PCD 342:2022  
 
 
 
 
 
 
 
 
 
 
DRAFT ZANZIBAR  NATIONAL  STANDARD  
 
 
Occupational safety for onshore oil and gas exploration 
and production operations — Requirements  
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
ZANZIBAR BUREAU OF STANDARDS  
 
 
©ZBS 2022 - All rights reserve d               First  E dition 
 
 
                                                                                                 PCD 342:2022  
                                                                ICS:13.100    
 
 
 
 
                                                                                                                   
 
                             
 
           PCD 342:2022  
 
©ZBS 2022 - All rights reserved  ii 
 Contents   
Foreword ................................ ................................ ................................ ..............  Error! Bookmark not defined.  
Introduction  ................................ ................................ ................................ ................................ ..........................  iv 
1 Scope  ................................ ................................ ................................ ................................ ............................  1 
2 Normative references  ................................ ................................ ................................ ................................ .... 1 
3 Terms and definitions  ................................ ................................ ................................ ................................ .... 1 
4 Safety  ................................ ................................ ................................ ................................ ............................  4 
4.1 Safety practices  ................................ ................................ ................................ ................................ .... 4 
4.2 Hazard communication  ................................ ................................ ................................ .........................  5 
4.3 Housekeeping  ................................ ................................ ................................ ................................ ....... 8 
4.4 Machinery and tools  ................................ ................................ ................................ .............................  9 
4.1 Welding and cutting equipment  ................................ ................................ ................................ ............  9 
4.2 Contractor safety and training  ................................ ................................ ................................ ............  10 
5 Safe work practices  ................................ ................................ ................................ ................................ ..... 11 
5.1 Load lifting  ................................ ................................ ................................ ................................ ..........  11 
5.2 Confined space, excavations, and hazardous environments  ................................ .............................  11 
5.3 Lockout/tag out  ................................ ................................ ................................ ................................ ... 12 
5.3.1  Gene ral ................................ ................................ ................................ ................................ ...........  12 
5.3.2  Well pumping units  ................................ ................................ ................................ .........................  13 
5.4 Hot work, welding, and flame cutting operations  ................................ ................................ ................  13 
5.4.1  General  ................................ ................................ ................................ ................................ ...........  13 
5.5 Work in proximity to exposed energized power sources  ................................ ................................ .... 15 
6 Design  ................................ ................................ ................................ ................................ .........................  16 
6.1 Emergency eye or body wash stations  ................................ ................................ ...............................  16 
6.2 Critical equipment  ................................ ................................ ................................ ...............................  16 
6.3 Chan ges to critical equipment  ................................ ................................ ................................ ............  16 
6.4 Fire prevention  ................................ ................................ ................................ ................................ .... 16 
6.1 Fire protection  ................................ ................................ ................................ ................................ ..... 17 
6.2 Grounding and bonding  ................................ ................................ ................................ ......................  17 
6.3 Flammable liquids  ................................ ................................ ................................ ...............................  17 
6.3.1  Containers  ................................ ................................ ................................ ................................ ...... 17 
6.4 Equipment  ................................ ................................ ................................ ................................ ...........  19 
6.4.1  Generators, motors, and lighting  ................................ ................................ ................................ .... 19 
6.4.2  Electrical systems  ................................ ................................ ................................ ...........................  20 
6.4.3  Classification of areas  ................................ ................................ ................................ ....................  20 
6.4.4  Tanks, separators and heater treaters  ................................ ................................ ...........................  20 
6.4.5 Vapour recovery systems  ................................ ................................ ................................ ...............  20 
7 Training  ................................ ................................ ................................ ................................ .......................  21 
8 Procedures  ................................ ................................ ................................ ................................ ..................  21 
Well Start -up ................................ ................................ ................................ ................................ ...................  21 
8.1.1  General  ................................ ................................ ................................ ................................ ...........  21 
8.1.2  Design review  ................................ ................................ ................................ ................................ . 21 
8.1.3  Pressu re relief  ................................ ................................ ................................ ................................ . 21 
8.1.4  Start -up procedures  ................................ ................................ ................................ ........................  21 
8.1.5  Training of employee and contractor personnel  ................................ ................................ .............  23 
9 Maintenance  ................................ ................................ ................................ ................................ ................  23 
9.1 General  ................................ ................................ ................................ ................................ ...............  23 
9.2 Tank cleaning  ................................ ................................ ................................ ................................ ..... 23 
9.3 Drilling and well servicing  ................................ ................................ ................................ ...................  23 
10 Incident investigation  ................................ ................................ ................................ ..............................  23 
11 Emergency response  ................................ ................................ ................................ ..............................  23 
11.1 General  ................................ ................................ ................................ ................................ ...............  23 
11.2 Medical services  ................................ ................................ ................................ ................................ . 24 
11.3 First aid  ................................ ................................ ................................ ................................ ...............  24 
12 Special operations  ................................ ................................ ................................ ................................ .. 24 
12.1 Well testing  ................................ ................................ ................................ ................................ .........  24 
12.2 Pumping and hot oil operations (flo w lines)  ................................ ................................ ........................  24 
12.3 Pigging operations  ................................ ................................ ................................ ..............................  25 
12.4 Hot tapping on equipment in service  ................................ ................................ ................................ .. 26 
  
 
PCD 342:2022  
 
iii ©ZBS 2022 - All rights reserved  
 Foreword  
 
This draft Zanzibar National standard has been developed by Environmental and Risk Management 
Technical Committee (TCE3). In accordance with ZBS general procedures, this draft standard is 
presented to the public in order to receive any technical and editori al comment concerns.  
 
Technical Committee Representatives  
 
This Draft Zanzibar National Standard was prepared by Environmental and Risk Management Standards 
Technical committee which consist of representatives from the following organizations:  
 
Zanzibar En vironmental Management Authority (ZEMA)  
Department of Environment (DoE)  
Tanzania Atomic Energy Commission (TAEC)  
Education for Development (E4D)  
Zanzibar Upstream Regulatory Authority (ZPRA)  
Ministry of Health (MoH)  
Directorate of Occupational Safety and H ealth (DOSH)  
State University of Zanzibar (SUZA)  
Zanzibar Bureau of Standards (ZBS) -Secretariat  
 
 
 
 
 
Zanzibar Bureau of Standard (ZBS)  
P.O.Box 1136  
Zanzibar  
Tel:  +255 24 2232225  
Fax: +255 24 2232225  
E-mail: info@zbs.go.tz  
Web: www.zbs.go.tz  
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
  
 
           PCD 342:2022  
 
©ZBS 2022 - All rights reserved  iv 
 Introduction  
 
The requirements in this Zanzibar National  Standard are intended to ensure that the oil and gas 
industry implements occupational safety practices concentrating on personal protection and safe 
workplace, to include: owners, op erators, contractors, and service providers during oil and gas 
exploration  and production operations . 
 
  
 
 
PCD 342:2022  
1 ©ZBS 2022 - All rights reserved  
 Occupational safety for onshore oil and gas production 
operations — Requirements  
1 Scope  
 
This Zanzibar National Standard covers occupational safety prac tices that apply to oil and gas 
exploration and production operations during drilling, well servicing and work over operations to 
ensure occupational safety of personnel within the oil and gas sector and/or industry.  
 
2 Normative references  
 
The following re ferenced documents are indispensable for the application of this document. For dated 
references, only the edition cited applies. For undated references, the latest edition of the referenced 
document (including any amendments) applies.  
 
ISO 1996 (Part 1),   Acoustics — Description, measurement and assessment of environmental noise 
— Part 1: Basic quantities and assessment procedures  
 
ISO 1996  (Part 2),    Acoustics — Description, measurement and assessment of environmental noise 
— Part 2: Determination of soun d pressure levels  
 
ISO 4007, Personal protective equipment — Eye and face protection — Vocabulary  
 
ISO 20345, Personal protective equipment — Safety footwear  
 
ISO 20346, Personal protective equipment — Protective footwear  
 
ISO 20347, Personal protective eq uipment — Occupational footwear  
 
ZNS 216, Liquefied  petroleum gas (LPG) — Specification  
 
3  Terms and definitions  
 
For the purposes of this standard, the following terms and definitions shall apply.  
 
