PETRONAS TECHNICAL STANDARDS

DESIGN AND ENGINEERING PRACTICE

MANUAL

INSTALLATIONS AND DEPOTS

PART 8 - MAINTENANCE AND
WORKSHOPS, GENERAL SERVICES
AND CHEMICAL HANDLING

PTS 20.158H
JUNE 1993

PREFACE

PETRONAS Technical Standards (PTS) publications reflect the views, at the time of publication,
of PETRONAS OPUs/Divisions.
They are based on the experience acquired during the involvement with the design, construction,
operation and maintenance of processing units and facilities. Where appropriate they are based
on, or reference is made to, national and international standards and codes of practice.
The objective is to set the recommended standard for good technical practice to be applied by
PETRONAS' OPUs in oil and gas production facilities, refineries, gas processing plants, chemical
plants, marketing facilities or any other such facility, and thereby to achieve maximum technical
and economic benefit from standardisation.
The information set forth in these publications is provided to users for their consideration and
decision to implement. This is of particular importance where PTS may not cover every
requirement or diversity of condition at each locality. The system of PTS is expected to be
sufficiently flexible to allow individual operating units to adapt the information set forth in PTS to
their own environment and requirements.
When Contractors or Manufacturers/Suppliers use PTS they shall be solely responsible for the
quality of work and the attainment of the required design and engineering standards. In
particular, for those requirements not specifically covered, the Principal will expect them to follow
those design and engineering practices which will achieve the same level of integrity as reflected
in the PTS. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his
own responsibility, consult the Principal or its technical advisor.
The right to use PTS rests with three categories of users :
1)
2)
3)

PETRONAS and its affiliates.

Other parties who are authorised to use PTS subject to appropriate contractual
arrangements.
Contractors/subcontractors and Manufacturers/Suppliers under a contract with
users referred to under 1) and 2) which requires that tenders for projects,
materials supplied or - generally - work performed on behalf of the said users
comply with the relevant standards.

Subject to any particular terms and conditions as may be set forth in specific agreements with
users, PETRONAS disclaims any liability of whatsoever nature for any damage (including injury
or death) suffered by any company or person whomsoever as a result of or in connection with the
use, application or implementation of any PTS, combination of PTS or any part thereof. The
benefit of this disclaimer shall inure in all respects to PETRONAS and/or any company affiliated
to PETRONAS that may issue PTS or require the use of PTS.
Without prejudice to any specific terms in respect of confidentiality under relevant contractual
arrangements, PTS shall not, without the prior written consent of PETRONAS, be disclosed by
users to any company or person whomsoever and the PTS shall be used exclusively for the
purpose they have been provided to the user. They shall be returned after use, including any
copies which shall only be made by users with the express prior written consent of PETRONAS.
The copyright of PTS vests in PETRONAS. Users shall arrange for PTS to be held in safe
custody and PETRONAS may at any time require information satisfactory to PETRONAS in order
to ascertain how users implement this requirement.

INSTALLATION AND DEPOTS MANUAL

Section List
Part 1

Section 00.00.00

Introduction

Section 01.00.00

Master Development Planning

Section 02.00.00

Construction Projects

Part 2

Section 03.00.00

Sites and Layouts

Part 3

Section 04.00.00

Building and Civil Engineering

Section 05.00.00

Tanks and Pressure Vessels

Part 4

Section 06.00.00

Pipelines

Part 5

Section 07.00.00

The Design of Berthing Facilities for Tankers and Small Craft

Section 08.00.00

Heating and Insulation

Part 6

Section 09.00.00

Plant and Equipment

Part 7

Section 10.00.00

Utilities

Section 11.00.00

Mechanical Handling

Section 12.00.00

Maintenance and Workshops

Section 13.00.00

General Services

Section 14.00.00

Chemicals Handling

Part 9

Section 15.00.00

Fire -Protection

Part 10

Section 16.00.00

Electrical and Static Electricity Hazards

Section 17.00.00

Bibliography

Part 8

CONTENTS
12.00.00.

MAINTENANCE AND WORKSHOPS

12.00.01.

