A Pipeline Contractor Safety Manual provides the written safety policies, programs, responsibilities, and procedures needed to address hazards associated with pipeline construction, installation, maintenance, repair, and related field operations.
Pipeline contractors may perform excavation and trenching, pipe unloading and stringing, welding, pipe bending, rigging, sideboom and pipelayer operations, lowering-in, pressure testing, right-of-way work, heavy-equipment operation, and work on or near existing pipeline systems. These activities can expose employees to cave-ins, struck-by and caught-between hazards, suspended loads, hazardous energy, welding hazards, pressure, flammable materials, hazardous atmospheres, traffic, weather, and other construction hazards.
An effective Pipeline Contractor Safety Manual should combine the company’s Core Construction Safety Programs with additional programs selected according to the contractor’s pipeline work, equipment, facilities, products, and customer requirements.
A comprehensive Pipeline Contractor Safety Manual may include core programs addressing:
The manual should also establish responsibilities for management, supervisors, employees, competent and qualified persons, hazard identification, inspections, safety training, hazard correction, incident reporting, recordkeeping, and periodic review of the company’s safety programs.
Pipeline construction frequently combines excavation, heavy equipment, suspended loads, welding, material handling, and large sections of pipe within the same work area.
Work should be planned so employees understand:
Hazards should be reassessed as work progresses because terrain, soil conditions, equipment, weather, utilities, and other conditions may change substantially along the pipeline right-of-way.
Pipeline contractors should evaluate hazards before each phase of work.
A Job Safety Analysis or Job Hazard Analysis may address:
The JSA should be reviewed and revised when equipment, personnel, work methods, terrain, weather, or other site conditions change.
Pipeline rights-of-way may extend across uneven terrain, roadways, agricultural areas, slopes, waterways, remote locations, and other challenging environments.
Safety planning should consider:
Employees should remain alert to changing conditions as operations move along the right-of-way.
Excavation and trenching are among the most significant hazards associated with pipeline construction.
Applicable procedures should address:
Underground installations should be identified before excavation begins, and their locations should be verified using safe and acceptable methods as work approaches them.
Excavations should be inspected by a competent person as required.
Inspection considerations may include:
Employees should be removed from hazardous excavations until unsafe conditions have been corrected.
Pipeline construction frequently occurs near existing pipelines, electrical lines, communications systems, water lines, sewer lines, and other underground installations.
Before ground disturbance begins, procedures should address:
Existing underground facilities should not be assumed to be exactly where drawings or surface markings indicate without appropriate verification.
Pipe delivery and unloading can create struck-by, rolling, pinch-point, and suspended-load hazards.
Procedures should address:
Employees should not position themselves where shifting or rolling pipe could trap them against trucks, equipment, stacked pipe, or fixed objects.
Pipe stringing places pipe sections along the right-of-way in preparation for welding and other construction activities.
Hazards can include:
Stringing operations should be coordinated so employees remain outside hazardous equipment zones whenever possible.
Large pipe can move unexpectedly when lifted, lowered, rolled, bent, repositioned, or released from supports.
Safe pipe-handling procedures should address:
Employees should never rely on body position alone to stop or control moving pipe.
Pipe should be adequately supported and restrained to prevent uncontrolled movement.
Cribbing, blocking, wedges, chocks, or other supports should be:
Employees should avoid placing hands, feet, or other body parts beneath unsupported pipe.
Sideboom tractors and pipelayers are specialized equipment commonly used during pipeline construction.
Procedures should address:
Ground employees should remain clear of areas where pipe, rigging, booms, or equipment could move unexpectedly.
Pipeline projects may involve:
Procedures should address:
Employees should avoid approaching operating equipment until communication has been established with the operator.
Pipeline work creates numerous opportunities for employees to be struck by equipment, moving pipe, rigging, released energy, or other materials.
Employees should avoid positioning themselves:
Pre-task planning should identify potential lines of fire and establish controls before work begins.
Pipeline bending may involve hydraulic bending machines and other specialized equipment.
Hazards can include:
Employees should remain clear of pinch points and areas where pipe could move unexpectedly.