3.1  
adequate ventilation   
ventilation (natural or artificial)  that is sufficient to prevent the accumulation of significant quantities of 
vapour -air mixtures in concentrations above 10 % of their lower explosive limit (LEL). Adequate 
ventilation is for the pr evention of fire and explosions  
 
3.2  
authorized person   
quali fied person assigned by an employer to perform or supervise the performance of a specific type 
of duty or duties at the work site  
 
3.3  
cellar   
excavation around the wellhead to provide space for items of equipment at the top of the wellbore  
 
3.4  
Christmas tree  
valves and fittings assembled at the top of a completed well to control the flow o f hydrocarbons and 
other fluids  
 
 
  
 
           PCD 342:2022  
 
©ZBS 2022 - All rights reserved  2 
 3.5   
combustible liquid   
any liquid having a flash -point at or above 37.78 o C 
 
3.6  
contractor   
any person or company that contracts or subcontrac ts to perform all or any part of oil and gas well 
production operations  
 
3.7  
critical equipment   
equipment and other systems determined to be essential in preventing the occurrence of, or mitigating 
the consequences of an uncontrolled event  
 
3.8  
electrical class ification of areas   
classified locations  
 
3.9  
flammable liquid  
any liquid  whose flash point does not exceed 37 °C  
 
3.10  
full body harness   
straps which may be secured about a person in a manner that will distribute the fall arrest forces over 
at least the thighs,  pelvis, waist, chest, and shoulders, with means for attaching it to other components 
of a personal fall arrest system  
 
3.11  
guarded   
covered, shielded, fenced, enclosed, or otherwise protected by means of suitable covers or casings, 
barrier rails, or screens to eliminate the possibility of accidental contact with or dangerous approach 
by persons, animals, or objects  
 
3.12  
hazardous substance   
any substance that, by reason of being explosive, flammable, toxic, corrosive, oxidizing, irritating, or 
otherwise harmful,  has the potential to cause injury, illness, or death  
 
3.13  
hot oil treatment   
process of heating oil and pumping it into piping, tubing, casing, or a formation to remove paraffin and 
asphaltenes  
 
3.14  
hot tapping (pipe tapping)   
process of drilling a hole through  the wall of pipe that is under pressure. A special saddle is used to 
attach a valve and lubricator to the pipe.  
 
3.15   
hot work  
work involving electric or gas welding, cutting, brazing, grinding or similar flame or spark producing 
operations  
 
 
  
3 ©ZBS 2022 - All rights reserved  
 3.16  
lanyard   
flexible line of rope, wire rope, or strap which generally has a connector at each end for connecting the 
body belt or body harness to a deceleration device, lifeline or anchorage  
3.17   
lockout/tag out   
procedure to control hazardous energy  
 
3.18  
operator   
entity resp onsible for managing operations in a field or undeveloped acreage position  
 
3.19  
Person  
Including individual whether acting in public or private capacity, a group of individuals, a community ,a 
judicial , a government institution or government corporate body  
 
3.20  
Personal Fall Arrest System (PFAS)   
system designed to provide protection to a person from falls. The PFAS should consist of an 
anchorage, connector and a synthetic webbing full body harness which may include a lanyard and a 
deceleration device.  
 
3.21  
Persona l Protective Equipment (PPE).   
includes all equipment, (including clothing affording protection against the weather) which is intended 
to be worn or held by person and which protects against one or more risks to health or safety  
 
3.22  
pumping unit  
surface equi pment used for the purpose of mechanically lifting fluids from a well  
 
3.23  
qualified person   
in respect of a specified duty, a person who, because of his knowledge, training and experience, is 
qualified to perform that duty safely and properly  
 
3.24  
rated working  pressure   
maximum internal pressure that equipment is designed to contain and/or control. Working pressure is 
not to be confused with test pressure.  
 
3.25   
simultaneous operations   
two or more of the following activities being performed in close proximity: pr oduction, drilling, and 
completion, work over, wire line (except routine operations), major construction operations, well 
testing and maintenance  
 
3.26  
supervisor   
person who has been given the control, direction, or supervision of work performed by one or mor e 
personnel  
 
3.27  
well servicing   
well work involving pulling or running tubulars or sucker rods, to include but not limited to re -drilling, 
completing, recompleting, work -over, and abandoning operations   
 
           PCD 342:2022  
 
©ZBS 2022 - All rights reserved  4 
 4 Safety  
4.1  Safety practices  
 
4.1.1  Personnel shall be properly tr ained in relation to their job duties. Additionally, pre -job safety 
meetings that include all affected personnel, including contractors, shall be held to review 
responsibilities for the operation(s) to be performed.  
 
4.1.2   Personnel shall receive instruction in  correct work methods to reduce chance of injury to 
themselves or fellow personnel.  
 
4.1.3  A safety program shall be established and maintained. The following elements shall be 
considered when developing a comprehensive safety program:  
 
a) confined space entry;  
 
b) contractor safety;  
 
c) electrical safety;  
 
d) emergency response;  
 
e) fire prevention and protection;  
 
f) first aid;  
 
g) general safety rules;  
 
h) hazard communication;  
 
i) hazardous environment;  
 
j) hot working/welding;  
 
k) housekeeping;  
 
l) hydrogen sulphide and sulphur dioxide;  
 
m) evacu ation plan ; 
 
n) lockout/tag out;  
 
o) other equipment safety (hoists, cranes, elevators, escallator etc);  
 
p) periodic reviews;  
 
q) personal protective equipment;  
 
r) personnel training;  
 
s) production equipment safety;  
 
t) roles and responsibilities;  
 
u) safe use of hand tools;  
 
v) safety meetings;  
  
5 ©ZBS 2022 - All rights reserved  
 w) transportation;  
 
x) trenching and excavation; and  
 
y) Pressure vessels  
 
4.1.4  Unsafe and potentially dangerous conditions shall be eliminated immediately, if possible, or 
reported to the supervisor in charge for corrective action.  
 
4.1.5  The off going sup ervisor shall inform the incoming supervisor of any known special hazards or 
work in progress that may affect the safety of the crew. Incoming personnel shall be alerted to work in 
progress that could affect their safety.  
. 
4.2 Hazard communication  
 
4.2.1  A hazard c ommunication program that evaluates the presence and potential hazards of 
chemicals found in the workplace shall be established for onshore oil and gas exploration and 
production operations. Workers shall be provided with information concerning the hazard of chemicals 
and appropriate measures to protect themselves while working with hazardous chemicals.  
 
4.2.2  The program shall be written and include information about hazard evaluation, labelling, 
material safety data sheets, employee training and methods to revi ew and update changes in the 
program based on chemical usage.  
 
Elements of a program include:  
 
a) hazard evaluation and inventory of all the hazardous chemicals in the work area shall be 
completed. An evaluation of the potential hazard of a chemical shall be conducted before the 
hazardous chemical is handled;  
 
b) generally applicable measures including engineering controls, safe work practices and PPE 
shall be considered for safe handling and use of a hazardous chemical. This information shall be 
communicated to the workers, contractors and the general public;  
 
c) a labelling system shall be developed that warns of the potential hazards of working with a 
hazardous chemical;  
 
d) hazardous chemicals shall identify (at minimum) the material or substance and the physical an d 
health hazards;  
 
e) Material Safety Data Sheet (MSDS). Chemical manufacturers are normally responsible for 
developing MSDSs;  
 
f)  a MSDS shall be available and readily accessible for each hazardous chemical used in the 
workplace. A system to collect, maintain and inform workers about the chemical hazard information 
found on a MSDS shall be part of the program;  
 
g) personnel shall be provided with hazard communication training upon:  
 
i) initial assignment to a work area;  
 
ii) when a new chemical has been introduced; and  
 
iii) a new physical or health hazard has been identified or a process change has occurred that 
involves a hazardous chemical;  
 
At minimum the training shall include:  
  
 
           PCD 342:2022  
 
©ZBS 2022 - All rights reserved  6 
 i) information regarding the method and observations  that can be used to detect the presence of 
a release of a hazardous chemical in the work area;  
 
ii) physical and health hazard information;  
 
iii) measures to protect the worker from harmful exposure, including, engineering control, safe 
work practices, emergency procedures, PPE use, etc.; and 
 
iv) specific deta ils on how to recognize and understand labels in the work area, MSDS 
interpretation, and safe procedures when working with hazardous chemicals. Non -routine task 
special considerations shall be developed to handle non -routine work (for example, upset or 
emergency conditions, cleaning out vessels);  
  
h) contractors hazard communication information shall be shared with contractors and their 
employees.  
 