Summary

12.01.00.

MANAGEMENT OF MAINTENANCE

12.01.01.

Planned Maintenance of Plant and Fixed Equipment

12.01.02.

(a)

Items identified on a yearly basis

(b)

Programmed inspections
maintenance work

(c)

Programmed inspections/servicing/maintenance planned on a regular basis usually related to time intervals derived from work done, or product
throughput - throughout the year.

(d)

Unforeseen and unplanned repairs caused by breakdowns and accidents

which

mayor

may

Organisation of Maintenance
(a)

Equipment Register

(b)

Inspection/Maintennace Schedule

(c)

Inspection/Maintenance Programme

(d)

Allocation of Duties and Job Specifications

(e)

Recording and Analysing Results

12.01.03.

Priority of Components of the Maintenance Programme

12.01.04.

Breakdown Maintenance - Plant and Equipment

12.01.05.

Computer Software Programs for Planned Maintenance

12.02.00.

WORKSHOPS

12.02.01.

General Considerations

12.02.02.

Sizing of Maintenance Facilities

12.02.03.

(a)

Plant Maintenance

(b)

Vehicle Maintenance

(c)

Retail Outlet Equipment

(d)

Aviation Fuelling Equipment

Maintenance Building Complex

(a)

Siting

(b)

Construction Materials

(c)

Main Entrance/Exit and Emergency Exits

(d)

Flooring and Wall Finishes

(e)

Lighting

not

require

follow-up

(f)

Electrical Equipment

(g)

Workshop/Machine Tools

12.02.04.

Safely Equipment

13.00.00.

GENERAL SERVICES

13.01.00

COMMUNICATIONS

13.01.01.

General Considerations

13.01.02

References
(a)

Telephones

(b)

Radio

(c)

Portable Loud Hailers

(d)

Two-way Loud Speaker System

(e)

Teleprinter (Telex) System

(f)

Visual Signals

(g)

Pneumatic Tube System

13.01.03.

Warning Notices, and Safety Signs

13.02.00.

ADMINISTRATION SERVICES

13.02.01.

Office Accommodation

13.02.02.

Laboratory

13.02.03.

Personnel Services
(a)

Medical

(b)

Training

(c)

Canteen

(d)

Living Accommodation

(e)

Protective Clothing

(f)

Uniforms

13.02.04.

Security

13.03.00.

FIRE-FIGHTING FACILITIES AND EQUIPMENT

13.03.01.

Summary

14.00.00.

CHEMICALS HANDLING

12.00.00

MAINTENANCE AND WORKSHOPS

12.00.01

Summary
The need for, and requirements of, inspection and maintenance of plant and
equipment must be taken into account at the design and layout stage in order to
minimise subsequent and expensive modifications.
Whether or not maintenance of plant and equipment should be undertaken by
contractors or own personnel - either wholly or partly - must be considered and
decided in relation to local conditions, the work to be done, the efficiency of both
methods and the costs.
PETRONAS companies carry out their operations in accordance with the rules and
standards designed to prevent harm to people or property and to protect the
environment. Therefore, when contractors are employed to do work inside or outside
PETRONAS premises they should meet the same standards. The most important
criterion in selecting a contractor for any job is the assessment of his ability to
perform the task efficiently and safely. Recommendations on selection of contractors
and other aspects are given in the publication 'Contractor Safety' issued by
PETRONAS Safety and Health Committee.
Depending on the size and complexity of the plant, workshop facilities may be
required for:
(i)

General plant and equipment maintenance; this may be justifiable because of

local conditions, and care of facilities such as heated fuel oil storage, bitumen
storage and packaging, luboil blending and packaging, LPG storage and
cylinder filling/testing, etc.

(ii)

Maintenance of retail outlet equipment centred on the plant.

(iii)

Maintenance of vehicles centred on the plant, and other mobile equipment.

