Line Breaking Procedures by fjhuangjun

VIEWS: 865 PAGES: 13

									Manual: Appendix E            Subject: Line Breaking Procedures   Reviewed by: RL
Effective: January 1, 2005    Supercedes: December , 2004         Page 1 of 10



I.      Purpose

        The purpose of these line breaking procedures is to prevent injuries from
        occurring during all line breaking jobs performed at Client/Owner various
        plants, facilities and constructions sites.

II.     Scope

        Line breaking operations include, but are not limited to, the opening of or
        working on any process lines, their connected fittings or valves,
        thermowells, gauges, sight glasses, pumps or vessels that contain or have
        ever contained acidic, alkaline, flammable, or otherwise hazardous liquids
        or gases. The replacing of packing in pumps in place, or on the agitator
        shafts of pressure vessels are also considered to be line breaking
        operations.

        Some tasks at various plants, facilities and construction sites (connecting
        and disconnecting the loading and unloading lines or railcars and tank
        trucks) are not governed by the line breaking procedures. For these
        tasks, personal protective equipment requirements are outlined in
        Standard Operating Procedures.

        The following materials/processes require line breaking permits and
        procedures to be completed while work is underway:

                 Sulfuric Acid, Oleum, Sulfur Dioxide, Sulfur Trioxide, Sulfur, etc.
                 Petroleum Products (Gasoline, jet Fuel, Diesel, Butane, LNG,
                 Caustic, Caustic Soda (Sodium Hydroxide), Chlorine, etc
                 Sewage, Sanitary, Waste Water, Hazardous Waste, etc.
                 Natural Gas
                 Nitrogen
                 Steam
                 Plant & Instrument Air

        This list shall not exclude any other Client/Owner plant area from
        consideration if circumstances indicate hazardous, pressurized lines
        may be present in those areas.

        PRIOR APPROVAL FROM THE CLIENT/OWNER, PLANT MANAGER
        OR HIS/HER DESIGNEE WILL BE REQUIRED IN ANY INSTANCE
        WHERE IT IS NOT FEASIBLE TO COMPLY FULLY WITH THESE
        PROCEDURES.
Manual: Appendix E                 Subject: Line Breaking Procedures   Reviewed by: RL
Effective: January 1, 2005         Supercedes: December , 2004         Page 2 of 10



III.    Responsibilities in Line Breaking Client/Owner Operations

        A.       Supervision in items 1, 2 and 3 refers to Production Supervisor,
                 Maintenance Foreman or Lead Person:

                 1.          Client/Owner Area supervision is responsible for determining
                             that equipment is safe to work on.

                 2.          Client/Owners Area Supervision at all levels must take
                             appropriate steps to prevent any violations of safeguards
                             established by these instructions.

                 3.          Line breaking jobs within a Client/Owner Supervisor's area
                             must be approved and frequently checked to insure
                             continuous compliance with these instructions until work is
                             completed.

                 All openings of lines made during the course of the job must be
                 checked for closure before the job is considered to be complete
                 and released for resumption of normal use.

        B.       Client/Owner Operations/Maintenance Personnel

                 A Line Breaking Permit is initiated by the person doing the job.
                 Richlynn and or Subcontractor employee initiates the permit with
                 the Client/Owner Production Foreman or designee. When the job
                 is completed, the person performing the job should return the
                 permit to the Richlynn Field Supervisor and Client/Owner
                 Production Foreman or designee and inform him that the job has
                 been completed.

IV.     Specific Requirements

        A.       Personal Protective Equipment

                 Standard PPE includes sturdy leather boots, a hard hat and long
                 sleeves. During line breaking, additional PPE may be required.
                 For each of the hazardous materials listed below, the following
                 minimum protective gear and clothing is required for line breaking
                 jobs at various Client/Owner facilities, plants and construction sites.
                 However, all jobs should be evaluated for additional protective gear
                 and clothing requirements and any additions should be recorded on
                 the permit.

                 All items include a hard hat unless the protective gear makes it
                 impossible to wear one. All items include spectacle-type safety
Manual: Appendix E                 Subject: Line Breaking Procedures   Reviewed by: RL
Effective: January 1, 2005         Supercedes: December , 2004         Page 3 of 10



                 glasses with side shields unless otherwise specified (e.g.
                 chemical safety goggles).

