barriers to prevent unauthorized access.
 Education and training of all persons working in or involved with confined space entry.
 Other hazardous conditions apply (hot work, working at heights or excavation).
 Potential for hazardous conditions to result from the work activities.

13.0 TRANSPORTATION
Transportation is a key aspect of OPAC’s Refineries operation. Cars and light vehicles are used for
personnel transport while heavy trucks are used for conveying products and equipment.
As such the safety of these trucks and whatever they are conveying is of utmost importance to us.

13.1 Traffic Management

 Wear your safety belt and wear it correctly.
 Be alert! Pay attention to traffic at all times.
 Keep enough distance between you and the vehicle in front of you.
 Check your blind spot when changing lanes.
 Avoid sharp turns.
 Do not drive in bad weather.
  Never eat, drink or use a mobile phone while driving.
 Be extra careful at intersections. Use your turn signals and remember to look around for
people and other vehicles.
 Keep your eyes on the road, hands on the wheel and your mind on the drive.
 Site speed limits of 10 km/h are to be used for the main access road and movement in
and around the active work areas shall also be limited to 10 km/h.
 In line with the Revised Nigerian Highway Code of 2016, all articulated vehicle
exceeding 3t max laden weight shall maintain 40 km/h max on highways passing
through the communities and 30km/h inside community town.
 Drivers are to observe the posted speed limits, with speed adjusted appropriately to
suit the road environment and prevailing weather conditions.
 Be careful while using vehicles during hours that children are travelling to and from
schools.
 Emergency Service Parking Area and access roads should not be occupied by other
vehicles.
 Do not park on footways or footpaths with construction vehicles on public highways in
the vicinity of the working width.
 Comply with the traffic signs used for the access roads.
 Pay attention and report damaged or missing traffic signs.

13.2 Vehicle Safety

Our vehicles must be inspected on daily basis to ascertain their fitness.
All vehicles must at all times have the following:
 A tagged fire extinguisher.
 An inflated and gauged spare tyre.
 A jack.
 A wheel spanner.
 A reflective angle.
 Functioning side mirrors on both sides and a rear mirror.
 Usable sit belts.
 Functioning brake (foot and hand brakes).

13.3 Drivers are to ensure the following:

 That they and their passengers always use their sit belts.
 Maintain appropriate speed limits on various roads as well as company’s set speed limit.
 No use of phones while driving.
 No alcohol or drug and their influences while driving.
 Follow prescribed Journey Management Plan.

Transportation of highly hazardous chemicals (HHC) like cooking gas, laboratory chemicals etc. must
be done with utmost care. Attention should be given to containers integrity and packaging.

14.0 SAFETY PROCEDURES AND PERMITS

To ensure the safe delivery of operations, OPAC Refineries maintains procedures that guarantees
the safety of persons and equipment. These procedures when complied with will reduce risk and
eliminate hazards in our works. All workers must cooperate with HSE Department carry out Risk
Assessment (RA) and Job Hazard Analysis (JHA) by requesting work permit before carrying out any of
the following works:
  Work at Height.
 Hot Work.
 Cold Work.
 Electrical Work.
 Mechanical Isolation.
 Confines Space.
 Excavation.

14.1 Lock-out and Tag-out

Certain aspect of our jobs requires us to carry out a Lock-out and Tag-out procedure to ensure safe
work. This is required in some electrical and mechanical works. When this is required, it must be
strictly followed and not bypassed.