Whatever the type and amount of work involved the primary objective should be
planned maintenance based on inspection; this can be defined as 'preventive
maintenance based on needs'. The system ensures that every facility is kept at, or
restored to an acceptable standard but it requires coordination of thinking, attitude
and actions by all personnel involved.
Gas-freeing and cleaning of tanks is covered in the Plant Operating Manual Section
08.13.00.
As many items of maintenance and repair fall into the category of non-routine work,
they may have to be covered by an appropriate work permit/safety certificate, see
Section 08.04.00 of the Plant Operating Manual.

12.01.00.

MANAGEMENT OF MAINTENANCE

12.01.01.

Planned Maintenance of Plant and Fixed Equipment

Unexpected breakdown of plant and equipment results in high expenditure for
alternative arrangement and premature renewal of assets. Such breakdowns, or substandard performances, can be minimised by arranging for scheduled inspections by
trained personnel who will report when maintenance and/or asset replacement is
required. This is the basis of a planned maintenance system which should be
supported by organisation and control documents; it is essential that the latter be kept
up-to-date. The system is necessary irrespective of whether the
maintenance/repair work is carried out by contractors or own personnel.

During the normal planning period of one year, the following components should form
the total maintenance package of any installation, depot or other worksite:
(a) Items identified on a yearly basis, for example:
(i) Statutory inspections
(ii) Tank cleaning/painting
(iii) Repairs to concrete roadways
(iv) Overhaul of pumps/motors
(v) Jetty repairs, etc.

(b) Programmed inspections which may or may not require follow-up

maintenance work, for example:
(i) Regular inspection of electrical equipment; this may be undertaken by a
specialist organisation who would recommend whatever rectification work
should be carried out.
(ii) Regular inspection of storage tank fittings such as pressure/vacuum valves,
manometers, and gauges.
(iii) Inspection and testing of pipelines.
(iv) Inspection and testing of fire equipment, etc.

(c) Programmed inspections/servicing/maintenance planned on a regular

basis - usually related to time intervals derived from work done, or product
throughput - throughout the year. This is servicing and maintenance
arising from normal operations, e.g.:
(i) Servicing of fixed prime movers, e.g. CI Engines.
(ii) Greasing of valves and similar mechanisms.
(iii) Checking, cleaning and changing of filters.
(iv) Checking and calibrating meters, etc.
(v) Servicing of mobile and fixed mechanical handling equipment, etc.

(d) Unforeseen and unplanned repairs caused by breakdowns and accidents.

No specific items of work are detailed here but it is nevertheless a
component for which budget provision must be made - usually on a
company-wide basis.

12.01.02.

Organisation of Maintenance
A planned-maintenance system comprises:
(i)

An operations schedule covering inspection, lubrication, adjustment, rectification

and periodic overhaul/unit change.

(ii) Some means of ensuring that all of these operations are carried out in
accordance with the schedule.
(iii) A method of recording the work as completed, and of assessing the results.
These aims can be achieved with the following arrangements:
(a)

Equipment Register
An equipment register should be kept. Its form will depend on the type and
amount of equipment to be covered, but in this case of large plants, it may
consist of a card index giving details of each mechanical, electrical and other
facility requiring periodic attention. Each card should be treated virtually as
the identity card for the particular piece of equipment or facility, and should
include technical and manufacturing information, a reference to a drawing, or
the manufacturer's handbook, and a note of the supplier and whether the item
is still available.

(b)

Inspection/Maintenance Schedule
Once the item is recorded in the equipment register, particulars must then be
entered in the overall maintenance schedule and should be kept to provide a
comprehensive picture of the maintenance requirements of the whole plant.
The schedule should show all the work to be done. At first it should be based
largely on the recommendations given in service manuals, or on records of
past repairs, replacements and downtime. Thereafter it will need to be
updated in the light of the experience gained from working the system and any
feedback of data. Recommendations on inspection/maintenance schedules
are given in Section 06.00.00 of the Plant Operating Manual: Volume 1.

(c)

Inspection/Maintenance Programme
Using the maintenance schedule, a maintenance programme should be
prepared listing each item of plant and its reference number, and specifying
when each should receive special attention throughout the planning period.
The mechanical, electrical and lubrication maintenance required by each item,
and the intervals between maintenance, should be given against each item
and entered on a time scale. Every operation will then fall within the specified
time limits, and the weekly maintenance working load will be spread as evenly
as possible.

