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I. Purpose

The intention of this program is to provide basic knowledge and safety

precautions to employees who use hand and power tools and who may be
exposed to the inherent hazards of falling, flying, abrasive and splashing
objects, or exposed to harmful dusts, fumes, mists, vapors, or gases.

II. Scope
This procedure shall be applied to all employees and contractor personnel
who will utilize hand and portable power tools or equipment while
executing their assigned duties within Petron facilities and/or plants.

III. Responsibility
A. Supervisor

a. Trains and/or instructs personnel on the proper use of the tools

which they are expected to operate.
b. Spot-checks the job sites to ensure personnel are using their tools
properly and as outlined in this program.
c. Provide employees the right tools for jobs they required to perform.

B. Tool Keeper/Store Supervisor

a. Ensures that the tools being withdrawn from the store are properly
maintained and in good condition.
b. Ensures that defective tools returned to the store are tagged “Do
Not Use” and shall no be reissued until appropriate repair is done by
qualified personnel.

C. Employee/Tool User
a. Uses the appropriate tool for the job and follows the safety
precautions stated in this policy.
b. Inspects the tools before use and reports any deficiency/damage to
the immediate supervisor.
c. Wears appropriate Personal Protective Equipment.

D. HSE
a. Assists in the selection of appropriate Personal Protective
Equipment.
b. Performs periodic safety inspections and audits to review
compliance with the tool requirements.
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c. Assists in the development of specific training, when needed.

IV. General Safety Precautions

The following are general safety rules to prevent all hazards involved in the
use of hand and power tools:

a. All tools, regardless of ownership, shall be of an approved type and

maintained in good condition. (Tools are subject to inspection at any
time. A supervisor has the authority and responsibility to condemn
unsafe tools, regardless of ownership).
b. Unsafe tools shall be tagged with an unsafe tag to prevent their use.
c. Employees shall always use the proper tool for the job to be performed.
Makeshift and substitute tools are prohibited.
d. Hammers with metal handles, screwdrivers with metal continuing
through the handle and metallic measuring tapes shall not be used on or
near energized electrical circuit or equipment.
e. Tools shall not be thrown from place to place or from person to person;
tools that must be raised or lowered from one elevation to another shall
be placed in tool buckets or firmly attached to hand lines.
f. Tools shall never be placed unsecured on elevated places.
g. Impact tools such as chisels, punches and drift pins that become
mushroomed or cracked shall be dressed, repaired or replaced before
further use.
h. Chisels, drills, punches, ground rods and pipes shall be held with
suitable holders or tongs (not with the hands) while being struck by
another employee.
i. Shims shall not be used to make a wrench fit.
j. Wrenches with sprung or damaged jaws shall not be used.
k. Pipe shall not be used to extend a wrench handle for added leverage
unless the wrench was designed for such use.
l. Tools shall be used only for the purposes for which they have been
approved.
m. Tools with sharp edges shall be stored and handled so that they will not
cause injury or damage. They shall not be carried in pockets unless
suitable protectors are in use to protect the edge.
n. Wooden handles that are loose, cracked or splintered shall be replaced.
The handle shall not be taped or lashed with wire.
o. Tools shall not be left lying around where they may cause a person to
trip or stumble.
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p. When working on or above open grating, a suitable covering shall be

used to cover the grating to prevent tools or parts from dropping to a
lower level where others are present, or the danger area shall be
barricaded or guarded.
q. The insulation on hand tools shall not be depended upon to protect
users from high voltage shock (except approved live line tools).
Appropriate PPE shall be used to prevent such hazard.

V. Hand Tools
Hand tools are tools that have no outside power source, other than the
physical force applied by the user.

A. Types of Hand Tools

Although it is not feasible to list the hundreds of hand tools available, they
may be grouped into the following general categories:
a. Striking tools (such as hammers, mallets, and sledges)
b. Turning tools (such as wrenches)
c. Metal-cutting tools (such as shears, snips, bolt cutters, wire cutters,
hacksaws, metal chisels, and files)
d. Wood-cutting tools (such as hand saws, drills, planes, axes, hatchets,
mauls, wedges, and wood chisels)
e. Material handling tools (such as crowbars and hooks)
f. Gardening tools (such as shovels, rakes, hoes, and post-hole diggers)
g. Screwdrivers
h. Pliers
i. Knives and miscellaneous cutting tools (such as scissors, scrapers, bits,
and awls)

B. Hazards

The primary hazards encountered when using hand tools include striking or
contacting part of the body with the hand tool or the work piece and
projectiles flying off the tool or work piece into the eyes. The most
common injuries from the use of hand tools are:

a. Laceration or cut from a knife blade, saw, or other tool with a sharp
surface or jagged edge.
b. Contusions, or bruises from striking the fingers with the tool.