Rigging is an integral part of pipeline construction.
Rigging procedures should address:
Rigging equipment should be appropriate for the load and inspected as required before use.
Employees should remain clear of suspended pipe and other suspended materials.
Work should be planned to minimize the need for employees to enter areas where loads could fall, swing, shift, or roll.
Where employees must assist with load control, safe positioning and communication methods should be established before the lift begins.
During lowering-in operations, multiple pipelayers or sidebooms may work together to place welded pipeline into the excavation.
Planning should address:
Employees should not be positioned where unexpected movement of pipe, rigging, or equipment could trap or strike them.
Pipeline construction frequently involves welding pipe sections, tie-ins, repairs, and related fabrication.
Welding procedures should address:
Additional precautions may be necessary when welding on or near existing pipelines containing flammable or hazardous products.
Pipeline work may involve:
Applicable controls should address:
Hot work should not proceed until applicable fire, atmospheric, and owner/operator precautions have been established.
Grinding and beveling operations may expose employees to:
Employees should use properly guarded equipment and appropriate eye, face, hearing, hand, and other PPE.
Pipeline welding and cutting may require oxygen, fuel gas, shielding gas, or other compressed gases.
Procedures should address:
Damaged cylinders, regulators, or hoses should be removed from service.
Work on or near existing pipelines can involve hazards that may not be present during new-line construction.
Depending on the pipeline and product, hazards may include:
Pipeline-owner or operator procedures should be incorporated into work planning where applicable.
Maintenance, repair, tie-in, valve, equipment, and facility work may expose employees to hazardous energy.
Potential energy sources can include:
Energy-isolation procedures should reflect the equipment and pipeline system involved and should include verification before work begins.
Pressurized piping, test systems, hydraulic equipment, hoses, fittings, valves, and temporary systems can store substantial energy.
Employees should remain outside potential release paths.
Work planning should address:
Pipeline contractors may perform hydrostatic, pneumatic, or other pressure testing.
Hazards may include:
Pressure-testing procedures should address:
Employees should not enter areas exposed to uncontrolled pressure-release hazards.
Atmospheric testing may be necessary where pipeline activities could expose employees to oxygen deficiency, flammable gases, toxic contaminants, or other hazardous atmospheres.
Testing may be appropriate for certain:
Testing equipment should be appropriate for the contaminants and conditions being evaluated.
Hydrogen sulfide may be present in certain oil and gas pipeline systems, facilities, excavations, or release areas.
Where H₂S exposure is reasonably possible, procedures should address:
H₂S procedures should be included based on the actual pipeline product, facility, and exposure potential rather than assumed for every pipeline contractor.
Pipeline contractors may encounter permit-required confined spaces such as certain tanks, vessels, vaults, pits, and facilities.
Where confined-space requirements apply, procedures should address:
An excavation should not automatically be treated as a confined space simply because it is deep or narrow. Excavation and confined-space requirements should be applied according to the work and conditions involved.
Pipeline operations involving fuels, flammable gases, hot work, engines, or existing pipeline products require careful ignition control.
Procedures may address:
Pipeline work can involve fuels, lubricants, hydraulic fluids, pipeline products, chemicals, and test media.
Procedures should address:
Employees should understand which releases they may safely address and when specialized emergency response is required.
Pipeline contractors may use welding products, coatings, fuels, solvents, cleaners, lubricants, adhesives, paints, and other hazardous chemicals.
Employees should have access to applicable Safety Data Sheets and receive required information and training.
Containers should be properly labeled, and hazardous materials should be stored and handled according to applicable requirements.
Some pipeline projects may use cranes for equipment, valve assemblies, fabrication, road crossings, compressor-station work, or other lifting activities.
Applicable crane procedures should address:
Forklifts and telehandlers may be used in yards, staging areas, facilities, and construction locations.
Procedures should address:
Pipeline rights-of-way often intersect highways, local roads, access roads, and public travel routes.
Traffic-control procedures may address:
Traffic-control arrangements should comply with applicable agency and project requirements.
Pipeline activities may occur near roads, homes, farms, businesses, trails, and other public areas.