4.3  Personal Protective Equipment (PPE)  
 
4.3.1  General  
4.3.1.1  Employers shall assess their work sites to evaluate the types of h azards present at their 
onshore oil and gas   exploration and production operations. When it is impractical to reduce a hazard 
to acceptable levels by administrative or engineering controls, personal protective equipment 
appropriate for the hazard shall be  selected for use.  
 
4.3.1.2  Personal protective equipment for hearing, eyes, face, head, extremities, protective clothing, 
respiratory protection and fall protection shall be considered for use to protect personnel.  
 
4.3.2  Wearing apparel  
 
4.3.2.1  When identified as part of the  employer’s PPE assessment, a safety hard hat shall be worn by  
each person in the work area.  
4.3.2.2  Eye protection equipment appropriate for the work being done shall be worn by personnel 
where there is a reasonable probability of injury to the eyes from flying objects, chemicals, or injurious 
light or heat that can be prevented by such equipment. This protective equipment shall meet the 
requirements of  ISO 4007.  
4.3.2.3  When identified as part of the employer’s PPE assessment, safety shoes, safety boots, or toe 
guards shall be worn. Safety -toe footwear shall meet the requirements of  ISO 20347 and  ISO 20345.  
4.3.2.4  The employers PPE assessment shall include possible chemical exposures that may 
necessitate the use of gloves, aprons, boots, or other protective equipment, as app ropriate. The 
assessment shall also evaluate the need for gloves or other protective clothing to provide protection 
from temperature extremes or sharp objects.  
4.3.2.5  Appropriate clothing shall be worn at all times. Loose or poorly fitted clothing shall not be 
worn. 
 
4.3.2.6  Personnel shall not work in clothing that is saturated with any flammable, hazardous, or irritating 
substance(s).  
 
4.3.2.7   Personnel shall not wear jewellery or other adornments subject to snagging or hanging and 
causing injury while in the work area.  
 
4.3.2.8  Perso nnel with hair of such length as to be a hazard in work areas should keep it contained in 
a suitable manner while performing their duties. Hair and beard styles shall not interfere with the  
7 ©ZBS 2022 - All rights reserved  
 effective functioning of head, eye, face, or respiratory protectiv e equipment, if such equipment is 
required at the work site.  
 
4.3.2.9  Personnel working over or near water where a danger of drowning exists shall be provided 
with approved personal floatation devices in serviceable condition.  
 
4.3.3  Hearing protection  
 
4.3.3.1  Protection again st the effects of noise exposure shall be provided when the sound levels 
exceed those shown in Table 1 (for guidance on measuring sound levels, see ISO 1996 (Part 1 and 
2). 
4.3.3.2  When personnel are subjected to sound levels exceeding those listed in Table 1, fea sible 
administrative or engineering controls shall be utilized. If such controls fail to reduce sound levels 
within the levels of Table 1, personal protective equipment shall be provided and used to reduce 
sound levels within the levels of the table.  
 
 
Table 1 :  Maximum permissible noise exposures   
Duration per day,  Sound levels dBA slow  
h response  
 
  
12 85 
  
8 90 
  
6 92 
  
4 95 
  
3 97 
  
2 100 
  
1½ 102 
  
1 105 
  
½ 110 
  
¼ or less  115 
  
 
4.3.3.3  Employers shall implement the elements of a hea ring conservation program as appropriate to 
protect the hearing of personnel.  
 
When the daily noise exposure is composed of two or more periods of noise exposure of different levels, 
their combined effect shall be considered rather than the individual effe ct of each. Exposure to impulsive or 
impact noise shall not exceed 140 dBA peak sound pressure level.  
 
4.3.4  Respiratory protection  
4.3.4.1  An assessment of the work area shall be done to identify the potential hazards that may 
require respiratory protection. Employees shall wear respiratory protection appropriate for potential 
workplace atmospheric hazards.  
  
 
           PCD 342:2022  
 
©ZBS 2022 - All rights reserved  8 
 4.3.4.2   For respiratory protection practices, including equipment selection, use medical surveillance, 
fit testing, storage, inspection, maintenance and training.  
 
4.3.4.3  Tight -fitting air purifying respirators shall be used only in areas where sufficient oxygen exists.  
 
4.3.4.4  Approved self -contained or supplied -air breathing equipment shall be used for those 
atmospheres where tests indicate toxic or hazardous gases are present in quant ities immediately 
dangerous to life or health (IDLH) or oxygen content is less than necessary to sustain life. Air from the 
utility system shall not be used as the source for breathing air supply.  
4.3.4.5  Cartridge type respirators shall not be used for protection  from hydrogen sulphide or sulphur 
dioxide.  
4.3.4.6  Personnel who may be expected to use breathing equipment shall be trained in the use and 
operation of breathing equipment available at the work site. Personnel shall be advised of the potential 
dangers of flammab le, hazardous, and insufficient oxygen atmosphere while conducting oil and gas 
producing and gas processing plant operations involving hydrogen sulphides.  
 
4.4 Fall protection  
 
All personnel, when engaged in work 1.8 m or higher above the ground or adjacent wo rking surfaces, shall 
be protected at all times from falling by guardrail systems, safety net systems, or personal fall arrest 
systems (PFAS). When the employer can demonstrate that it is unfeasible or creates a greater hazard to 
use these  systems, the emp loyer shall develop and implement an alternative fall protection plan that 
provides for personnel safety. When PFAS are used, the following shall apply : 
 
a) personnel shall use a full body harness;  
 
b) PFAS shall be inspected prior to each use;  
 
c) the full body ha rness shall be attached by means of a lanyard with double -locking snap -hooks 
to an anchor or structural member capable of supporting a minimum dead weight of 2 450 kg;  
 
d) a separate lanyard shall be used by each person requiring lanyard;  
 
e) the lanyard shall b e adjusted to permit a maximum drop of 1.52 m case of a fall; and  
 
f) the manufacturer’s instructions for inspection and replacement of PFAS shall be followed.  
 
4.5 Housekeeping  
 
4.5.1  Work areas shall be maintained clean and free of debris and tripping hazards.  
 
4.5.2  Leaks  or spills shall be promptly cleaned up to eliminate personnel slipping and fire hazards.  
 
4.5.3  If personnel are required to work in a cellar, it shall be kept reasonably clear of water or oil 
accumulation. No loose equipment or materials shall be in the cellar  except those in use or about to be 
used.  
 
4.5.4  Care shall be taken to leave egress routes open.  
 
4.5.5  Tools and equipment shall be securely placed and stored in a position or manner so they will 
not fall.  
  
9 ©ZBS 2022 - All rights reserved  
 4.5.6  Clear access to control devices, emergency shutdown system,  emergency equipment, etc shall 
be maintained.  
 
4.6 Machinery and tools  
 
4.6.1  Personnel shall only operate machinery that they are qualified to operate.  
 
4.6.2   All belts drive chains, gears, and drives shall have guards installed to prevent personnel from 
coming in cont act with moving parts.  
 
4.6.3  Machinery shall not be operated unless all guards are in position and are in properly maintained 
condition. During maintenance or repair work limited operation of the equipment can be done during 
testing by qualified personnel witho ut guards in place.  
 
