Line break safety

[Audio] Line break safety. Line break safety.

[Audio] Line break intent To identify and manage loss of containment of hazardous materials during activities that require opening process lines or process equipment that could result in personal injuries, property damage, community impacts, environmental impacts, or business impacts.

[Audio] Examples of line break Removing process pump for maintenance activities Replacing a pump seal or packing Replacing a valve Replacing process instrumentation Replacing process piping Modifying process piping Opening equipment for inspection Installing isolation blinds Replacing valve packing Replacing agitator seal or packing Removing pressure relief device for maintenance Replacing gaskets in piping and equipment Removing a blind flange on the end of a line.

[Audio] Line break best practices Non-routine work increases process risk and can directly lead to conditions that make a catastrophic accident much more likely. Safe work practices are critical elements in the management of this non-routine work. Safe work practices include an integrated management system of policies, procedures and permits that help protect workers from hazards and prevent the sudden release of process materials or energy during non-routine work activities. Safe work procedures and permits help ensure that workers understand the hazards and take appropriate actions to manage risk when performing non-routine work activities..

[Audio] Documents and Forms- program should be fully documented, authorized, version controlled and subject to periodic review. Accountability- Roles should be specified for all people involved in the planning, approval and execution of the work practices. These should include a description of all responsibilities and the necessary competence needed to fulfill these roles. Training and Competency- All individuals involved in Safe Work Practices should be trained and certified for all roles they fulfill in the system. This training should include complete understanding of the planning, approval and execution of the practices and intent of the system. Planning and Scheduling- The task objective, method and tools should be specified along with the specific location and equipment to be worked upon. The need for special provisions should be identified such as Energy Isolation (Lock Out / Tag Out), confined spaces, lifting, scaffolding / mobile platform, hazardous materials handling, skills / competency, noise, temperature, etc..

[Audio] Risk Assess Hazards- With an understanding of the work method, tools to be used, work party skills/ competence and process status, the hazards should be identified and risk assessed. When the risk is unacceptable, barriers should be specified to control the hazards to an extent where the residual risk is acceptable. Permit Control Process- Hazardous work should be controlled by a permitted process (i.e., a defined process with various levels of authorization from plant staff). Communicate- The party or person raising the permit has a responsibility to communicate all hazards and controls to the work party before the task commences. This is normally carried out during a "tailgate" or briefing meeting where the work scope is outlined, hazards and barrier identified, specific responsibilities defined and members sign up to the work sheet. Monitor and Manage Ongoing Work- Once a permit has been issued, the plant staff should monitor progress to some extent. Typically, the more hazardous the task, the higher the level of surveillance necessary. Where specific hazards are present, permanent monitoring may be necessary such as "fire watcher" for hot work or "Entry Attendant" for Confined Space Work.

[Audio] Work Left In Safe Condition Upon Completion- When a task is complete, the work area should be cleared of all tools, equipment and materials and all surfaces cleaned remove any tripping or slipping hazards Verification and Assurance- Verification or Compliance Audits and spot checks should be carried out regularly to ensure that the Permit to Work system is functioning correctly. Capture, Incorporate and Share Lessons Learned- Most safe systems of work include a process for capturing and sharing lessons learned. These include lessons on the task carried out, the risk assessment, the approvals process and the work preparation. Communicates Obligation and Authority to Stop Unsafe Work- It should be recognized that all staff and contractors on the plant have the Authority and Obligation to stop work when an unsafe condition or act is observed that could affect the safety of personnel and / or the environment..

[Audio] Why is line break safety necessary On February 23, 1999, 4 people were killed and 1 injured during maintenance work on a naphtha line. U.S. Chemical Safety Board concluded in their investigation report: "…..job planning procedures did not require a formal evaluation of the hazards of replacing the naphtha piping. The pipe repair work was classified as low risk maintenance. Despite serious hazards caused by the inability to drain and isolate the line – known to supervisors and workers during the week prior to the incident – the low risk classification was not reevaluated nor did management formulate a plan to control the known hazards." – U.S. Chemical Safety Board, 2001.

[Audio] Potential consequences Property Damage (Fire / Explosion) A release of hazardous material during a line or equipment opening can cause property damage if released materials are flammable. Depending on the surrounding area, the released material may find an ignition source and cause a fire or an explosion..