(d)

Allocation of Duties and Job Specifications

A comprehensive maintenance schedule needs to be divided into statutory,
major and minor items, detailing the type of inspection, and nominating the
grade of person required to undertake the work. Briefly the recommended
classifications comprise:

(i)

Statutory inspections: There are inspections required by local authorities on

such items as boilers, pressure vessels, lifts and lifting gear; they are usually
carried out by approved organisations such as Bureau Veritas, Lloyds, etc.
These inspections usually result in a programme of work to be done during the
ensuring year which must be arranged and controlled by the company's
engineer.

(ii)

Major inspections: This involves plant and equipment which requires a qualified
engineer's assessment on whether rectification/replacement is required. These

items are normally identified on a yearly basis, e.g. tank conditions, repairs to
roadways, jetties, and overhaul of equipment, prior to preparation of the
revenue expenditure budget.
(iii)

Minor items: This involves inspection and servicing of plant and equipment in
the form of lubrication and adjustments which can be undertaken by
experienced depot personnel under supervision.

(e)

Recording and Analysing Results

A history card should be kept for all items of plant, summarising the scheduled
inspection/maintenance, any failures suffered and the action taken to rectify
them, the causes and effects of breakdown, the man-hours devoted to
maintenance operations, and the plant/machine downtime. The history card
will provide a measure of the efficiency of the maintenance organisation and
the methods used.

12.01.03.

Priority of Components of the Maintenance Programme

Assessment for budget purposes may require the components of the maintenance
programme to be ranked in priority. In this event the justifications should be treated in
the following order:
(i) Safety and Environmental aspects: Accident/fire prevention and government
regulations
(ii) Operational: Maximise utilisation of plant/equipment; reduce out-of-service time;
improve profits.
(iii) Preservation of assets; reduced repair/replacement costs.
(iv) Industrial and public relations.
Because of the importance of safety, i.e. accident and fire prevention - not only for
humanitarian and cost control reasons but also because of the effect on the other
justifications e.g. environmental aspects, it is essential that an appropriate and costeffective maintenance programme incorporating components (a), (b) and (c) of
Section 12.01.01 be put into practice with the aim of minimising both the frequency
and consequence of component (d) - accidents and breakdowns which can be costly
in terms of manpower and physical assets.

12.01.04.

Breakdown Maintenance - Plant and Equipment

When breakdowns occur the reasons should be investigated and entered on the
history card for the asset. The rate of breakdowns will influence the renewal of assets
and changes to the planned maintenance inspection checks. If breakdowns never
occur then maintenance checks may be too frequent; if however they occur frequently
then either the intervals between maintenance checks should be reduced or the
plant/equipment is inadequate for the task for which it was installed.
Breakdown maintenance should be in the form of planned corrective work which is
carried out after a failure, for which advance provision has been made in the form of
spares, materials and labour.

12.01.05.

Computer Software Programs for Planned Maintenance

Maintenance covers a wide range of activities; the maintenance engineer/manager
must concern himself with purchasing, planning, costing, quality control and analysis
of history, quite apart from the engineering aspects of his job. To carry out this
function effectively, it is necessary to collect, store and recall more and more
information. In large complex plants manual clerical systems and storage of
information are costly and to minimise this, the application of computers and software
programs to maintenance control should be considered. Software systems which
include modules for the asset register, maintenance planning, work order control,
equipment history, manpower analysis and reporting facilities, etc., are now available.
A typical information flow-chart is shown in Figure 12.01.01.
Further information on computing equipment and Group endorsed products can be
obtained from PETRONAS.

TYPICAL INFORMATION FLOW CHART

FIGURE 12.01.01

PLANNED MAINTENANCE SYSTEM

12.02.00.

WORKSHOPS

12.02.01.