4.6.4   Maintenance personnel shall report to the supervisor prior to beginning repairs. They shall 
report hazards that may be introduced. They shall report when repairs are completed.  
 
4.6.5  Personnel shall not clean, lubricate, or repair any mach inery where there is a hazard of contact 
with moving parts until such machinery has been stopped or such parts have been properly guarded 
(see lockout/tag out).  
 
4.6.6  Hand power tools and similar equipment shall be maintained in a safe condition.  
 
4.6.7  Electric hand  tools shall be double insulated or grounded.  
 
4.6.8  Electric or pneumatic hand tools shall be arranged so that the starting switch cannot be locked 
in. 
 
4.6.9  When personnel are climbing ladders, any tools or other such materials they are carrying should 
be secured r ather than hand held.   
 
4.7 Welding and cutting equipment  
 
4.7.1  Apparatus such as torches, regulators, hoses and arc welding machines shall be in good 
operating condition and repair. Only approved oxygen and acetylene cylinders shall be used.  
 
4.7.2  Oxygen and acetylene torches shall be equipped with flash -back arrestors.  
 
4.7.3  All cylinders shall be equipped with a valve protection cap, a collar, or recess to protect the 
valve.  Valve caps should be in place except when cylinders are connected for use.  
 
4.7.4  Cylinders should be sto red in assigned places and shall be secured to prevent accidental 
overturning.  
 
4.7.5  Cylinders shall not be kept in unventilated enclosures, such as lockers and cupboards.  
 
4.7.6  Oxygen cylinders in storage shall be separated from fuel gas cylinders or combustible ma terials 
a minimum distance of 6.1m or by a non-combustible  barrier at least 1.52 m high.  
 
4.7.7  Acetylene cylinders shall be stored valve end up with protective caps affixed and properly 
secured. When a job using acetylene devices is completed or prior to transp orting acetylene cylinders, 
the valve on the acetylene cylinder shall be closed and pressure on the hoses bled to zero.  
  
 
           PCD 342:2022  
 
©ZBS 2022 - All rights reserved  10 
 4.7.8  When transporting cylinders by a crane or derrick, a cradle, bin, or other suitable platform shall 
be used. Slings alone shall not be u sed on a cylinder being transported or lifted. Also, cylinders shall 
not be dropped, struck, or permitted to strike each other.  
 
4.7.9   On arc welding machines, the control apparatus shall be enclosed except for the operating 
wheels, levers, or handles.  
 
4.7.10    Input  power terminals, top charge devices, and electrically energized metal parts shall be 
completely enclosed and accessible only by means of tools.  
 
4.7.11   Terminals from welding leads shall be protected from accidental contact by personnel or 
metal objects.  
 
4.7.12   The frame or case of an electrically driven arc welding machine shall be grounded.  
 
4.7.13   Cables with splices within 3.1 m of the rod holder shall not be used. The welder shall not coil or 
loop welding electrode cables around parts of his body.  
 
4.8 Contractor safety a nd training  
 
4.8.1  When selecting contractors, operators shall obtain and evaluate information regarding a 
contractor’s safety policies and practices, and performance there under, and the contractor’s 
procedures for selecting subcontractors.  
 
4.8.2  Contractors shall t rain their personnel in the work practices necessary to perform their jobs in a 
safe manner.  
 
4.8.3  The training provided to contract personnel shall include applicable site specific safety 
procedures and rules pertaining to the facility and the applicable provi sions of emergency action plans. 
This section applies to contractors performing operating duties, maintenance or repair, turnaround, 
major renovation, or specialty work at the facility.  
 
4.8.4  Except for transportation safety orientation, emergency evacuation tr aining, and other 
applicable safety training, this sub -clause does not apply to contractors providing incidental services 
that do not influence operation of the facility, such as, janitorial work, food and drink services, laundry, 
delivery, other supply se rvices, etc.  
 
  
4.8.5  The operator shall verify contractor training utilizing a variety of methods, which may include 
audits of the contractor’s safety training programs; worksite checks of individual contractor employees 
training; and operator observation of co ntractor work performance.  
 
4.8.6  A major step in achieving acceptable contractor performance is selecting a safe contractor. 
Therefore, it is appropriate for operators to request that contractors submit specific performance 
information in their contract respons e proposals.  
 
Such information shall include but not be limited to:  
 
a) assurance of a contractor’s written safety policies and practices endorsed by the contractor’s 
top management;  
 
b) a statement of commitment by the contractor to comply with all applicable s afety regulations 
and provisions of this standard;  
 
c) recordable injury and illness experience for the previous three years;  
  
11 ©ZBS 2022 - All rights reserved  
 d) experience Modification Rates (EMR) for Worker’s Compensation Insurance for the previous 
three years;  
 
e) an outline of the contractor’ s initial employee safety orientation;  
 
f)  evidence of the existence of a disciplinary action procedure dealing with safety and 
environmental related infractions;  
 
g) descriptions of the contractors various safety programs, including: accident investigation 
procedures; how safety inspections are performed; safety meetings; safety incentive programs; 
substance abuse prevention programs; and  
 
h) description of the safety and environmental training that each contractor employee has received 
and the contractor’s progra ms for refresher training.  
5 Safe work practices  
5.1 Load lifting  
 
The manufacturers rated load capacity shall not be exceeded on cranes or other load lifting devices. 
This equipment should be operated and maintained in accordance with manufacturers 
recommendati ons. Tag lines should be used to guide and steady all loads being lifted. Lifting 
machines should be periodically inspected and the report should be in place,  date of  next inspection 
should be attached on the machine.  
5.2 Confined space, excavations, and haz ardous environments  
 
5.2.1   Where hydrogen sulphide, sulphur dioxide, carbon dioxide or other hazardous atmosphere is 
known or suspected to exist, the operator shall ensure that personnel, contractor, and service 
company supervisors are advised of the potential hazards.  
 
5.2.2  A confined space is an area which:  
 
a) has adequate size and configuration for people to enter;  
 
b) has limited means of entry or exit; and  
 
c) is not designed for continuous employee occupancy.  
 
5.2.3  Examples of confined spaces that can be found at onshore pr oducing facilities are:  
 
a) well cellars;  
 
b) electrical vaults;  
 
c) fin fan coolers;  
 
d) tanks;  
 
e) vessels;  
 
f) some diked areas;  
 
g) valve pits;  
 
h) sewage;  
 
i)  tunnels ;  and  
  
 
           PCD 342:2022  
 
©ZBS 2022 - All rights reserved  12 
 j)  pipes  
 
5.2.4   Confined space hazards shall be identified for all facilities in the workplace and safe work  
practices shall be established for working in the confined spaces.  
 
5.2.5   A confined space entry permit shall be used to enter any confined space that has atmospheric, 
engulfment or configuration hazards. Attendant and emergency rescue services shall be provid ed for 
all permit required confined spaces.  
 
5.2.6   When preparing the confined space for entry, precautions shall be in place to ensure the space 
remains safe. This may include forced air ventilation, equipment isolation or other measures. For 
equipment isolati on, consideration should be given to blinding, double block and bleed, or other 
equipment and energy isolation controls.  
 
5.2.7   When operations require excavating and preparing trenches, persons shall be knowledgeable 
regarding the hazards and precautions neces sary for preparing and working in trenches.  
 
5.2.7.1   When preparing an excavation, consider the hazards of underground installations. These 
include electrical equipment, oil and gas transmission, sewers, water lines, telephone lines and other 
utilities.  
 
5.2.7.2  Any tren ch or greater in depth is usually considered a confined space. Entry into these spaces 
shall be controlled by special safety procedures where oxygen deficient (low oxygen) or toxic gas 
hazards can reasonably be expected, such as near landfills or near wher e hazardous materials are 
used or stored. There is concern that heavy gases can collect inside a trench.  
5.2.7.3  Vehicle traffic and falling loads vehicles on nearby roadways and construction equipment can 
present hazards at an excavated site. Ensure that barricad es and warnings are in place. Construction 
equipment shall not lift material over people in the trench or excavation. The soil from the trench is 
also a hazard to personnel inside the trench, for this reason it shall be piled at least 0.6 m from the 
edge o f the trench.  
 
