VALERO – KROTZ SPRINGS
SHG #27
Page 1 of 14
Revised 07/09/02
FALL PROTECTION AND ELEVATED WORK GUIDELINES INDEX
A
J
Acceptable And Unacceptable Anchorage ........... 14
Access Ways............................................................... 6
Adjustable .................................................................... 4
Anchorage ....................................................... 3, 11, 14
Anchorage Connectors ............................................ 11
Appendix 1 ................................................................ 13
Appendix 2 ................................................................ 14
Arrest System ............................................ 3, 4, 7, 9, 11
Job Specific Requirements ........................................ 6
B
M
Body Support ............................................................. 10
Miscellaneous Requirements ..................................... 8
Mobile Cranes ........................................................... 14
Mobile Equipment ....................................................... 7
C
Cone Roof Access ...................................................... 6
Contractor ................................................................... 5
Contractor Supervisors............................................... 5
Crane ........................................................................... 8
Crane Operator .................................................. 14, 15
D
Deceleration Device.............................................. 3, 11
Definitions .................................................................... 3
Designed Access Ways ............................................. 6
Distance Considerations .......................................... 10
Docks ........................................................................... 6
D-ring ......................................................... 3, 10, 11, 15
Dual Lanyard ............................................................... 4
E
Excavations ................................................................. 7
F
Fall Hazards ........................................................ 3, 5, 8
Fall Prevention ............................................................ 3
Fall Protection ....................... 3, 4, 6, 7, 8, 9, 10, 11, 12
Fall Protection Equipment .............................. 5, 7, 8, 9
Free Fall ....................................................................... 3
G
Guardrail .................................................................... 13
Guidelines .................................................................... 6
H
Harness...................................................................... 10
Horizontal Lifelines .................................................... 12
I
Inspection .................................................................... 9
L
Ladders ................................................................ 3, 5, 6
Lanyards............................................................... 11, 12
Leading Edge........................................................... 4, 7
Lifelines .......................................................... 4, 7, 8, 14
Low Sloped Roof ......................................................... 4
N
Natural Fiber Ropes .................................................... 9
O
Operator ..................................................................... 15
Owning Area Lead Technicians Or Designees ........ 5
P
Personal Fall Arrest System ....................................... 4
Pipe............................................................................. 14
Pipe Rack ..................................................................... 7
Positioning Lanyard ..................................................... 3
Project Engineer ......................................................... 5
Purpose ........................................................................ 3
Q
Qualified Person ...................................... 4, 5, 9, 11, 12
R
Removal From Service ............................................... 9
Responsibilities ............................................................ 5
Restraint Lines ........................................................... 13
Retractable....................................................... 4, 12, 15
Retractable Lanyards ............................................... 14
Rooftops ....................................................................... 6
Rope ....................................................................... 9, 13
S
Safety Department ....................................... 5, 8, 9, 15
Scaffold ........................................................................ 7
Scope ........................................................................... 3
Signal Person ............................................................ 14
Snaphooks ................................................................. 10
Storage ....................................................................... 10
VALERO – KROTZ SPRINGS
Structural Steel .......................................................... 14
Supervisor ........................................................... 14, 15
T
Tank Cars .................................................................... 7
Trailers ......................................................................... 7
Training ........................................................................ 9
Trucks .......................................................................... 7
V
Valero Representative ............................................. 14
Vertical Lifelines ........................................................ 12
W
Warning Line System ............................................... 13
SHG #27
Page 2 of 14
Revised 07/09/02
VALERO – KROTZ SPRINGS
SHG #27
Page 3 of 14
Revised 07/09/02
FALL PROTECTION AND ELEVATED WORK GUIDELINES
1.0
PURPOSE
To ensure the safety of all personnel where fall hazards exist.
2.0
SCOPE
The provisions of this Safety and Health Guide will apply to all Valero and contractor personnel
within this facility.
Personnel must be continuously protected from injury due to falls, including movement to and
from the actual work area, whenever exposed to an unprotected side or edge with a fall hazard of
6 feet or more or above a recognized hazard (open vat, rotating equipment, etc.).
3.0
DEFINITIONS

Anchorage - a structural member or suitable anchor point to which the fall protection
system is ultimately connected. When a fixed anchor point is not practical, a mobile crane
can be used as an anchor point. (refer to Appendix 2)

Anchorage Connector - component which couples the fall arrest system to the anchorage
if direct attachment is not possible. (examples: sling or chokers designed for fall arrest)

Deceleration Device (Shock Absorber) - a device that serves to dissipate a substantial
amount of energy during a fall arrest or otherwise limits the energy imposed on the body
during fall arrest.