                 1.          Corrosive Materials: (Sulfuric Acid, Oleum, and Caustic)
                             a.    Acid Suit: Acid Coat, overalls--rubber, neoprene, or PVC
                                   (Raincoat is not allowed.)
                             b.    Acid Hood (e.g. Overhead Work, CP Acid Facility or jobs
                                   that take place above the waist.)
                             c.    Face Shields
                             d.    Goggles
                             e.    Gloves: gauntlet type made of neoprene, PVC or an
                                   equally resistant material
                             f.    Rubber Boots with steel toes
                             g.    Breathing apparatus if needed. (Worn in
                                   accordance with plant respirator policy.)

                 2.          Petroleum Materials: (Gasoline, Jet Fuel, Diesel, Butane, LNG,
                                    etc)
                             a.     6.0 Nomex Coveralls: Rain Coat, overalls--rubber,
                                    neoprene, or PVC
                             e.     Rain Hood (e.g. Overhead Work, jobs that take place
                                    above the waist.)
                             f.     Face Shields
                             g.    Goggles
                             e.    Gloves: gauntlet type made of neoprene, PVC or an
                                   equally resistant material
                             f.    Rubber Boots with steel toes
                             g.    Breathing apparatus if needed. (Worn in
                                   accordance with plant respirator policy.)

                 3.          Hazardous Material: (Sewage, Sanitary and Mold,)
                             a.    4.0 Tyvek Suit: Coveralls
                             h.    Tyvek Hood (e.g. Overhead Work, jobs that take place
                                   above the waist.)
                             i.    Face Shields
                             j.    Goggles
                             e.    Gloves: gauntlet type made of neoprene, PVC or an
                                   equally resistant material
                             f.    Rubber Boots with steel toes
                             g.    Breathing apparatus if needed. (Worn in
                                   accordance with plant respirator policy.)
                 4.          Sulfur Lines:
                             a.    Face Shield
                             b.    Leather Gloves
                             c.    Goggles
                             d.    Breathing apparatus if needed. (Worn in
                                   accordance with plant respirator policy.)
Manual: Appendix E                 Subject: Line Breaking Procedures   Reviewed by: RL
Effective: January 1, 2005         Supercedes: December , 2004         Page 4 of 10




                 5.          Steam Lines:
                             a.   Face Shield
                             b.   Leather Gloves

                 6.          High Pressure Air Lines or Natural Gas Lines:
                             a.    Face Shield
                             b.    Leather Gloves

                 7.          Nitrogen Lines:
                             a.    Face Shield
                             b.    Leather Gloves
                             c.    Breathing apparatus if needed. (Worn in accordance
                                   with plant respirator policy.)

        B.       Precautions in Breaking Lines

                 Breaking a line is in essence breaking into a closed system.
                 Regardless of the checking done and the instruments employed, it
                 must be assumed that at the point where the line is to be broken
                 there is product or gas that will spurt out. Anticipate the unknown
                 and unplanned cross connection.

                 1.          Client/Owner or his designee competent supervision (e.g.
                             Production Supervisor, Maintenance Foreman or Lead
                             Person) must be onsite when a hazardous chemical line is
                             broken. (The lead person is assigned the supervisory
                             responsibility on off-shifts and weekends unless
                             Management designates otherwise. A minimum of three
                             different signatures will be required on the permits.)
                             Client/Owner must make arrangements to provide this
                             supervision on off-shifts, weekends, and for emergencies.

                 2.          Client/Owner or his designee shall neutral or discharge (i.e. -
                             washout, steam, clear blockages, open, drains, vents,
                             depressurize, lockout/tagout prior to Richlynn and or
                             Subcontractor begins line breaking. Richlynn and or
                             Subcontractor will contain residual product will be handled in
                             accordance with Client/Owner current approved pollution
                             control policy and practice such as containment, vaccum
                             truck stand-by pump, etc..

                 3.          For a hazardous substance line breaking job, a water hose
                             will be stretched to the point of line breaking, with the water
                             running or valved at the end. Take precautions if the hose
                             could freeze.
Manual: Appendix E                 Subject: Line Breaking Procedures   Reviewed by: RL
Effective: January 1, 2005         Supercedes: December , 2004         Page 5 of 10




                 4.          Switches will be locked out and danger tags attached. Push
                             buttons that operate pumps or blowers must be tried. In
                             addition, in cases where pumps are actuated only by a float
                             valve, or where it is not possible to make a positive check on
                             the lockout, the equipment will be isolated by either pulling
                             the fuses, disconnecting wires or by some other means to
                             deactivate the source of energy.