5.2.7.4  Before beginning an excavation consideration shall be given to nearby buildings, light poles or 
other structures in the area to ensure their stability. Additional support, installed by professionals, may 
be needed.  
5.2.7.5  Escape means from trenches  a stairway; ladder or ramp shall be located in any trench that is 
at least 1.2 m deep. The escape means shall be placed so that a person is never more than 7.6 away 
from an escape means.  
5.2.7.6  A qualified person shall inspect the trench at least daily and more frequently if needed, such 
as after a rainstorm or other hazardous occurrence.  
5.2.7.7  Any trench 1.52 m or deeper, that is not in entirely stable rock, shall be sloped or shored in 
accordance with recognized engineering practices to prevent cave -ins. 
5.3 Lockout/tag out 
 
5.3.1  General  
 
A lockout/tag out program shall be established to control hazardous energy as follows:  
 
a) locks and/or tags shall be placed to plainly identify the equipment or circuits being worked on. 
Systems locked or tagged shall include the identity or jo b title of person installing the lock or tag;  
 
b) personnel shall be trained and disciplined in the use of this system to prevent unexpected 
operation of any equipment that stores any type of energy that might inflict injury to personnel; and   
13 ©ZBS 2022 - All rights reserved  
  
c) the lock or tag  shall be removed by the person who installed it. In the event the individual is not 
available, the lock or tag may be removed by the supervisor after ensuring that no hazard will be 
created by energizing the locked or tagged equipment or circuit(s).  
5.3.2  Well pumping units  
5.3.2.1  Power to the pumping unit shall be de -energized and locked or tagged out to eliminate 
potential hazards during well servicing operations. In confined locations, overhead electric power to 
the pumping unit control panel should be de -energized.  Where necessary, power service should be 
de-energized while moving the rig in or out and during rig -up and rig -down operations (see lockout/tag 
out). 
 
5.3.2.2  During well servicing operations, the pumping unit shall be secured to prevent unintended 
movement. Use of the brake only or the brake and brake pawl are not acceptable means of securing 
the pump unit . 
5.3.2.3  Chain or wire rope sling of suitable strength should be used to handle the horse head if 
removal or installation operations are necessary. On installation, th e horse head shall be bolted or 
latched in accordance with the manufacturer specifications.  
5.3.2.4  Upon completion of well servicing operations and before energizing the power source, 
precautions shall be taken to ensure that all personnel and equipment are clear  of the weight and 
beam movement.  
 
5.3.2.5   Brake systems on all pumping units in service shall be maintained in safe working order.  
 
5.3.2.6  After well servicing operations are completed all pumping unit guards and enclosure guards 
(belt and motor sheaves) shall be reins talled prior to start -up. Guards need not be in place until all final 
adjustments (pump, spacing, etc.) are made, so long as the safety of personnel is not compromised.  
5.4 Hot work, welding, and flame cutting operations  
 
5.4.1  General  
 
5.4.1.1  A written safe work permit (h ot work permit) system covering welding and flame cutting 
operations shall be observed. In general, a safe work permit system shall consist of authorization to do 
the work along with the following:  
 
a) simultaneous operations;  
 
b) air/gas testing;  
 
c) equipment iso lation;  
 
d) equipment preparation;  
 
e) identification of hazards;  
 
f)  emergency procedures;  
 
g) work -in-progress stage;  
 
h) posting of permit;  
 
i) air/gas testing;  
 
j) personal protective equipment requirements;   
 
           PCD 342:2022  
 
©ZBS 2022 - All rights reserved  14 
  
k) fire watch; and  
 
l) special procedures/precautions.  
 
5.4.1.2  The superviso r shall hold a pre -job meeting with the crew and other involved persons to 
review responsibilities for the operation to be performed.  
5.4.1.3  Welding and flame cutting operations shall not be permitted close to flammable liquids, 
accumulations of crude oil, escapi ng gas, or locations where sparks, flames, heat, or hot slag could be 
sources of ignition.  
5.4.1.4  Only qualified persons shall perform welding or flame cutting operations on equipment used to 
contain hydrocarbons or hazardous materials.  
5.4.1.5  Appropriate personal prote ctive equipment shall be utilized for hot work operations.  
 
5.4.2  Welding and flame cutting operations  
5.4.2.1  If the object to be cut or welded cannot readily be moved, all movable fire hazards in the 
vicinity shall be taken to a safe place.  
5.4.2.2  If the object to be welded or cut cannot be moved, and if all the fire hazards cannot be 
removed, guards shall be used to confine the heat, sparks, and slag and to protect the immovable fire 
hazards.  
5.4.2.3  A safe welding area may be designated. In this area, welding and flame cutting oper ations can 
be conducted with minimal concern of providing an ignition source for flammable hydrocarbons or 
combustible materials. A safety work permit is not normally required for welding operations in an 
approved safe welding area.  
5.4.2.4  Properly maintained fir e extinguishing equipment shall be available for immediate use. A dry 
chemical fire extinguisher shall be immediately available during welding or cutting operations. This 
equipment is in addition to the general fire protection equipment.  
5.4.2.5  Fire watches with extinguishing equipment shall be required whenever welding or cutting is 
performed in locations other than designated safe welding areas.  
5.4.2.6  A fire watch shall be maintained for at least one half hour after completion of welding or 
cutting operations.  
5.4.2.7  Before cutting or welding is permitted in areas outside a designated safe welding area, the 
area shall be inspected by the individual responsible for authorizing cutting or welding operations. This 
individual shall designate the precautions to be followed in gran ting authorization to proceed.  
5.4.2.8   Cutting or welding shall not be permitted in the following situations:  
 
a) in areas not authorized by the supervisor;  
 
b) in the presence of an explosive atmosphere;  
 
c) in areas near storage of large quantities of exposed readily -ignitable materials;  
 
d) where ignition can be caused by heat conduction, such as on metal walls or pipes in  contact 
with combustibles on the other side; and  
 
e) on used containers such as drums unless properly cleaned.  
  
15 ©ZBS 2022 - All rights reserved  
 5.4.2.9  Toxicity depends on the composition and con centration of the fumes. The composition and 
quantity of fumes depends on the materials being welded, the composition of the welding rods, any 
coatings or paints encountered in the welding operations, the process used, and the circumstances of 
use. Toxic f umes can be generated from welding on metals coated with or containing alloys of lead, 
zinc, cadmium, beryllium, and certain other metals. Some paints and cleaning compounds may also 
produce toxic fumes when heated. The potential health effects range in ty pe and severity, depending 
on these factors; and some effects can be extremely serious . 
5.4.2.10  Mechanical ventilation at the minimum rate of 0.944 m3/s  (2 0ft3/min) per welder shall be 
provided when welding:  
 
a) in confined spaces or where the welding space contain s partitions, balconies, or other 
structural barriers to the extent that they significantly obstruct cross ventilation;  
 
b) where the nature of the welding, cutting, or brazing work is such that the release of toxic 
fumes or gases is possible; and  
 
c) this inclu des work on stainless steel, zinc, lead, and degreasing or cleaning compounds 
containing hydrocarbons.  
5.4.2.11  Adherence to confined space entry procedures shall be followed prior to any re -entries. For 
example, releases from acetylene cutting equipment could chan ge the atmosphere within the confined 
space.  
5.5 Work in proximity to exposed energized power sources  
 
5.5.1  Neither equipment nor machines on rigs (includes guy lines) shall be operated closer to power 
lines than the recommended minimum clearances shown in Table 2,  except when such lines have 
been de -energized and visibly grounded or when barriers are present to prevent physical contact with 
the lines.  
 
Table 2: Recommended minimum clearances between power lines and derricks, masts, or guy 
lines   
Equipment  Line Volt age, Minimum clearance  
 V  
   
Operating  All 3.0 m. For each additional 10 kV over 50 kV  
   
In transit (lowered mast)  less than or equal to 50 kV  1.22 m  
   
 greater than 50 kV  1.22 m for every additional 10 kV  
   
 
 
5.5.2  An individual shall be designated  to observe equipment clearance as defined in Table 2. The 
operator shall notify the observer if he is having any difficulty in determining the clearance. The 
observer shall sound a warning at any time the clearance is not maintained.  
 