Fall Prevention - means used to stop the initiation of a fall to a lower level and designed so
that personnel cannot reach the unprotected edge.

Fall Protection - the use of passive equipment designed to stop and/or control the free fall
once a fall has been initiated.

Free Fall - distance the harness D-ring travels from the onset of a fall to the time when the
fall arrest system is activated (excludes deceleration distance and any elongation).

Positioning Lanyard – a flexible strap rigged to allow an employee to be supported on an
elevated vertical surface such as a wall or a ladder, and work with both hands free while
leaning. A fall protection lanyard shall be used in conjunction with a positioning lanyard.
VALERO – KROTZ SPRINGS
SHG #27
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Revised 07/09/02

Fall Protection Lanyard - a flexible energy absorbing strap with a connector at each end
for connecting to the full-body harness at one end and an anchorage or anchorage
connector at the other. The four types of fall protection lanyards that may be used in the
refinery are:
∙
Adjustable - designed with a buckle or other device that allows the strap length to
be changed.
∙
Dual - designed with two straps in a "Y" configuration but with a single point of
attachment to the body support harness.
∙
Retractable - drum wound lanyard which automatically locks to arrest a fall.
∙
Traditional - single strap with end connectors, normally 6’ long but available in
various lengths.

Leading Edge - unprotected edge of a walking/working surface that changes location as
floor, roof or deck is added or removed.

Lifeline - a flexible line for connection to an anchorage at one end to hang vertically
(vertical lifeline) or for connection at both ends to stretch horizontally (horizontal lifeline)
and to which other elements of a fall arrest system are attached.

Personal Fall Arrest System - fall protection consisting of anchorage’s, locking connectors,
deceleration device, full body harness, and a lanyard, lifeline, or combination of these.

Qualified Person- individual trained and authorized to perform the stated task or function.

Low Sloped Roof - a roof having a slope less than or equal to 4 on 12 inches vertical to
horizontal.
VALERO – KROTZ SPRINGS
4.0
SHG #27
Page 5 of 14
Revised 07/09/02
RESPONSIBILITIES
Individual/Group
Owning Area Lead
Technicians or Designees
And Contractor Supervisors
Assigned Responsibility
∙
Ensure that personnel are trained and fall hazards are
identified and properly addressed prior to job initiation.
∙
Coordinate and document training of personnel on equipment
that they will be expected to use.
Ensure that permanently installed fall protection equipment is
inspected at required frequencies by a qualified person.
Render unusable and remove from service any personal fall
protection equipment subjected to the forces of a fall.
Coordinate periodic inspections (every six months) of the
portable fall protection equipment.
Keep all records of inspection of fall protection equipment on
file.
Aid department(s) in ordering new fall protection equipment.
Inspect and approve the use of mobile cranes for anchor
points.
Perform annual inspections of ladders, tagging each with the
inspection date, the name of the person who inspected the ladder,
and the weight limit for the ladder.
Must inspect fall protection equipment prior to each use.
Report any fall to supervision immediately.
Ensure all equipment is used as designed and report any
misuse.
Ensure methods to address fall hazards are included during
project design and construction.
Provide all fall protection equipment required for their job.
All fall protection equipment used by contractors must meet
OSHA and Valero requirements.
Responsible for use, care and inspection of equipment used
by their employees, and must ensure that the equipment is
appropriate for its intended use.
∙
∙
∙
Safety Department
∙
∙
∙
∙
All Personnel
Project Engineer
∙
∙
∙
∙
∙
∙
Contractor
5.0
∙
GUIDELINES
5.1.
JOB SPECIFIC REQUIREMENTS
5.1.1 DESIGNED ACCESS WAYS
Personnel using designed access ways (cab, crane, truck, rail car, access ladders, etc.)
shall maintain three-points-of-contact when climbing or descending, i.e., the individual
must not carry anything in his/her hands. Materials must be carried in pouches or brought
up/let down by other means.
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SHG #27
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5.1.2

WORK WHILE ON LADDERS:
Fall protection is required on ladders if the working elevation is 6 feet or above (as
measured from the bottom of the feet) and the work requires the use of both
hands.

Prior to using a ladder, it must be inspected and if found to be unacceptable for
use, remove from service. In addition, Safety must be notified.