General Considerations
If equipment is to be maintained by company personnel then, as a general rule,
workshop facilities should be provided only for carrying out minor maintenance and
repairs to plant and equipment at installations, but not necessarily at depots particularly if these are satellites.
Facilities for carrying out major repairs to such items as power plant, retail outlet
equipment and transport should be provided only when it is uneconomical to use
outside workshop facilities.
In many countries statutory requirements exist pertaining to the oil industry and hence
the following guidelines should be regarded as complementary to such requirements.
Reference should also be made to the following:
(i) Operational Procedures for Maintenance of Vehicles - Section 03.00.00 of the
Plant Operating Manual, Volume 5.
(ii) Vehicle Maintenance Facilities - Section 08.00.00 of the Road Transport Manual.
All workshops should be in a safe area within the plant boundaries and adjacent to
the main traffic area for product handling. In regard to explanations of terms particularly in respect of Work Permits and Hazardous Zones - the definitions given in
Section 03.04.00 and Plant Operating Manual 08.04.00 must be consulted and
adopted.

12.02.02.

Sizing of Maintenance Facilities

Firstly, all workshops and tool/parts/unit stores should be grouped together so as to
facilitate administration, to minimise materials/equipment and to optimise manpower.
The complex should be built as one block with suitable road access and vehicle
standing areas. The possibility of future extensions should also be considered in the
layout, the location of which is determined by the master development plan for the
installation.
The size of workshops will depend upon the activities and the workload. The possible
requirements are discussed below:
(a) Plant Maintenance
For routine maintenance and repairs at main installations the following machine
tools will meet all normal requirements; they are only needed where contract
services are not available:

One drilling machine to drill holes up to 30 mm diameter.

One power hacksaw.

One wet-and-dry grinder.

A centre lathe is unlikely to be required having regard for the availability of

materials and spare parts.
Provision must be made for storing portable welding sets, compressor sets and
pump sets, if such equipment is not available for hire. If it is necessary to provide
such equipment it should be pooled and made available for use at other
installations and up-country depots as required

(b) Vehicle Maintenance

Workshop and servicing facilities are covered in Section 08.00.00 of the Road
Transport Manual. Figure 12.02.01 shows a multi-purpose maintenance building. If
the location and space allowance permits, drive-through type inspection/service
bays are preferred. The wash-bay at the end of the building should, preferably, be
in the open.

(c) Retail Outlet Equipment

As the trend in most countries is to contract out pump and equipment service to
manufacturers' agents or to independent contractors, the work requirement which
might arise, e.g. examination and testing of new or existing items of equipment,
might be absorbed in the plant and transport facilities.
On the other hand, if maintenance has to be undertaken by the company then all
systems of field maintenance should be operated in conjunction with a unit
replacement scheme. The latter necessitates sub-dividing assemblies into a
number of main units; for example, dispensing pumps are sub-divided into meters,
motors, pumping units, hoses, register mechanisms, etc. When a breakdown
occurs, the faulty unit is replaced by a new or reconditioned unit and returned to
the workshop for repair. By this means, the out-of-operation periods are reduced to
a minimum, and fewer field fitters and vans are required on the road because they
need carry out only minor repairs on site, or replace complete units. Additionally
with an organised flow of units from the field for overhaul, the stores layout and
repair work can be economically planned.
With this arrangement adequate space for benches, hand tools and test
equipment, is required in the workshop, and a separate section in the stores for
spare parts and units. Field maintenance necessitates the use of retail equipment
service vans. The body interior fittings and shelving partitions should be arranged
in such a manner that complete units and spare parts can be safely housed yet
remain readily accessible. Tools and spare parts required in such a van will vary
according to the equipment to be maintained; the main tools are:

Pipe vice and stand.

Bench vice.

Semi-rotary pump.

Set of measures (depending upon system employed and local authorities).

Hand tools: stocks and dies, pipe wrenches, hammers, spanners, chisels,
spirit level, etc.

Funnel with 250 x 20 Hollander weave filter.

(d) Aviation Fuelling Equipment

This equipment can be included in the vehicle maintenance organisation and
facilities if it is not adequately covered by airfield depots.
A suggested layout sketch embodying all the above facilities is given in Figure
12.02.01; some comments are given in (b) above.

12.02.03.