5.5.3  When cage -type boom guards, insulating guy lines, insulating links, or proximity warning 
devices on rigs or guy lines are used, the recommendations of Table 2 are applicable.  
  
 
           PCD 342:2022  
 
©ZBS 2022 - All rights reserved  16 
 5.5.4  Overhead wires shall be considered energized (live) unless either the electrical system owner 
report s them to be non -energized, or a qualified electrical person tests and finds them to be non -
energized.  
6 Design  
6.1 Emergency eye or body wash stations  
 
Where the eyes or body of personnel may be exposed to injurious materials, eyewash and shower 
equipment for e mergency use shall be provided.  
6.2 Critical equipment  
 
6.2.1  Critical equipment is defined as equipment and other systems determined to be essential in 
preventing the occurrence of, or mitigating the consequences of an uncontrolled event. Such 
equipment shall inclu de pressure vessels, pressure relief devices, compressors, alarms, interlocks, 
and emergency shutdown systems , boilers and lifting equipment . 
 
6.2.2  Critical equipment shall be periodically inspected and tested as recommended by the 
manufacturer   and the report should be in place, date of  next inspection should be attached on the 
machine (reports and checked see lifting equipment)  or in accordance with recognized engineering 
practices.  
 
6.2.3  When using non -destructive testing (NDT) methods, qualified persons shall co nduct the tests in 
accordance with recognized methodology and acceptance criteria . 
 
6.2.4  Other types of inspection should be conducted by qualified persons.  
 
6.2.5  When critical equipment is removed from service, a program shall be in place to ensure 
equivalent prote ction is provided.  
6.3 Changes to critical equipment  
 
Procedures to manage changes (except for replacements in kind) to critical equipment shall be 
implemented, as appropriate. These procedures should address the following prior to making the 
change:  
 
a) the basi s for the proposed change;  
 
b) impact of change on safety and health;  
 
c) modifications to operating procedures; and  
 
d) authorization requirements for the proposed change.  
 
Employees whose job tasks will be affected by the change in the critical equipment shall be  informed 
of the change prior to start -up. 
6.4 Fire prevention  
 
6.4.1  Safe storage and location of combustible and flammable materials and the prevention of 
accumulation of rubbish are important to fire prevention.  
  
17 ©ZBS 2022 - All rights reserved  
 6.4.2  Smoking shall be prohibited at or in the vicinity of operations that constitute a fire hazard. Such 
locations should be conspicuously posted with a sign, “NO SMOKING OR OPEN FLAME” or 
equivalent . 
 
6.4.3  Smoking shall be permitted only in areas designated for smoking.  
 
6.4.4  Change rooms and other buildings where smok ing is permitted shall be located in areas 
designated safe for smoking.  
 
6.4.5   No source of ignition should be permitted in an area where smoking has been prohibited, 
unless it is first determined safe to do so by the supervisor in charge or his designated repr esentative.   
. 
6.4.6  Potential sources of ignition shall be permitted only in designated areas located at a safe 
distance from the wellhead or flammable liquid storage areas.  
 
6.4.7  Equipment, cellars, ground areas around and adjacent to the facility shall be kept fre e from oil 
and gas accumulations that might create or aggravate fire hazards.  
 
6.4.8  Combustible materials such as oily rags and waste shall be stored in covered metal containers 
and the covers kept in place . 
 
6.4.9  Natural gas or liquefied petroleum gas shall not be used to operate spray guns or pneumatic 
tools.  
 
6.4.10   Material used for cleaning shall have a flash point of not less than 37.7 oC. 
 
6.5 Fire protection  
 
6.5.1  Firefighting equipment shall not be tampered with and shall not be removed for other than fire 
protection, Fire fighting purposes, and services. A firefighting water system may be used for wash 
down and other utility purposes so long as its firefighting capability is not compromised.  
 
6.5.2  Fire extinguishers and other firefighting equipment shall be suitably located, rea dily accessible, 
and plainly labelled as to their type and method of operation.  
 
6.5.3  Fire suppression equipment (extinguishers, fixed automatic systems, etc.) shall be periodically 
inspected and maintained in operating condition at all times. A record of the m ost recent equipment 
inspection shall be maintained.  
6.5.4  Portable fire extinguishers shall be tagged with a durable tag showing the date of the last 
inspection, maintenance, or recharge or accomplished using other acceptable recordkeeping media.  
6.5.5  Personnel shal l be familiar with the location of fire control and selected personnel trained in the 
use of such equipment. Firefighting equipment shall be accessible and free of obstructions.  
 
6.6 Grounding and bonding  
 
Production facilities are subject to various forms of electrical hazards that shall be protected against. 
Static electricity can be generated by fluid movement in vessels, piping and tankage. Results in static 
sparks being generated which can be an ignition source. Lightning strikes to a facility are also an 
ignition source. Electrical equipment failure can occur exposing personnel to shock hazards.  
 
6.7 Flammable liquids  
6.7.1  Containers  
  
 
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©ZBS 2022 - All rights reserved  18 
 6.7.1.1  Hand portable containers for storing flammable liquids shall be Underwriters Laboratories (UL) 
listed or Factory Mutual (FM) approve d, or equivalent.  
6.7.1.2  Tanks, drums, and other containers containing flammable liquids shall be properly labelled to 
denote their contents and shall be properly stored when not in use . 
6.7.1.3  Metal or other conductive material containers shall be used in handling, sto ring, or 
transporting flammable liquids. The handling of flammable liquids in plastic containers is potentially 
dangerous due to static charge build up.  
 
Metal parts on any plastic containers used in such service shall be bonded to the fill connection. If 
plastic containers are used, the conductive fill connection or a grounded rod should be inserted prior to 
filling the container with any flammable liquid.   
. 
6.7.2   Fuel and oil transfers and refuelling  
6.7.2.1   Hydrocarbon -fuelled engines shall be shut down during refu elling operations.  
6.7.2.2   Fuel tanks shall be monitored while they are being filled to prevent over fill and spillage.  
 
6.7.2.3  During refuelling operations, the filling nozzle shall be kept in contact with the intake pipe to 
ensure bonding and prevent fuel spillage.  
6.7.3   Liquefied Petroleum Gas (LPG) and compressed gas  
6.7.3.1  Handling, connecting, and transfer operations involving liquefied petroleum gas (LPG) shall 
conform to ZNS 216.  
6.7.3.2  Ignition source controls shall be established in any area where flammable or oxidizing 
compresse d gases are stored or used.  
 
6.7.3.3  Where compressed gas cylinders are designed to accept valve protective caps, the user shall 
keep such caps on compressed gas cylinders at all times except when being filled or connected for 
use. 
6.7.3.4  Where gas -tight valve outlet cap s or plugs are provided, the user shall keep such devices on 
the valve outlet at all times except when compressed gas cylinders are being filled or connected for 
use. 
6.7.3.5  Compressed or liquefied gas cylinders in use or in storage shall be secured to prevent th em 
from falling or being knocked over.  
6.7.3.6   Compressed gas cylinders shall be transported, stored and used in an upright position.  
6.7.3.7  Compressed gas cylinders exposed to fire shall not be used until they are re -qualified in 
accordance with the pressure vessel cod e under which they were manufactured.  
6.7.3.8  Containers that show denting, bulging, gouging, or excessive corrosion shall be removed from 
service . 
  
19 ©ZBS 2022 - All rights reserved  
 6.7.3.9  Repair or alteration of containers shall comply with the regulations, rules, or code under which 
the container was fabricated.  
6.7.3.10  Compressed gas cylinders shall be marked or labelled. Such markings or labels should not 
be removed.  
6.7.3.11  Compressed gas cylinders shall not be placed where they could become a part of an 
electrical circuit.  
 