All ladders will be inspected yearly by a member of the safety staff. Each inspected
ladder will be tagged with the inspection date, the name of the person who
inspected the ladder, and the weight limit for each ladder.
5.1.3 WORK ON ROOFTOPS
When performing work on equipment located on low sloped roof tops, fall prevention or
protection is required only if the work demands that the employee be within 6 feet of the
roof edge, not including access to and egress from the roof. Persons involved in roofing
work must be protected by either a fall prevention or fall protection system. This does not
include the inspection of the area prior to beginning work.
5.1.4 CONE ROOF ACCESS
Inside the marked area (indicated by black/yellow stripes), you do not need fall protection
or a thickness check. To access a cone roof tank outside the marked area, a thickness
check by Maintenance is required. Fall protection is also required if work is to be
performed within 6 feet of the edge (i.e., restraint lines attached to center vent).
5.1.5 WAREHOUSE/MARINE DOCKS
A warning device, such as removable chains and well marked areas, i.e., (painted black
and yellow stripes) is required for any dock with an unprotected edge where a fall of 6 Ft.
or more may occur.
5.1.6

MOBILE EQUIPMENT:
Tank Cars – Personnel working at loading racks do not need to wear fall protection
equipment if working within the handrail enclosed areas of the gangway or top tank
hatch. If a work activity requires an individual to leave the enclosed areas, fall
protection shall be worn.

Trucks or trailers –personnel accessing the tops of trucks or trailers must maintain
three points of contact or must be tied off for Fall Protection.

Self Propelled Mobile Equipment - Before beginning work on self-propelled, mobile
equipment (field maintenance on cranes, boom erection, loading or unloading
flatbed trucks, etc.), personnel involved will consider routes of access and egress
and how fall protection can be provided. Personnel working from or riding in any
aerial lift device, i.e. manlift, shall wear a fall restraint device with the lanyard
attached to a designated anchor point.
VALERO – KROTZ SPRINGS
SHG #27
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5.1.7 LEADING EDGE WORK
Each Valero or contractor employee involved in constructing a leading edge or if his/her
work may require them to approach a leading edge (i.e. decks, platforms, roofs, vessels,
and tanks), 6 feet or higher than the next lower level, shall be protected from falling by
guardrails or a personal fall arrest system.
5.1.8 EXCAVATIONS
Valero and/or contractor employees working near the edge of an excavation that has
hidden edges or is 6 feet or more in depth must be protected from falling in by guardrails,
fences, barricades, earthen dike or personal fall protection.
5.1.9 SCAFFOLD ERECTION, DISASSEMBLY AND USE
When erecting and disassembling scaffold fall protection will be required above 10 feet.
Once the scaffold is erected, individuals may work within the guarded area of the handrails
without fall protection, if it is approved and green tagged.
5.1.10 PIPE RACK ACCESS
To minimize the hazards involved in pipe rack access/egress, one of the following
alternatives may be used:
∙ Ladders, scaffolds or manlifts.
∙ Permanent access platforms.
5.1.11 PIPE RACK TRAVERSING
Personnel traversing a pipe rack are required to be continuously tied off to lifelines or other
suitable anchor points.
5.1.12 CRANE BOOM SETUP
Certain activities involved in setting up a crane contain fall hazards. Ladders, manlifts, or
horizontal lifelines will be used during crane erection.
5.2
MISCELLANEOUS REQUIREMENTS
5.2.1

PURCHASE
Fall protection equipment is considered Personal Protective Equipment (PPE).
Only equipment that has been approved by the Safety Department may be
purchased for use by Valero employees.

New equipment will be received and inspected by the Safety Department. It will be
tagged with the next inspection due date and entered into the maintenance
tracking system as appropriate prior to being used.
5.2.2

EXCLUSIVE USE
Fall protection equipment is for fall protection use only.

Any equipment which is used as part of a fall protection system but could also be
used for other activities (such as slings, chokers, etc.) must be tagged or otherwise
identified as fall protection equipment.
VALERO – KROTZ SPRINGS
SHG #27
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5.2.3

INSPECTION
All fall protection equipment must be inspected by the user prior to each use. If the
next inspection due date has passed, return the equipment to the Safety
Department for inspection prior to use.

An inspection of portable fall protection equipment will be performed every six
months by the Safety Department. Red electrical ties will be placed on each
piece of fall protection when it is inspected in June. Green ties will be used when
the equipment is inspected in December.

Some types of equipment (such as self-retracting lanyards) also require periodic
recertification by the manufacturer at scheduled frequencies.
The Safety
Department will manage this process, as well as the associated documentation.
Permanently installed equipment must have a documented inspection performed
annually by a qualified person designated by the Maintenance Director.
5.2.4

REMOVAL FROM SERVICE
The Safety Department will determine the parts of a personal fall arrest system
that must be immediately removed from service if subjected to fall forces.