                 5.          If such pumps, motors or equivalent are activated by
                             mechanical devices such as floats, the devices will be
                             operated manually to insure that the system has been
                             deactivated by Client/Owner or his designee.

                 6.          If such pumps, motors or equivalent are energized by steam
                             (i.e. steam turbine), the energy source will be isolated, and
                             danger tags attached. Push buttons that operate such
                             equipment must be tried by Client/Owner or his designee.

                 7.          Electrical bonding continuity must be maintained and
                             temporary grounding must be installed if a disruption is
                             anticipated or needed.

                 8.          Client/Owner or his designee must de-pressurize the system
                             before opening lines (or other equipment) by Richlynn and or
                             subcontractor to atmospheric pressure or as near
                             atmospheric as practical using the Lockout/Tagout
                             Procedure in this Safety Manual.

                 9.          The Client/Owner is responsible to assure all lines will be
                             drained and purged completely making certain that vents are
                             open to prevent the possibility of an air lock prior to Richlynn
                             and or Subcontractor commencing work. Always presume
                             the possibility of a line pluggage by material and/or
                             corrosion.

                 10.         Whenever possible, Client/Owner shall wash out or steam
                             lines containing flammable liquids before Richlynn and or
                             Subcontractor break a line.

                 11.         The portion of the line being worked on will be isolated from
                             those preceding and following it in the most effective way.
                             This will usually consist of blanking, shutting valves and
                             locking them. A Client/Owner Department Process Foreman
                             or a Process Employee with rank of at least operator, who is
                             familiar with the individual valve, will be the judge of whether
Manual: Appendix E                 Subject: Line Breaking Procedures   Reviewed by: RL
Effective: January 1, 2005         Supercedes: December , 2004         Page 6 of 10



                             a valve is in the closed position. This last precaution guards
                             against confusion arising out of the use of non-rising stem
                             valves, quick opening valves, and other valves that are
                             peculiar to the unit, or which have their own peculiarities,
                             perhaps known only to the Client/Owner department
                             involved.     The supervisor will inspect the valve and
                             determine that it is closed.

                 12.         Before the moment of breaking occurs, the area will be
                             marked off for maximum protection to passersby and nearby
                             workers with either screening or roping. A funnel or suitable
                             container to collect the drainage will be used where
                             applicable. Where floor openings are near, isolate exposed
                             areas on other floors.

                 13.         If activities which have the potential to have an impact on the
                             line break location (i.e., opening valves upstream) are taking
                             place where there is not a direct line of sight of the area of
                             the line break or other personnel involved with the job, plant
                             or construction radios shall be used for communication prior
                             to these other activities taking place. The activity shall not
                             take place until the area of the line break is sufficiently clear
                             of all personnel.

                 14.         It is difficult to prescribe a general set of rules covering the
                             precise and safest way to effect all line openings. However,
                             the best standards applicable to the particular job shall be
                             followed. When dismantling of opening closed pressurized
                             or gravity fed systems, internal pressure shall be relieved or
                             other methods utilized to prevent sudden release or pressure
                             or spraying of liquid. These will include:

                             a)     Loosen the bolts of a flange that are farthest
                                    from the mechanic. Replace old or corroded
                                    bolts one at a time prior to the actual line
                                    breaking.

                             b)     Shield wherever possible, including the partial
                                    use of flange covers. Stand aside to avoid any
                                    spray.
                             c)     With proper regard for waste water
                                    management and the possible need for
                                    pollution control, wash out the lines and fittings
                                    with water twice by the mechanic or other
                                    person performing work on the line, or
                                    preparing to store in the scrap pile. Dismantled
Manual: Appendix E                Subject: Line Breaking Procedures   Reviewed by: RL
Effective: January 1, 2005        Supercedes: December , 2004         Page 7 of 10



                                   lines and fittings should be free of acid or
                                   hazardous materials before leaving the job site.

                             d)    Flange spreaders or flange jacks should be
                                   used for opening flange joints whenever the
                                   use of such tools is possible and practical.
                                   Where the use of such tools is impossible or
                                   impractical due to close quarters or size of
                                   pipe, only standard wedges will be used as an
                                   alternate. In such cases, a suitable chain or a
                                   strong flexible wire must be attached to the
                                   wedge through the eye, the other end being
                                   firmly secured to the pipe line or other fixed
                                   objects, so as to prevent the wedge from flying
                                   in the event it slips out of the joint.