14.2 Barricades and Signs

Barricades and signs are required around all excavations, holes or openings in the floor or roof
areas, edges of roof and elevated platforms; around certain types of overhead work, Radiation
activities and wherever necessary to warn people about existing hazards.
 Anyone who makes a hole or opening is responsible for having it barricaded.
 Barricades must be 42 inches high, square and level.
 Keep 4 feet back from the edge of excavations, holes, platforms and roofs unless
a protective barricade is used.
 Erect a barricade before the hole is cut and extend it as the excavation progress.
 Any barrier removed to carryout work must be replaced before leaving the area.
 Return barricades to the barricade storage rack when they are no longer needed.
 Numerous excavations in one area may be barricaded efficiently by erecting a barricade
around the general area.
 Leave an entrance, opening or gate where practical.
 Warning signs must be clearly displayed.
 While operating heavy equipment, maintain one to one rule if in close proximity to a
trench or other excavation i.e. for an 8 feet (2.5m) depth stay at least 8 feet (2.5m)
away from wall of excavation.

14.3 Office Safety

 Know the location of the two nearest exist from your work area.
 Emergency exits and the passageways shall be free from obstructions.
 All floor surfaces shall be kept clean, dry, and free from protruding splinters and nails,
loose boards, holes, broken tiles and other protrusions.
 Defective tile or carpet should be repaired immediately.
 Never store items under your desk or on top of cupboards.
 Always keep desk drawers and file cabinets closed.
 The computer screen should be 45-60cm away from the user’s eyes.
 Always maintain proper posture.
 Do not overload extension cords or electrical outlets.
 Turn Off electrical, electronic equipment when not in use.
 Never lift heavy loads.
 Loose lying cables can cause:
A tripping hazard.
 Electrocution.
 People can hook on cables and pull expensive equipment from tables.
 Never stand on the chair to reach anything, particular if the chair has wheels or is of the
swivel kind.

15.0 ENVIRONMENTAL PROTECTION

Environmental protection is a key aspect of our operation and we will not carry out any operation
unless in an environmentally safe manner and within the stipulations of environmental regulations.
Our environmental protection plan is achievable through the following;

15.1 Environmental Regulations and Guidelines

Our Environmental Management System (EMS) is guided by the requirements of ISO 14001,
Environmental Guidelines and Standards for the Petroleum Industry in Nigeria (EGASPIN) and other
local and international regulations.

15.2 Environmental Preservation

We will not operate, handle, use, sell, transport, or dispose of a product unless we can do so safely
and in an environmentally sound manner. We operate and work with a cleanliness mindset at all
times. Employees must keep our environment clean.

15.3 Environment
Environmental Management during the operation will be managed in accordance with the following
Environmental Management Plans:
 Environmental Management and Monitoring (EMM).
 Pollution Prevention.
 Waste Management.
 Traffic Management.
 Oil Spill Response.

15.5 Environmental Management and Monitoring (EMM)

 Do not disturb the local communities or the environment.
 Comply with all project and operational environmental policies and principles.
 If an unauthorized person observed in project and operational area, inform Site
manager immediately.
 Be careful about dangerous animals that may be present in the project/operation area,
especially at night.
 The hunting of animals by operational Personnel or their Contractors is strictly
prohibited.

15.6 Pollution Prevention

 Avoid the unnecessary usage of equipment, vehicles and machines.
 Ensure your equipment is maintained and clean.
 Do not cause concrete spills onto the roads and ground.
 Clear spilled concrete immediately.
 Do not light a fire.
 Keep spill response kit ready.
15.7 Waste Management
Waste segregation at source before disposing into our different waste bins is a central to our waste
management drive. Segregate all wastes (clinical wastes, paper and cards, plastics, metals, etc.) and
keep them in the containers, which are clearly identified.
Hazardous wastes are to be handled by approved persons.

15.8 Oil Spill management and Response

Response to all kinds of spill is prompt and must be done in the safest way possible using the right
kit. Metals must not be used for spill control and management especially when a hazardous
substance is involved. If you observe any spill or leakage, immediately inform your supervisor.
Remove leaking or empty oil drums from the site immediately.

ACKNOWLEGDEMENT
I acknowledge that I have read and understood the content of this handbook and will abide by it.
Name of Employee:______________________________________________________________
Department:___________________________________________________________________
Signature:__________________________________ Date:_________________________