Any component of a fall protection system with a significant defect, such as cuts,
tears, abrasions, mold, or undue stretching; alterations or additions which might
affect its efficiency; damage due to deterioration, contact with high heat, acids or
corrosives; distorted hooks or faulty hook springs; tongues unfitted to shoulder of
buckles; loose or damaged mountings; or non-functioning parts must be
immediately removed from service and returned to the Safety Department to be
destroyed.
5.2.5

TRAINING
Personnel required to use fall protection must receive training on this procedure as
well as training specific to the type of equipment being used.

All training must be documented, including the name of the employee, the date of
training, and the signature of the person conducting the training.

Contractors must train their employees on this Fall Protection Guideline SHG #27.
5.2.6 NATURAL FIBER ROPES
Natural fiber ropes are not allowed for use in any fall prevention or protection system.
5.2.7 STORAGE
Equipment not being used must be stored in a protected area away from exposure to
extreme heat and chemicals.
VALERO – KROTZ SPRINGS
SHG #27
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5.2.8

DISTANCE CONSIDERATIONS
A free fall protection system should not allow greater than a 6-foot free fall.

The user must not be allowed to contact the next lower level should the fall occur.
Therefore, total fall distance must be less than the height above the next level.
This includes:
∙ free fall distance (6 foot maximum)
∙ system elongation (6 inches)
∙ deceleration distance (shock absorber lengthening of up to 3.5 feet)
∙ employee's height (measured from the "D" ring) (allow 5 feet)

5.3
Use Appendices A and B of the OSHA standard to help in fall protection selection.
REQUIREMENTS FOR SPECIFIC EQUIPMENT
5.3.1

BODY SUPPORT
A body harness must be worn snug at the upper legs and with all straps tucked in
so as not to get caught during movement. The chest strap must be between the
chest and the collarbone, and the rear D-ring attached between the shoulder
blades. Body belts are not allowed.

Harness D-ring use is based on its location:
Location
Use
Back
General Fall Protection
Front
Fall Protection during climbing activities and rescue
5.3.2

SNAPHOOKS
Only self-closing, self-locking type snaphooks will be allowed for fall protection use
in order to reduce the potential for accidental "roll-out".

The snaphook must open and close freely and must be fully closed around the
anchorage or anchorage connector.
5.3.3

ANCHORAGE CONNECTORS
Anchorage connectors are used when the fall arrest system cannot be directly
attached to the anchorage. Examples of connectors include designated fall
protection slings, chokers and shackles.

Connectors must meet the strength requirements of the system as a whole, that is
5000 lbs. as designed by a qualified person.
VALERO – KROTZ SPRINGS
SHG #27
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5.3.4

ANCHORAGE
The anchorage point should be at least D-ring high, preferably overhead, to
minimize pendulum-like swing fall.

The anchorage must be either capable of 5000 lbs. dead weight per person
attached, or be designed by a qualified person.

See Appendix # 2 for acceptable and unacceptable anchorage, which meet the
5000 lbs. dead weight minimum.

See Appendix # 2 for use of mobile cranes as approved anchor points
5.3.5

DECELERATION DEVICES
A deceleration device is required as part of an overall fall arrest system.
5.3.6

GENERAL LANYARDS
The shortest length lanyard possible should always be used unless connecting to a
vertical lifeline that is not within 3 feet of the worker. In these specialized cases, a
longer lanyard may be used to connect higher on the lifeline to minimize swing in
the event of a fall.

Use a cut or heat resistant pad, if the lanyard may be exposed to abrasive edges
or hot surfaces.

When worn but not in use, ensure the lanyard is wrapped or tucked in so as not to
present a tripping hazard.
5.3.7

DUAL LANYARDS
One leg of the lanyard must be secured at all times when exposed to the fall
hazard. The dead leg must not be left hanging where it could become entangled
and cause a fall. The loose end of the lanyard should be attached to the user's
harness in such a manner that will not entangle the user.
VALERO – KROTZ SPRINGS
SHG #27
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Revised 07/09/02
5.3.8

RETRACTABLE LANYARDS
These devices are designed to arrest the fall within 2 feet. Never allow these
devices to retract uncontrolled. This may require the use of a tag line to extract
and retract the line.

These devices must be positioned overhead and used in a manner to prevent a
swing fall impact.
5.3.9

VERTICAL LIFELINES
These must have a formed eye or other approved termination on one end for
suspension from the anchorage point and must extend below the lowest level of
travel.

The grab device must be compatible with the size and type of cable used and
should remain above the shoulders of the user.

Only short lanyards (no longer than 3 feet in length) should be connected to a
vertical lifeline in order to ensure a minimum fall distance.