                             e)    Wherever possible, old flange bolts will be
                                   removed one at a time and replaced with new
                                   bolts that can be gradually backed off as the
                                   wedge is being inserted. This will prevent
                                   sudden openings of the joint, particularly where
                                   it is under stress.

                                   The use of drift pins, cold chisels, spud
                                   wrenches and similar tools as alternates is
                                   strictly forbidden.

        C.       Precautions in Breaking Lines with Explosive Mixture Hazards

                 Where it is necessary to burn flange bolts off, the following
                 procedures are mandatory:

                 1.          The line must be broken at the nearest flange without the
                             use of a burning torch.
                 2.          If line cannot be broken without burning flange bolts, all
                             flange bolts must be replaced one at a time without
                             separating the flanged joint. Keep flange area cool.

                 3.          After all bolts have been replaced, the flange may be
                             separated.

                 4.          The line must be separated and remain open to the
                             atmosphere. The remaining portion of the line not being
                             worked on must be blanked.
Manual: Appendix E                 Subject: Line Breaking Procedures   Reviewed by: RL
Effective: January 1, 2005         Supercedes: December , 2004         Page 8 of 10



                 5.          Explosive meter tests must be taken by a qualified person.
                             The person taking the explosive tests must insure that the
                             meter used is properly calibrated and the calibration will be
                             logged in the permit log book.

                 6.          If an explosive mixture is found, the line must be purged with
                             air and re-tested. This procedure is repeated until an
                             explosive mixture is not found.

                 7.          A hot work permit must be issued to cover required hot work.
                             See the Hot Work Procedures section of this Safety Manual.

                 8.          A flange spreader or flange jack will be used, except in those
                             cases where it is necessary to use wedges, as outlined in
                             13d above.

        D.       After Initial Line Breaking

                 After the initial break has been made, the work will proceed
                 cautiously until the desired degree of dismantlement or
                 replacement is effected. Any parts destined for the scrap heap will
                 be washed thoroughly on the site before transporting. Any material
                 or scrap returned to any shop or scrap dealer must be thoroughly
                 cleaned or decontaminated.

        E.       Down Time After Line Breaking

                 Where line breaking includes an extended period of down time
                 following the breaking, such as in the replacement of a pump, the
                 breaks in the system will be properly capped as with blind flanges
                 of the appropriate material of construction. For acid, bleach service
                 the blind will be made of Teflon with metal backup. For other
                 services, such as sulfur, petroleum products, gas, steam or water,
                 the material of construction may be rubber, Garlock or carbon steel.
                 All blinded lines are indicated by a tab at the point in which the blind
                 is installed. In all cases, the blind flanges shall be of sufficient
                 strength, and installed as to provide safe conditions of pressure,
                 temperature and service.

                 Safeguards such as locked switches and locked valves will be
                 continued until the system is again a closed or continuous one.

                 Where there is the possibility of a line refilling, a drain valve will be
                 attached to blank flange used.
Manual: Appendix E            Subject: Line Breaking Procedures   Reviewed by: RL
Effective: January 1, 2005    Supercedes: December , 2004         Page 9 of 10



        F.       Blind List

                 A blind list must be maintained to formally track blinds and
                 document when and where blinds are installed and when they are
                 removed. This ongoing blind list will be maintained by the
                 Client/Owner or his designee and or Richlynn Site Supervisor
                 posted at jobsite. The blind list form is included in Attachment A.

V.      Line Breaking Permits

        A properly completed (both sides) Line Breaking Permit must be
        displayed at the job site. A blank permit is shown in Attachment B.

        Unless the entire job is completed by the personnel who start it, a Line
        Breaking Permit covers only a single shift. A new permit must be
        executed at the start of each shift when new personnel arrive at the site to
        continue the job.

        A Line Breaking Permit is initiated by the person doing the job. He/she
        initiates the permit with the lead person. A new number is added to the
        blank permit and the permit is logged into the permit log. The new number
        that is used is the next consecutive number in the permit log for line
        breaking permits (denoted with LB). The new number is added to the top
        right hand corner of the blank permit. The procedures outlined on the next
        pages are then followed to complete the permit. Any permit that was
        initiated but the job was canceled or the permit was not used for some
        other reason, will be canceled on the permit by writing VOID across the
        permit and by writing VOID across the corresponding permit entry in the
        log book.