These injuries are generally caused by:

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a. Not wearing appropriate PPE.

b. Using the wrong tool for the work to be performed.
c. Improper use of the tool.
d. Failure to inspect the tool before use.
e. Defective tools.

VI. Power Tools

In general, the hazards from portable power tools are similar to hand tools,
however they are more dangerous than hand tools because they are
energized.
Portable power tools are normally grouped according to their power source,
for example:

a. Electric (such as saws, drills, and grinders).

b. Gasoline (such as mowers, trimmers, and edgers).
c. Hydraulic (such as jacks).
d. Pneumatic (such as chipping tools, impact wrenches, spray painting
units, and roto-hammers).
e. Powder-actuated (such as nail and/or fastener drivers).

The following are safety precautions that should be observed by power tool
users:

a. Never carry a tool by the cord or hose.

b. Never yank the cord or the hose to disconnect it from the receptacle.
c. Keep cords and hoses away from heat, oil, and sharp edges.
d. Disconnect tools when not in use, before servicing, and when changing
accessories such as blades, bits and cutters.
e. All observers should be kept at a safe distance away from the work
area.
f. Secure work with clamps or a vise, freeing both hands to operate the
tool.
g. Avoid accidental starting. The worker should not hold a finger on the
switch button while carrying a plugged-in tool.
h. Tools should be maintained with care. They should be kept sharp and
clean for the best performance. Follow instructions in the user's manual
for lubricating and changing accessories.
i. Be sure to keep good footing and maintain good balance.
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j. The proper apparel should be worn. Loose clothing, ties, or jewelry can
become caught in moving parts.
k. All portable electric tools that are damaged shall be removed from use
and tagged "Do Not Use."

A. Electric Tools

Among the chief hazards of electric-powered tools are burns and slight
shocks which can lead to injuries or even heart failure. Under certain
conditions, even a small amount of current can result in fibrillation of the
heart and eventual death. A shock also can cause the user to fall off a
ladder or other elevated work surface.

In addition to the above, the following are specific safe practices to be

observed when using electric tools:

a. Electric tools should be operated within their design limitations.

b. Gloves, rubber mat and safety footwear are recommended during use of
electric tools.
c. When not in use, tools should be stored in a dry place.
d. Electric tools should not be used in damp or wet locations.
e. Electrical tools shall not be used where there is hazard of flammable
vapors, gases, or dusts.
f. The non-current carrying metal parts of portable electric tools such as
drills, saws and grinders shall be effectively grounded when connected
to a power source unless:
1. The tool is an approved double-insulated type, or
2. The tool is connected to the power supply by means of an isolating
transformer or other isolated power supply.

Powered abrasive grinding, cutting, polishing, and wire buffing wheels

create special safety problems because they may throw off flying
fragments.

Before an abrasive wheel is mounted, it should be inspected closely and

sound- or ring-tested to be sure that it is free from cracks or defects. To
test, wheels should be tapped gently with a light non-metallic instrument.
If they sound cracked or dead, they could fly apart in operation and so must
not be used. A sound and undamaged wheel will give a clear metallic tone
or "ring." Please see figure 1.
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To prevent the wheel from cracking, the user should be sure it fits freely on
the spindle. The spindle nut must be tightened enough to hold the wheel in
place, without distorting the flange. Follow the manufacturer's
recommendations. Care must be taken to assure that the spindle wheel will
not exceed the abrasive wheel specifications. Please see figure 2.

Due to the possibility of a wheel disintegrating (exploding) during start-up,

the employee should never stand directly in front of the wheel as it
accelerates to full operating speed.

Portable grinding tools need to be equipped with safety guards to protect

workers not only from the moving wheel surface, but also from flying
fragments in case of breakage.