Maintenance Building Complex

(a) Siting
This will depend upon available space and will be determined from the master
development plan for the installation. If possible, the building with associated
accommodation, e.g. office, staff amenities, equipment and tool stores, should be
built as one block with suitable road access and vehicle standing areas. Future
extensions and safety/environmental factors must always be considered at the
design/layout stage.

(b) Construction Materials

The methods of construction and the materials used should be chosen for their
economy in first-cost and future maintenance commitment. Modular factory
produced units can be used for the associated accommodation where appropriate
to the sub-division required and acceptable to the local authority.

(c) Main Entrance/Exit and Emergency Exits

Door openings should be sufficiently high and wide to permit easy movement of all
mobile equipment into and out of the building. Suitably illuminated emergency exits
- remote from the main-doors - should be provided.
(d) Flooring and Wall Finishes
The flooring in workshops and stores should be hard wearing and resistant to oil
saturation. Wall surfaces should be smooth faced and painted.
(e) Lighting
Maximum use of natural light should be made in the working areas, e.g. by means
of wall glazing in the side and back walls of the building and/or glazing in the roof.
However, to minimise window breakages it is advisable to design the sill height to
be approximately 2.5 metres above ground level.
The minimum level of illumination in service bays and wash bays should be 200 lux
at ground level. Bench lighting should be a minimum of 300 lux.
(f) Electrical Equipment
Different areas of the maintenance building require separate standards of
electrical installation; these are:
(i)

Lighting and other electrics in pits - both fitted or portable - should be

certified as suitable for Zone 1 areas.

(ii)

All other inspection, service and repair bay facilities and those of offices,
stores, etc. that open directly into the vehicle bays should be certified for
Zone 2 areas (see Figure 12.02.01).

(iii)

Other electrical installations in offices, stores, etc. that do not have direct
access into the vehicle bays, can be standard equipment suitable for
industrial areas.

(iv)

No electrical outlet socket when fitted in Zone 1 or Zone 2 areas - should be

greater than 25 volts. This includes sockets for all portable inspection lamps
and adjustable bench lights.

(g) Workshop/Machine Tools

Fixed equipment such as machine tools, or welding units, battery chargers, etc.
must not be installed in vehicle service/maintenance bays, i.e. Zone 1 and 2 areas.
A separate workshop should be provided for this equipment including compressed
air and electrical power equipment. This workshop should serve for plant, retail and
transport requirements.

12.02.04.

Safety Equipment
(i) Fire Extinguishers and Other Fire-fighting Appliances
These should be provided on the scale of one 11kg dry chemical powder
extinguisher per 200 m - of floor area (minimum 2) - see Section 15.00.00. The
locations of the extinguishers should be clearly indicated. The office, spare parts
stores, and enclosed bays should each have one 11 kg dry powder extinguisher.
(ii) Fire Alarm
A suitable type of fire alarm should be provided which is audible both inside and
outside the maintenance building.
(iii) First Aid
To enable minor injuries such as abrasions, cuts and splinters to be treated, a firstaid box with suitable contents should be provided.
Treatment of major injuries should be dealt with as prescribed by standing orders
of the plant.
(iv) Protective Clothing and Footwear
These should be used where there is a risk of injury or bodily contamination.
Recommendations for protective clothing, e.g. footwear, goggles, masks, etc. are
given in the Personal Protection Equipment Guid , e issued by the PETRONAS
Safety Committee.

FIGURE 12.02.01

MULTI-PURPOSE MAINTENANCE BUILDING

Notes: 1. Hot workshop is at furthest point from vehicle bays with wash rooms in between
2. The wash bay is adjacent to the maintenance building, but not normally enclosed

13.00.00.

GENERAL SERVICES

13.01.00.

COMMUNICATIONS

13.01.01.