The lower end of the lifeline must be either attached to a second anchor point or
be weighted down to provide stability. The weight may be attached with a knot in
this case.

Only one person can utilize a given vertical lifeline at any given time.
5.3.10 HORIZONTAL LIFELINES

These must be designed by a qualified person.

If the span of the lifeline requires intermediate supports, these must be designed to
allow freedom of movement throughout the length of the lifeline. If not, a dual
lanyard will be required to maintain continuous fall protection.
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SHG #27
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APPENDIX 1
MINIMUM REQUIREMENTS FOR FALL PREVENTION SYSTEMS
GUARDRAIL
Top Rail
Capable of 200 lbs. of force with < 3 inches in deflection and no permanent
deformation, optimum 42 inches high, 39 inches minimum
Mid Rail
Capable of 150 lbs. of force with no permanent deformation, maximum opening of
19 inches between rails
Wood
At least a 2x4 top rail and a 1x6 mid rail on 8-foot maximum centers. Minimum
1500 psi construction grade lumber
Pipe
1.5" Nominal Pipe Size (NPS) Schedule 80 on 8-foot maximum centers
Steel
2" by 2" by 1/4" angle iron on 8-foot maximum centers
Wire Rope
1/4" diameter cable stretched taut (< 3" deflection)
RESTRAINT LINES
Capable of 3000 lb. tensile load. Limit travel so no edges are reachable in ANY direction.
WARNING LINE SYSTEM
Use only in low sloped area!
System must be erected 6 feet or more from the unprotected edge. The access path must be marked
with warning lines to the ladders, storage areas, etc.
Stanchions must be capable of withstanding 16 lb. tipping strength horizontally.
Cable, wire, rope or chain capable of 500-lbs. break or tensile strength shall be installed between 34" and
39" above the work surface. It shall be flagged at 6-foot intervals with high visibility materials.
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SHG #27
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APPENDIX 2
ACCEPTABLE AND UNACCEPTABLE ANCHORAGE POINTS
These are general guidelines. Use a designed anchor point when available. Good judgment shall be
used when selecting a substantial anchor point. Consider fall distance, load carrying capacity of the
anchor point, and mechanical integrity of the structure.
1.
PIPE



2.
STRUCTURAL STEEL

3.
2" x 2" x ¼ “ angle. Span must be 10 feet or less.
LIFELINES



4.
Three (3) inch NPS, of any metal pipe, may be used as an anchorage point if in good
condition.
The pipe must be attached or supported on either side of the anchor point so that it will
withstand the force of a fall should one occur.
Long runs of pipe, such as in a pipe rack, should be continuous for at least two
supports on either side of the attachment or anchor point. Pipe support spans must
not be greater than 20 ft apart for any pipe size if the pipe is to be used for an
anchorage point.
∙
Do not tie off on insulated pipe of any size.
∙
Do not tie off on plastic pipe.
∙
Do not tie off on electrical conduit of any size.
Rated for 5,000#
3/8” diameter galvanized steel cable
Lifeline cables that are part of a climbing protection device are acceptable. Major
distance between supports 20’. All horizontal lifelines have signs indicating 2 persons
max capacity and retractable lanyard to be used.
MOBILE CRANES AS ANCHOR POINTS (when no other reasonable means of anchorage is
available).






Conduct a pre-lift meeting involving all personnel included in the work. This will
consist of, but not be limited to, crane operator, signal person, job supervisor,
persons to be anchored to the crane, etc. Contractors must have their Valero
Representative present.
The crane will be on stable ground and all outriggers down.
A designated, competent signal person will maintain visual and/or radio contact with
the crane operator and the people anchored to the crane.
The retractable lanyards and body harness will be connected to the hook and
positioned above the work area. The hook should be positioned with sufficient height
to avoid contact with personnel.
The engine will be shut off and the crane will not be moved with personnel anchored
to it.
The Operator must be out of the machine during the use of the machine as an
anchoring point.
VALERO – KROTZ SPRINGS
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
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
SHG #27
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The Operator must stay within a 10’ radius of the machine at all times.
Retractable Lanyards will be used.
Two persons maximum on the anchor point.
Notification of the Safety Department is required before work activity.
NOTE: When securing to an anchorage point, the user must take into consideration the deflection
of the pipe or the cable and for the amount of lanyard that would be lengthened from the shock
absorber unstitching, plus an individual's length measured from the D-ring. Also check the
anchorage point for corrosion. When a retractable is used, the swing hazard will be minimized.
If the situation occurs that the above conditions cannot be met as an anchorage point, the employee
will contact his/her Supervisor who will determine if the selected anchorage point meets the
requirements of this procedure.