B. Pneumatic Tools

Pneumatic tools use air as a power source. Such tools include chipping
tools, impact wrenches, spray painting units, roto-hammers, grinders, saws,
and drills. These tools operate under air pressure and must have a pressure-
regulating device mounted in line between the supplied air and the tool.
The air-line hose used must be designed to withstand the pressure being
applied.

There are several dangers encountered in the use of pneumatic tools. The
main one is the danger of getting hit by one of the tool's attachments or by
fasteners the worker is using with the tool.
The following are specific safety requirements when using portable
pneumatic tools:

a. Eye protection is required and face protection is recommended for

employees working with pneumatic tools.
b. Noise is another hazard. Working with noisy tools such as jackhammers
requires proper and effective use of hearing protection.
c. Pneumatic tools shall never be pointed at another person.
d. Pneumatic power tools shall be secured to the hose by an approved
clamp to prevent the tool from becoming accidentally disconnected.
e. Safety clips or retainers shall be securely installed and maintained on
pneumatic tools’ couplings and fittings to prevent attachments from
being accidentally expelled.
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f. All pneumatically driven nailers, staplers, and other similar equipment

provided with automatic fastener feed, which operate at more than 100
p.s.i. pressure at the tool shall have a safety device on the muzzle to
prevent the tool from ejecting fasteners, unless the muzzle is in contact
with the work surface.
g. Compressed air shall not be used to blow dust or dirt from clothing.
h. The manufacturers stated safe operating pressure for hoses, pipes,
valves, filters and other fittings shall not be exceeded.
i. The use of hoses for hoisting or lowering tools shall not be permitted.
j. Before making adjustments or changing air tools, unless equipped with
quick-change connectors, the air shall be shut off at the air supply valve
ahead of the hose. The hose shall be bled at the tool before breaking
the connection.
k. Compressed air tools, while under pressure, shall not be left
unattended.
l. All connections to air tools shall be made secure before turning on air
pressure.
m. While blowing down hose, do not point it toward people.
n. Powered tools shall be operated only by competent persons who have
been trained in their use.
o. Conductive hose shall not be used near energized equipment.
p. Where appropriate, screens must be set up to protect nearby workers
from being struck by flying fragments around chippers, riveting guns,
staplers, or air drills.

C. Powder-Actuated (or Cartridge Operated) Tools

Powder-actuated tools are hand tools capable of driving a pin, stud, bolt or
similar object into or through building materials, by means of an explosive
force derived from the detonation of a cartridge containing an explosive.
They operate like a loaded gun and should be treated with the same respect
and precautions. In fact, they are so dangerous that only personnel who
have received the manufacturer’s training and have been licensed may
operate explosive-actuated fastening tools.

Safety precautions to remember include the following:

a. These tools should not be used in an explosive or flammable

atmosphere.
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b. Before using the tool, the worker should inspect it to determine that it
is clean, that all moving parts operate freely, and that the barrel is free
from obstructions.
c. The tool should never be pointed at anybody.
d. The tool should not be loaded unless it is to be used immediately. A
loaded tool should not be left unattended, especially where it would be
available to unauthorized persons.
e. Hands should be kept clear of the barrel end. To prevent the tool from
firing accidentally, two separate motions are required for firing: one to
bring the tool into position, and another to pull the trigger. The tools
must not be able to operate until they are pressed against the work
surface with a force of at least 5 pounds greater than the total weight
of the tool.
f. If a powder-actuated tool misfires, the user should wait at least 30
seconds, then try firing it again. If it still would not fire, the user should
wait another 30 seconds so that the faulty cartridge is less likely to
explode, than carefully remove the load. The bad cartridge should be
put in water.
g. Suitable eye and face protection are essential when using a powder-
actuated tool.
h. The muzzle end of the tool must have a protective shield or guard
centered perpendicularly on the barrel to confine any flying fragments
or particles that might otherwise create a hazard when the tool is fired.
The tool must be designed so that it will not fire unless it has this kind
of safety device.
i. All powder-actuated tools must be designed for varying powder charges
so that the user can select a powder level necessary to do the work
without excessive force.
j. If the tool develops a defect during use it should be tagged and taken
out of service immediately until it is properly repaired.
k. When using powder-actuated tools to apply fasteners, there are some
precautions to consider. Fasteners must not be fired into material that
would let them pass through to the other side. The fastener must not be
driven into materials like brick or concrete any closer than 3 inches to
an edge or corner. In steel, the fastener must not come any closer than
one-half inch from a corner or edge. Fasteners must not be driven into
very hard or brittle materials which might chip or splatter, or make the
fastener ricochet.
l. When fastening other materials, such as a 2- by 4-inch wood section to a
concrete surface, it is permissible to drive a fastener of no greater than
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7/32-inch shank diameter not closer than 2 inches from the unsupported
edge or corner of the work surface.
m. Fasteners shall not be driven through existing holes unless a positive
guide is used to secure accurate alignment.
n. No fastener shall be driven into a spalled area caused by an
unsatisfactory fastening.
o. All tools shall be used with the correct shield, guard, or attachment
recommended by the manufacturer.
p. The tool shall be inspected and repaired in accordance with the
manufacturer's specifications.