General Considerations
The provision and use of communications systems are determined by operational and
administrative requirements. They should be suitable for use in either non-hazardous
or hazardous areas as appropriate, within the plant and associated facilities such as
jetties, pump stations, etc. The equipment should conform with local authorities'
requirements, or PETRONAS standards whichever is the most stringent.
Local authorities should be consulted with a view to their providing and installing the
requisite equipment on a rental basis before consideration is given to installing
independent systems.
New developments in communications technology must be considered at the depot
design or plant modification stage. The most significant is the fundamental changes in
the way closed-circuit television/telephones/computers/video recorders will be applied
to operational, administrative, training, security and maintenance requirements of
plant. Meanwhile, the various kinds of standard communications methods and
equipment likely to be required at installations and depots are considered in this
section.

13.01.02.

References
(a) Telephones
Recommendations are detailed in the Electrical Engineering Guidelines for
Marketing Facilities.

(b) Radio
Where the distance to be spanned does not exceed 30 km, Very-HighFrequency (VHF) radio equipment is recommended, see the Electrical
Engineering Guidelines for Marketing Facilities.

(c) Portable Loud Hailers

Suitable equipment is recommended in the Electrical Engineering Guidelines
for Marketing Facilities.

(d) Two-way Loud Speaker System

Recommendations are given in the Electrical Engineering Guidelines for
Marketing Facilities.

(e) Teleprinter (Telex) System

See the Electrical Engineering Guidelines for Marketing Facilities.

(f) Visual Signals

Where it is not practicable to install telephones or other means of communication,
visual aids may be used for locating personnel, see the Electrical Engineering
Guidelines for Marketing Facilities.

(g) Pneumatic Tube System

This is a convenient system of conveying documents over short distances
between two or more points; for details see the Electrical Engineering Guidelines
for Marketing Facilities.
Further precautions are mentioned in the Electrical Engineering Guidelines for
Marketing Facilities Section 3 and the Electrical Safety publication issued by the
PETRONAS Safety Committee.
When 'Safe' equipment is repaired locally; it must be ensured that the degree of
protection originally provided has not been reduced.

13.01.03.

Warning Notices and Safety Signs

Warning notices must be prominently displayed wherever a hazard exists for which
specific safety precautions must be observed. Safety signs must be prominently and
strategically sited.

13.02.00.

ADMINISTRATION SERVICES

13.02.01.

Office Accommodation
Offices not only provide suitable working conditions for the administrative staff and a
focal point for the control of operations, but also present a shop window to the public.
For this reason consideration should be given to layout and architectural features as
follows:
(a)

The exterior should be designed with due regard to local architecture and
materials.

(b) The building should be so sited that visitors can park their cars and gain access
to the office without entering the installation or depot working area.
(c) Allowance for future expansion should be made (upwards as well as outwards).
(d) Unless other methods of heating are more economical, preference should be
given to oil-fired systems.
(e) Air-conditioning should be considered for offices and mess rooms in hot climates,
see 04.03.11.

(f) Spare requirements, operations, or local regulations, may require provision of

storerooms, lavatories, mess rooms, etc. in the main office block. This
arrangement is usually more economical and presents a more pleasing
appearance than a group of small separate structures - see 04.01.07. In
composite buildings, hygienic standards require that rooms such as lavatories
are properly located in relation to offices, mess rooms or kitchens.
(g) Spacious, cool, well-lit and well-ventilated accommodation has a beneficial effect
on staff relations and work efficiency. Floor areas in offices should be such that
each person will be allotted a minimum of about 6m2 after deductions for
passages and built-in furniture.
(h) All rooms where personnel work should be shielded against direct sunlight by
suitable blinds or shades. In insect-ridden districts, doors and windows should be
screened.

13.02.02.

Laboratory
Laboratories are preferably located in the same building as the plant office for:
(i) Administrative convenience, and
(ii) Because it enables the laboratory to be entered from outside the plant when
facilities are provided for testing customers' oils, checking samples of joint industry
cargoes, etc.
If control laboratories are sited far from the blending or reception facilities,
consideration must be given to providing transport, or a pneumatic tube system [see
13.01.02(g)] to ensure quick transmission of documents.

References
The essential safety features in laboratory layout and design are given in Section
08.11.00 of the Plant Operating Manual and PETRONAS Safely and Health
Committee - Guidelines for Laboratory Safety.

13.02.03.