Controls may include:
Unauthorized persons should be prevented from entering hazardous work areas.
Pipelayers, cranes, excavators, trucks, long pipe sections, and other equipment can create serious hazards near overhead electrical lines.
Power-line locations should be identified during planning.
Applicable clearance requirements and protective measures should be maintained when equipment or materials could approach energized lines.
Electrical hazards may be encountered through:
Employees should follow applicable electrical safe-work practices and use appropriate protective equipment.
Pipeline employees may use:
Tools should be inspected, properly guarded where required, and used according to manufacturer instructions.
PPE should be selected according to the hazards involved.
Depending on the work, PPE may include:
Customer or pipeline-owner requirements may establish additional PPE requirements.
Pipeline employees may be exposed to high noise from:
Where employee exposures meet applicable criteria, the company should implement required hearing-conservation measures.
Pipeline work is frequently performed outdoors and can involve substantial physical exertion.
Heat-stress procedures should address:
Pipeline construction may continue during cold, rain, snow, wind, and other adverse weather.
Planning should consider effects on:
Work should be modified or suspended when weather creates unacceptable hazards.
Pipeline contractors may operate pickups, trucks, trailers, buses, service vehicles, and other fleet vehicles over long distances and remote roads.
Procedures may address:
Pipeline projects may be located far from communities or immediate emergency services.
Where employees work alone or in remote areas, procedures should address:
Certain high-hazard activities should not be performed alone where immediate assistance may be necessary.
Pipeline emergency planning should consider:
Employees should understand how to report emergencies, summon assistance, provide accurate worksite location information, and follow applicable owner/operator emergency procedures.
Employees should receive training appropriate to their assigned tasks and hazards.
Training may include:
Competent-person, qualified-person, operator, or other specialized training should be provided where required.
Pipeline-specific JSAs may address:
The JSA should reflect the actual equipment, terrain, pipeline size, work sequence, personnel, and environmental conditions involved.
Not every pipeline contractor requires every safety program.
Depending on the company’s work, additional programs may include:
Programs should be selected according to the contractor’s actual operations rather than simply because they are associated with the pipeline industry.
Pipeline contractors frequently perform work for pipeline owners, operators, energy companies, utilities, general contractors, and other clients that maintain their own contractor safety requirements.
These requirements may address:
Where customer or operator requirements apply, they should be incorporated into project planning and followed in addition to the contractor’s own safety programs.
Pipeline projects may involve welding subcontractors, trucking companies, excavation contractors, testing companies, inspection personnel, environmental contractors, and other employers.
Coordination should address:
Each employer remains responsible for protecting its employees while coordinating hazards that may affect employees of other employers.
Pipeline toolbox talks can reinforce current field hazards and safe-work practices.
Useful topics may include:
Toolbox talks supplement required training but do not replace training specifically required by applicable OSHA standards.
A Pipeline Contractor Safety Manual establishes the company’s overall written safety programs and procedures.
A Site-Specific Safety Plan (SSSP) applies those programs to a particular pipeline project, right-of-way, facility, or worksite.
For example, the company manual may contain Excavation, Rigging, Heavy Equipment, Welding, Pressure Testing, H₂S, Traffic Control, and Emergency Action programs. Project-specific planning can then address the actual terrain, pipeline diameter, equipment, excavation conditions, existing utilities, pipeline products, owner requirements, emergency access, and weather conditions at that location.
The company safety manual therefore provides the foundation for project-specific planning.
A practical Pipeline Contractor Safety Manual should reflect the operations the contractor actually performs.
When selecting programs, consider:
Selecting programs according to actual operations produces a safety manual that addresses the contractor’s real hazards without filling the document with unrelated safety programs.
Pipeline contractors can request a customized Construction Safety Manual containing the Core Safety Programs and additional programs applicable to their pipeline construction, excavation, pipe handling, welding, equipment, pressure-testing, and related operations.
Programs can be selected according to the company’s actual work, equipment, customer requirements, and hazards so the manual addresses relevant pipeline operations without including large numbers of unrelated safety programs.
Individual safety programs can also be selected when a pipeline contractor needs to add or update a particular program within an existing manual.