Note: An effective log inventory system should be established by the tool

room supervisor in order to control the issuance and receiving of cartridges
and powder actuated tools. Only the personnel in possession of a valid user
certificated shall be allowed to withdraw such tools or cartridges from the
store and all issued cartridges, i.e. used, unused and misfired should be
returned with the tool for inventory purposes.

D. Hydraulic Powered Tools

Hydraulic power tools are typically used for compression, such as work
requiring the use of drill presses and jacks. These tools operate under
pressure and can cause injury if a hose bursts or develops a pinhole leak.
Use the manufacturer-recommended hose that is designed to withstand the
pressure being applied. Where physical damage to the
hydraulic hose is likely, armored hose should be used.

The fluid used in hydraulic power tools must be an approved fire-resistant

fluid and must retain its operating characteristics at the most extreme
temperatures to which it will be exposed.

The manufacturer's recommended safe operating pressure for hoses, valves,

pipes, filters, and other fittings must not be exceeded.

All jacks - lever and ratchet jacks, screw jacks, and hydraulic jacks - must
have a device that stops them from jacking up too high. Also, the
manufacturer's load limit must be permanently marked in a prominent place
on the jack and should not be exceeded.
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A jack should never be used to support a lifted load. Once the load has
been lifted, it must immediately be blocked up.

Use wooden blocking under the base if necessary to make the jack level and
secure. If the lift surface is metal, place a 1-inch-thick hardwood block or
equivalent between it and the metal jack head to reduce the danger of
slippage.

To set up a jack, make certain of the following:

A. the base rests on a firm level surface,

B. the jack is correctly centered,
C. the jack head bears against a level surface, and
D. the lift force is applied evenly.

Proper maintenance of jacks is essential for safety. All jacks must be

inspected before each use and lubricated regularly. If a jack is subjected to
an abnormal load or shock, it should be thoroughly examined to make sure
it has not been damaged.
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E. Fuel Powered Tools

This type of tool is fuel powered, usually by gasoline. The most serious
hazard with fuel-powered tools come from fuel vapors that can burn or
explode and give off dangerous exhaust fumes.

The worker must be careful in handling, transporting, and storing the gas or
fuel in approved flammable liquid containers, according to proper
procedures for flammable liquids.

Before the tank for a fuel-powered tool is refilled the user must shut the
engine down and allow it to cool to prevent accidental igniting of
flammable vapors.

If a fuel-powered tool is used inside a closed area, effective ventilation

and/or personal protective equipment is necessary to avoid breathing
carbon monoxide. Fire extinguishers must be available in the area.

VII. Guarding Requirements

Hazardous moving parts of a power tool need to be safeguarded. For

example, belts, gears, shafts, pulleys, sprockets, spindles, drums, fly
wheels, chains, or other reciprocating, rotating, or moving parts of
equipment must be guarded if such parts are exposed to contact by
employees.

Guards, as necessary, should be provided to protect the user and others

from the following:

• point of operation,
• in-running pinch points,
• rotating parts, and
• flying chips and sparks.

Safety guards must never be removed when a tool is being used. For
example, portable circular saws must be equipped with guards. An upper
guard must cover the entire blade of the saw. A retractable lower guard
must cover the teeth of the saw, except when it makes contact with the
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work material. The lower guard must automatically return to the covering
position when the tool is withdrawn from the work. Please see figure 3.