Personnel Services
The standard of personnel services provided must conform with local regulations and
customs. The following items must be considered at the design or rebuilding stages:
(a) Medical
The extent of medical facilities and equipment to be provided will depend upon
local conditions and the medical service available in the locality, see Occupational
Health and Protection, Section 6.1 of the Shell Marketing Safety Code.
(b) Training
Consideration should be given to the provision of training facilities for installation
and depot personnel.

(c) Canteen
When personnel are required to remain at the installation or depot during meal
times, accommodation should be provided for meals. Whether the
accommodation also includes facilities for preparing or heating meals must
depend upon local conditions; see also 01.01.02(q).
(d) Living Accommodation
Living accommodation for company and employees should not be provided within
the plant boundary; see also 01.01.02(v).
(e) Protective Clothing
The provision of protective clothing will depend upon the nature of the work.
Recommendations regarding safety clothing are contained in the Personal
Protection Equipment Guide issued by the PETRONAS Safety Committee.
(f) Uniforms
Uniforms, or suitably marked overalls for personnel should be limited to specific
jobs, for example, personnel delivering to customers (vehicle drivers, bunker
crews, etc.) and watchmen.

13.02.04.

Security
Other than fencing/walls, gate checks and suitable notices, the extent of
arrangements for security must depend upon local operating conditions; see also
03.03.00. Such precautions are night watchmen, internal patrols (plus time clocks) or
flood lighting are not considered to be necessary where good external security exists
maintained by the local authority.
Specific advice on security precautions - particularly against sabotage - can be
obtained from PETRONAS.

13.03.00.

FIRE-FIGHTING FACILITIES AND EQUIPMENT

13.03.01.

Summary
Installation and depot layout, equipment and operating procedures must be planned
so that the risk of fires is remote, and to preventing their spread if they do occur as a
result of accidental spillage, human error or other unforeseen hazards. It is essential
that:
(i) Fire fighting equipment is provided on a scale which accords with proven design
and operational standards.
(ii) Fire alarm systems are designed to enable an immediate alarm to be given in the
event of fire.
(iii) Personnel are properly trained in the fire emergency plan.

Advice on aspects of fire protection and fire fighting is given in Section 15.00.00 and
the following manuals:
Electrical Engineering Guidelines for Marketing Facilities - Electrical Fire Alarms
Plant Operating Manual, Volume 1 - Section 07.00.00 - Fire Fighting
Cc

International Safety Guide for Oil Tankers and Terminals (ISGOTT).

14.00.00.

CHEMICALS HANDLING
In many countries the PETRONAS Marketing Company may provide Supply and Distribution
Operations Services to the Chemical Marketing Function.
The following notes are intended to provide general guidance in such instances.
The range of chemicals marketed by the group have a greater spread of
physical/chemical characteristics and hazards than main products.
For example, Chemical solvents e.g. Acetone and Isopropyl Alcohol are water
miscible whereas Hydrocarbon Solvents e.g. Xylene and Toluene are water
immiscible. Moreover, chemicals may be flammable, toxic, corrosive, oxidising agents
or be reactive with water and in may cases possess a combination of these hazards.
Because of this, very specific advice on their reception, storage and handling is
required in order to ensure a viable and safe operation.
Advice relating to the reception, storage and handling of chemicals can be found in:

'Chemicals Handling and Safety Manual'.

'Depot Manual'.

'Agriculture Safety Guide'.

'The PETRONAS Guide to The Warehousing of Chemicals'.

Advice on hazard classification and hazard labelling requirements can be found in:

'International

Transport

and

EC

Supply

Classification

Manual'.

Advice on packaging can be found in:

'Packaging Manual'.

Product Sections I, II and III.

Container Sections I and II.

'Packaging Handbook'.

Advice on label formatting and requirements in relation to product hazard can be

found in:

Shell Chemicals 'Visual Identity' Manual (Revised 1990). (CPA).

Note: Irrespective of the availability of the above reference sources a Materials Safety
Data Sheet (MSDS) should be held for every Chemical Product received, handled or
stored at Group or Third Party operational or storage locations.