6.7.3.12  Compressed gas cylinders shall not be ex posed to temperatures exceeding 51.67 oC. 
Cylinders shall not be subjected to direct heating to increase vapour pressure.  
6.7.3.13  Stoves and heaters used with LPG fuel only be used in well -ventilated areas. Personnel 
shall ensure proper ventilation exists before l ighting the heater/stove. All hoses and connections on 
LPG stove or heater systems shall be checked frequently to ensure they do not leak.  
 
6.7.3.14  Only qualified personnel shall be allowed to fill LPG bottles. Protective gloves should be 
worn when refilling or re placing LPG bottles. There is a possibility of freeze burns if propane comes in 
contact with skin.  
 
6.7.4   Storage  
6.7.4.1   Flammable liquids storage areas within any building or shed shall:  
 
a) be adequately vented;  
 
b) have unobstructed exit(s) leading from the building;  
 
c) be maintained with due regard to fire potential with respect to housekeeping and materials 
storage;  
 
d) be identified as a hazard and have appropriate warning signs posted;  
 
e) have a Class BC fire extinguisher readily available; and  
 
f) be properly classified for e lectrical installations.  
 
6.7.4.2  Paint and solvents shall be stored in an adequately vented area safely away from heat and 
ignition sources.  
6.7.4.3  Flammable liquids shall not be stored within 15.2 m of the wellbore, except for fuel in the tanks 
of operating equipment. Where terrain and location configuration do not permit maintaining this 
distance, equivalent safety measures shall be taken.  
 
6.8 Equipment  
6.8.1  Generators, motors, and lighting  
 
6.8.1.1   All electrical conductors and switch gear shall be sized.  
6.8.1.2  All generators shall have a n overload safety device that will provide protection from shorting 
and burnout.  
  
 
           PCD 342:2022  
 
©ZBS 2022 - All rights reserved  20 
 6.8.1.3  When adequate fixed illumination cannot be made available, temporary portable lights 
approved for the electrical classification shall be provided. Where possible, floodlights  in use shall be 
placed in positions so as not to impair vision of persons in the work area. Operations shall not be 
performed using vehicle headlights as a substitute for lighting.  
6.8.1.4  All electrical extension cords shall be properly insulated and plugs and r eceptacles shall be in 
good condition.  
 
6.8.1.5  Light fixtures shall be placed and maintained to provide illumination for work areas.  
 
6.8.1.6  Repairs to electrical equipment shall not be performed unless the power source has been 
isolated and the control has been locked out/tagged out, and the person making the repairs is 
authorized to do so.  
6.8.1.7   Electric motors, generators, and control panels shall be grounded.  
6.8.2  Electrical systems  
 
6.8.2.1  Electrical equipment used in hazardous locations shall be designed for such locations, and 
listed or approved by a nationally recognized testing laboratory. All wiring components and electrical 
equipment shall be maintained in accordance with the manufacturer’s recommendation.  
6.8.2.2  Wiring shall be replaced or properly repaired and sealed as necessary wh en insulation 
damage is detected.  
6.8.2.3  Because of fire and other hazards, makeshift wiring components and installations shall not be 
used.  
 
6.8.3  Classification of areas   Classification of areas shall be in accordance with  applicable standards in Zanzibar . 
 
6.8.4  Tanks, se parators and heater treaters  
6.8.4.1  Tanks, separators and heater treaters shall be installed and maintained in accordance with 
accepted engineering practices or manufacturer’s recommendations.  
 
6.8.4.2  Walking directly on the roof of a tank is discouraged. However, if pe rsonnel are required to 
access the roof of a tank, roof integrity shall be checked and appropriate walking surfaces, guardrails 
or fall protection shall be provided.  
 
6.8.5  Vapour recovery systems  
6.8.5.1  This sub clause describes the safety guidelines for vapour recove ry systems, especially 
thermal combustion systems and carbon absorption systems which are systems designed to minimize 
vapour releases to the environment.  
 
6.8.5.2  Vapour recovery systems shall be considered potential sources of ignition; facility design shall 
consider system location with respect to potential sources of hydrocarbon vapours.  
6.8.5.3  Procedures shall be developed for switching carbon beds and changing out the activated 
carbon in the absorbers.  
  
21 ©ZBS 2022 - All rights reserved  
 6.8.5.4  Devices shall be installed to prevent a flame from propagating from the vapour recovery unit 
into the production equipment.  
7 Training  
 
7.1 All personnel should be trained to work safely in accordance with their duties and responsibilities. 
Personnel shall understand the safety and health hazards associated with the chemica ls and 
processes they work with.  
 
7.2 Contractor personnel performing operating duties, maintenance or repair, turnaround, major 
renovation or specialty work shall be knowledgeable of site -specific safety procedures and rules 
pertaining to the facility and the  applicable provisions of emergency action plans.  
 
7.3 Persons  assigned to operate the facility or maintain the integrity of the equipment shall possess 
the required knowledge and skills to carry out their duties and responsibilities and shall be evaluated 
periodically to determine if the necessary skills and knowledge are adequate.  
 
7.4   Any major change that requires modification of existing operating practices may require 
additional training before personnel are expected to operate or maintain the facility.  
 
 
8 Procedures  
 
8.1 Well Start -up 
8.1.1  General  
 
Introducing a new or worked -over well to a separation process, pipeline or storage facility may create 
additional hazards to the operation. The properties of the well shall be reviewed to determine the 
extent of the hazard s. Depending upon the risks of the hazards the elements in 8.1.2 to 8.1.5 shall be 
considered.  
8.1.2  Design review  
8.1.2.1  A design review shall be performed to verify that the facility’s equipment can safely process 
the well stream.  
 
8.1.2.2  The design information shall includ e, as appropriate, a simplified process flow diagram and 
acceptable upper and lower limits, where applicable, for items such as temperature, pressure, flow 
and hydrocarbon composition. Where process flow diagrams no longer exist, similar information may 
be developed in conjunction with a hazards analysis in sufficient detail to support the analysis.  
 
8.1.3  Pressure relief  
 
Pressure relief systems shall be properly sized, installed, maintained and operated to minimize 
overpressure.  
 
8.1.4  Start -up procedures  
8.1.4.1  General  
 
Oil and gas wells have varying characteristics as follows:  
 
a) shallow versus deep;  
 
b) low versus  high pressure; and  
  
 
           PCD 342:2022  
 
©ZBS 2022 - All rights reserved  22 
 c) sweet versus sour.  
 
Start -up procedures shall be tailored to the particular well characteristics. Well start -ups are classified 
as initial start -up, normal or routine start -ups, and start -up after an extended shutdown.  
8.1.4.2   Pre start -up safety review  
 
Prior to start -up of a new facility, or after modification of an existing facility, certain activities shall be 
conducted to prepare the facility for sa fe operations. The following areas shall be considered:  
 
a) construction has been completed according to design requirements;  
 
b) piping and valves are properly installed;  
 
c) all safety and control devices are set and operate properly;  
 
d) applicable safety and contr ol devices are functioning properly;  
 
e) eliminate potential ignition sources; and  
 
f) pre-job safety meeting.  
 
8.1.4.3   Initial start -up 
 
The following procedures shall be considered:  
 
a) pressure test from well to choke at maximum wellhead pressure;  
 
b) pressure test from c hoke to production equipment, including flow lines, at expected line 
pressure;  
 
c) pressure relief systems are operable;  
 
d) valves are set correctly;  
 
e) purge air from the well and associated equipment using hydrocarbons or other acceptable 
means;  
 
f)  monitor flow and bring well online; and  
 
g) pre-job safety meeting.   
8.1.4.4  Normal or routine start -up 
 
The following procedures shall be considered:  
 
a) pressure relief systems are operable;  
 
b) valves are set correctly;  
 
c) monitor flow and bring well online; and  
 
d) pre-job safety meetin g. 
8.1.4.5  Start -up after extended shutdown  
  
23 ©ZBS 2022 - All rights reserved  
 8.1.4.5.1  After an extended shutdown, an equipment assessment shall be conducted prior to well 
start-up. 
 