Typical machine guarding are is shown in figure 4.

Specific guarding requirements for portable powered tools are stated in

OSHA 1910.243 (Guarding of Portable Powered Tools).

VIII. Safety Switches

a. All hand-held powered platen sanders, grinders with wheels 2-inch

diameter or less, routers, planers, laminate trimmers, nibblers, shears,
scroll saws, and jigsaws with blade shanks one-fourth of an inch wide or
less may be equipped with only a positive "on-off" control.
b. All hand-held powered drills, tappers, fastener drivers, horizontal,
vertical, and angle grinders with wheels greater than 2 inches in
diameter, disc sanders, belt sanders, reciprocating saws, saber saws,
and other similar operating powered tools shall be equipped with a
momentary contact "on-off" control and may have a lock-on control
provided that turnoff can be accomplished by a single motion of the
same finger or fingers that turn it on.
c. All other hand-held powered tools, such as circular saws, chain saws,
and percussion tools without positive accessory holding means, shall be
equipped with a constant pressure switch that will shut off the power
when the pressure is released.
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IX. Personal Protective Equipment

Engineering controls that eliminate the hazard at the source and do not rely
on the operator's behavior for their effectiveness offer the best and most
reliable means of safeguarding. Therefore, engineering controls are the first
choice for eliminating machine hazards. But whenever engineering controls
are not available or are not fully capable of protecting the operator,
operators must wear personal protective equipment.

Employees using hand and power tools and exposed to the hazard of falling,
flying, abrasive, and splashing objects, or exposed to harmful dusts, fumes,
mists, vapors, or gases shall be provided with the particular personal
protective equipment necessary to protect them from the hazard. All
personal protective equipment shall meet the requirements and be
maintained according to HSE Manual Section 2, Subject No.2 (Personal
Protective Equipment Program).

X. Maintenance and Care of Tools

The manufacturer’s recommendations and instructions for the

maintenance, use and care of tools, are usually available when tools are
purchased. The information contained in these manuals are relevant in
establishing preventive maintenance and inspection programs.

XI. Training

Personnel who use tools must be trained. Instruction manuals from tool
manufacturers or factory trained instructors should be used as the primary
source of information. The training should include:
a. How to select the proper tool for the job.
b. How to inspect the tool.
c. How to use the tool and know its limitations.
d. Tool storage.
e. The procedures for repair of faulty tools.

Supervisors shall ensure that their personnel are properly trained in the
operation of any tool before its use. If personnel are unfamiliar with the
operation of the tool, they shall receive instruction before starting the job.
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XII. Applicable Standards and References

a. Occupational Safety and Health Administration (OSHA) 29 CFR 1910

Subpart O (Machinery and Machine Guarding) and Subpart P (Hand and
Portable Powered Tools and Other Hand-Held Equipment).
b. Occupational Safety and Health Administration (OSHA) 29 CFR 1926
Subpart I (Hand and Power Tools).
c. Petron HSE Manual Section 2, Subject No. 2 (Personal Protective
Equipment Program).
d. Petron HSE Manual Section 2, Subject No. 5 (Work Permit System).

XIII. List of Figures

a. Figure 1 - Abrasive Wheel “Ring Test”

b. Figure 2 - Correctly Mounted Grinding Wheel
c. Figure 3 – Self Adjusting Guard (Circular Saw)
d. Figure 4 – Bench Grinder Guards

Rev. No. Date Description Prepared/Reviewed/Approved

by :
0 9/1/03 Original Document NSE/CVT
1 7/05 Change font to Trebuchet EMT/CVT

Figure 1 - Abrasive Wheel “Ring Test”

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Figure 2 - Correctly Mounted Grinding Wheel

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Figure 3 – Self Adjusting Guard (Circular Saw)

Figure 4 – Bench Grinder Guards

Notes :
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1. Work rests shall be kept adjusted to the wheel with a maximum gap of 1/8 inch.
2. Tongue guards shall be kept adjusted closely to the wheel with maximum opening
of ¼ inch.
3. The maximum angular exposure of the grinding wheel periphery should not
exceed 90 degrees. This exposure shall begin at a point not more than 65
degrees above the horizontal plane.
4. Whenever the nature of work requires contact with the wheel below horizontal
plane, the exposure should not exceed 125 degrees.