        Space is provided on the permit form for the proper signatures from the
        operating and maintenance departments. Line breaking permits will be
        removed from the job site promptly upon completion of the work they
        cover. The person performing the job will return the permit to the lead
        person and inform him/her that the job has been completed.

        Safety personnel and/or location management will review the completed
        Line Breaking Permits on a monthly basis to ensure that suitable safety
        precautions are being taken in performing the work involved. The permits
        may be disposed of after this review is completed. "Retain for 12 months
        from date issued".
Manual: Appendix E           Subject: Line Breaking Procedures   Reviewed by: RL
Effective: January 1, 2005   Supercedes: December , 2004         Page 10 of 10
Manual: Appendix E                      Subject: Line Breaking Procedures                   Reviewed by: RL
Effective: January 1, 2005              Supercedes: December , 2004                         Page 11 of 10




ATTACHMENT B
                             LINEBREAKING PERMIT PROCEDURES
Section 1 (Up to Letter D)

To be filled out by the Client/Owner Supervisor, Richlynn Supervisor an or Subcontractor Supervisor and person doing the
work:      Permit is good for the date of issue only and is good for one shift only, unless the entire job is completed by the
personnel starting it. This would be indicated on "Good on this date only" and the times indicated under "From" and "To".
           The "Client/Owner Department" would be maintenance or operations and the "Location" would be the location of
the line being broken. The "job to be performed" would be described.
           "The line for which this permit is issued last contained" is self explanatory.

The permit is then given to the operator and he takes care of items B and C if needed and checks them off as required. If
they are not applicable, write NA next to them.


Section 2 (Signatures)

          This section is for signatures when the permit has been completed. Back side of the permit (which is described
on the next page) should be filled out before signing.

For Operating Department: signed by operator after completing sections 1 and 3

Person or Persons performing job: signed by person(s) doing job after completing section 3

Operating Department Foreman or Supervisor: Signed by lead person or production supervisor after completing
Section 1 and Section 4 and making sure Section 3 has been completed by going to the job site and double checking all
items.

Foreman or Supervisor of person performing job: Signed by Foreman or Supervisor of person performing the job after
checking that Sections 1, 3, and 4 have been done by going to the job site and double checking all items.

Note: During the weekend and off hours the lead person will sign both sections for Operating Department Foreman and
Foreman of person performing the job since he is covering both positions. A minimum of three different signatures will be
required on the permits.

Section 3 (Numbers 1-3)

      Operator performs steps 1, 2, and 3 and checks them off when completed. The, maintenance double checks to
make sure everything is locked out properly and tries the push buttons to make sure they are not working and then checks
off on the permit. If these items are not applicable, write NA next to them.

Section 4 (Number 4-12)

     These items are checked off by the lead person as they are required.

4.   "Ample water supply and hose must be on site" should be available when working on an acid line.

5 and 6. Areas should be roped off and signs posted when working overhead or in a walkway (when something could fall
or drip on someone passing by).

Adequate ingress/egress route should always be established and checked off.

7.   A cutting and welding permit should be filled out in accordance with Hot Work permit rules when needed.

8. Protective Equipment: Hard Hat, Safety Glasses with side shields, Steel Toed Safety Shoes required for all.
Additional equipment for the type of line broken is shown below:
     Acid Line:     Acid Suit, Acid Hood (Face Shield may be permitted under certain circumstances),
          Rubber Gloves, Rubber Steel Toed Boots, Respirator if needed.
     Sulfur Line:   Face Shield, Leather Gloves, and Respirator if needed.
     Steam Line: Face Shield, Leather Gloves
     Nitrogen Lines: Face Shield
     High Pressure Plant Air Lines and Natural Gas Lines: No additional equipment

9. The joint should be adequately sheathed to prevent spray when possible.
"Personnel assigned to job know safe work methods, hazards and are qualified to perform work and wear required
equipment." Although there is not a separate box for this, this item should be checked every time and separately from the
box next to #9. A box can be drawn in and checked or just a check can be written in.

10. "Nearest safety shower must be tested prior to work commencing" should be checked every time.

11 and 12. As the job requires as outlined in line breaking procedures.
                                RICHLYNN BLIND LIST

Date In   Date Out   Location                Description   Material(s) Possibly in Line

								
To top