8.1.4.5.2  This assessment shall include inspections for corrosion, missing or modified equipment, and 
overall integrity of the facili ty. 
 
8.1.4.5.3  After the assessment is completed, and repairs and corrections are made, well start -up 
shall follow initial start -up procedures or normal start -up procedures, as applicable.  
 
8.1.5  Training of employee and contractor personnel  
 
Personnel conducting well sta rt-up operations shall be properly trained, qualified, and familiar with well 
start-up procedures for the specific facility.  
9  Maintenance  
9.1   General  
 
The maintenance supervisor shall hold a pre -job meeting with his crew, and others if applicable, to 
review responsibilities for the operation(s) to be performed.  
 
9.2 Tank cleaning  
 
Tank cleaning shall be completed following, guidance, safe practices and additional information 
covering specific aspects of tank entry and cleaning, including a comprehensive tank clea ning 
checklist.  
9.3 Drilling and well servicing  
 
Drilling and well servicing shall be performed.  
 
10  Incident investigation  
 
10.1 All incidents with the potential for serious safety consequences shall be reported to OSH office 
and investigated to determine causal fac tors and steps taken to prevent a recurrence.  
 
10.2  The results of the investigation should be communicated to affected personnel including 
contractors as appropriate.  
11 Emergency response  
11.1 General  
11.1.1.1  Written action plans shall be established for production faciliti es to assign authority to the 
appropriate qualified person(s) for initiating effective emergency response and control. These plans 
shall also address emergency reporting and response requirements.  
 
11.1.1.2  Every occupational injury or illness shall be immediately reported to first aider and the 
supervisor. The y  shall arrange for any necessary medical or first aid treatment.  
 
11.1.1.3  A report shall be prepared as soon as practical, to record information (or the circumstances) 
surrounding the injury or illness. Additional r eports to regulatory agencies and others may be required.  
  
 
           PCD 342:2022  
 
©ZBS 2022 - All rights reserved  24 
 11.2  Medical services  
11.2.1.1  Telephone numbers, location, and other relevant information pertaining to availability of 
medical personnel, transportation, and medical facilities shall be available.  
11.2.1.2  Provisions shall be made for medical attention in case of injury.  
11.3 First aid  
11.3.1.1  An individual trained in first aid and Cardiopulmonary resuscitation (CPR) techniques shall 
be available to render aid. This individual shall be trained using approved courses or equivalent 
training . 
 
11.3.1.2  A first aid kit shall be available at the worksite shall contain appropriate materials for the 
potential injuries, and shall be inspected at frequent intervals, replenished as necessary, and be 
immediately available at all times.  
 
12 Special operati ons 
 
12.1  Well testing  
 
12.1.1.1  A clean -up tank shall be used instead of a work over pit during well testing. Testing of casing 
relief valves using fluids other than fresh water shall have the relief piped to a catch tank.  
12.1.1.2  When pressure testing surface equipment, use a 50/50 mixture of glycol and 2 % potassium 
chloride (KCl) water or equivalent to prevent ice formation.  
 
12.1.1.3  During well testing, the equipment shall be pressure tested to maximum expected formation 
pressure . 
  
The following equipment shall be included during  the pressure testing:  
 
a) test tree and casing for 10 min and record;  
 
b) secure and pressure test lines upstream of choke prior to flow back;  
 
c) test lubricator; and  
 
d) test surface lines.  
12.2 Pumping and hot oil operations (flow lines)  
 
12.2.1   All trucks and tanks shall be  located a minimum of 30.5 m upwind from the wellhead, or   
equivalent safety measures shall be taken where terrain, location, or other conditions do not permit. At 
locations where this recommendation may be impractical, appropriate safety measures should b e 
implemented.  
 
12.2.2   All lines connected from the pumping equipment to the Christmas tree or wellhead shall have a 
check valve installed as close to the well as practicable. In addition, when a multi -pump manifold is 
used, a check valve shall be placed in each  discharge line as close to the manifold as possible.  
 
12.2.3   When used, recording equipment shall be located a safe distance from the wellhead and 
discharge line.  
  
25 ©ZBS 2022 - All rights reserved  
 12.2.4   When pumping flammable fluids, all blending equipment used shall be grounded and all 
equipment u nloading sand into the hopper shall be bonded to the blending equipment.  
 
12.2.5   When pumping flammable fluids, all charged suction hoses shall be covered with hose covers 
to deflect fluids in case of rupture.  
 
12.2.6   Lines containing flammable fluids shall not be pla ced under any vehicle.  
 
12.2.7   A pre -treatment pressure test on the pump and discharge lines shall be made at a pressure no 
less than the maximum expected treating pressure specified by the operator, but not to exceed the 
rated working pressure of the equipment with the lowest rated working pressure.  
 
12.2.8   Personnel not directly involved in the operations shall remain beyond a designated minimum 
distance during all pressure testing and pumping operations.  
 
12.2.9   The supervisor or the person he designates shall check to se e that all valves in discharge lines 
are open prior to pumping.  
 
12.2.10  Pump operators shall remain at the controls while the pump is in operation, unless relieved as 
directed by the special services supervisor. Pump operators shall remain alert for communication s 
from the special services supervisor.  
12.3  Pigging operations  
 
12.3.1   Procedures shall be developed for launching and receiving pigs, scrapers, swabs, and internal 
inspection pigs (smart pigs). These procedures shall address the following elements:  
 
a)  description o f the process fluids and vapours, personnel hazards, and PPE;  
 
b)  selecting and verifying the proper pig is available;  
 
c) preparing the pig launcher/receiver, including isolation, de -pressuring, and setting pig indicators;  
and 
 
d) verifying that the vessel is not  pressurized;  
 
CAUTION: Gauges alone may not insure that the vessel is fully depressurized. Intentionally 
opening a pig launcher/receiver under pressure using any style of opener is prohibited;  
 
e) opening the pig launcher/receiver;  
 
CAUTION: Ensure all perso nnel are positioned at the side of the pig launcher/receiver. Do not stand 
in front of the pig launcher/receiver closure when the closure is being opened;  
 
f) inserting and removing pigs, including isolation of ignition sources, containment of liquid wastes 
and exposure to toxic compounds;  
 
g) inspecting and repairing as necessary pig launcher/receiver closures, valves, pressure gauges, 
pig indicators, and other ancillary components each time the closure is opened;  
 
h) closure of the pig launcher/receiver and retur ning it to service; and  
 
i) a procedure to take in the event  that the pig is stuck or any of the valves do not operate 
properly.  
 
12.3.2   Only qualified persons in pig launching/receiving should perform pigging operations.  
  
 
           PCD 342:2022  
 
©ZBS 2022 - All rights reserved  26 
 12.3.3   A pre -job safety review shall be pre -formed prior to all pig launching/receiving operations. Pig 
launchers/receivers shall be depressurized whenever left isolated from the pipeline.  
 
12.3.4   Fire extinguishing equipment shall be positioned near the pig launcher/receiver when pigging 
operations are bein g performed.  
12.4  Hot tapping on equipment in service  
 
12.4.1   Hot tapping operations should be conducted with Welding or Hot Tapping on Equipment in 
Service.  
 
12.4.2    Hot tapping operations shall be under the direct supervision of a qualified person. The rated 
working pre ssure of all equipment used in hot tapping operations should be equal to or greater than 
the rated working pressure of the equipment to which it is being attached.  
 
12.4.3  After necessary equipment has been rigged up to perform hot tapping operations, it should b e 
pressure tested for a minimum of three minutes to a level not exceeding the rated working pressure of 
either the equipment being tapped or the tapping equipment and not to exceed one and a half times 
the expected maximum pressure. The possibility of carr ier or untapped pipe collapse from external 
pressure may dictate a reduction in test pressure.  
 
12.4.4   During the hot tapping operation, pressure inside the lubricator should not exceed the pressure 
inside the equipment penetrated.  
 
12.4.5   Hot taps or other hot works are not permitted on the roof of a tank or within th e gas vapour 
space of the tank.