[Audio] Personal Injury (Safety / Human Health) Line or Equipment Opening, if not done properly, can lead to release of hazardous materials and personnel exposure with serious injuries or fatalities Exposure to corrosive materials (i.e. acids or caustic) causing chemical burns Exposure to corrosive materials (i.e. acids or caustic) causing chemical burns Exposure to toxic materials (i.e. benzene, hydrogen sulfide, phenol) Exposure to hot materials (i.e. steam) causing thermal burns Release of material under pressure causing an injury If these materials are flammable the release may find an ignition source leading to a fire or an explosion..

[Audio] Chemical Release / Environmental Impact (On-Site) In addition to the Property Damage and Personal Injury consequences stated above, facilities must also consider the potential for escalation that could result in environmental damage or additional personal injuries occurring on-site. Environmental damage due to releases to the air, soil, or bodies of water resulting from line or equipment opening hazardous material releases Personnel injuries outside of the immediate area due the release of toxic materials from line or equipment opening activities Personal injuries outside of the immediate area due to fire or explosions resulting from possible ignition of flammable materials released during line or equipment opening..

[Audio] Chemical Release / Environmental Impact (Off-Site) Environmental damage due to releases to the air, soil, or bodies of water resulting from line or equipment opening hazardous material releases Personnel injuries outside of the plant boundaries due the release of toxic materials from line or equipment opening activities Personal injuries outside of the plant boundaries due to fire or explosions resulting from possible ignition of flammable materials released during line or equipment opening..

[Audio] Effective Practices to Manage and Mitigate Hazards Reduce risk by minimizing work on lines connected to equipment still in operation Properly isolate line or equipment to be worked on Verify that the lines or equipment are drained and clean before proceeding with line opening task Assure that personnel are not exposed to hazardous materials while draining the lines or equipment Treat initial line/equipment opening as if hazardous material is present Identify location of each line or equipment opening Identify access issue or congestion in the area Avoid sparks if the line must be cut Analyze hazards and identify means of control.

[Audio] Effective Practices to Manage and Mitigate Hazards Understand operational status Recognize changes in process conditions Ensure resources to adequately assess safe work activitie Create safe environment Ensure that all workers are competent to execute their responsibilities Continuous monitoring of the envi-ronment; stopping work if hazardous material is detected in the line Communication is essential between the control room, the Operating personnel and the people conducting the work.

[Audio] Reduce risk by minimizing work on lines connected to equipment still in operation Consider deferring line breaking to a future turnaround or outage when inventories of hazardous materials are at a minimum or eliminated.

[Audio] Properly isolate line or equipment to be worked on Use of manual valves. Use of a double-block-and-bleed configuration to ensure manual valves are not leaking through. Do not use control valves as an isolation device. Do not work on line or equipment if there is an indication that isolation valve may be leaking through. Lock-out/tag-out (LOTO) should be complete before line opening permit is issued..

[Audio] Clean the line or equipment before opening Develop procedures to clean or flush the line to minimize the amount of hazardous materials present. Develop procedures to ensure that the lines or equipment are emptied, purged, flushed, drained, vented, isolated and locked/tagged as applicable to confirm the system is free from recognized hazards. Verify that drains are not plugged giving a false indication that the line is empty..

[Audio] Assure that personnel are not exposed to hazardous materials while draining the lines or equipment Develop procedures to empty, purge, flush, drain, vent and properly isolate lines and equipment. Verify that de-pressurization of lines or equipment and absence of material has been accomplished by opening vents and drains or by other means deemed appropriate. Include proper disposal of hazardous materials in draining procedures. For Line/Equipment Opening inside an operating building, extra caution may be needed to address potential asphyxiation hazards..

[Audio] Treat initial line/equipment opening as if hazardous material is present Require personnel performing line breaking to wear proper PPE for the hazardous material that is normally in the line. PPE should remain in place until personnel verifies that the line is empty and clean. Loosen the flange bolts away from you first to minimize exposure in case of a release..

[Audio] Identify location of each line or equipment opening Identify the location of line opening by marking on the pipe. Positively identify location of each line opening at the time of on-site inspection. During on-site inspection verify that person performing the work or accepting the permit knows the location of the line opening. Use the P&ID to determine all isolation/blinding or block/bleed valve locations. Develop an Isolation/blinding/block/bleed list for the job..

[Audio] Identify access issue or congestion in the area Assure adequate access to the location of the line opening is available. Identify any congestion issues and possible additional hazard (i.e. ¼" valves that could be bumped open on another line)..

[Audio] Avoid sparks if the line must be cut Obtain Hot Work permit. On lines or equipment which may have contained flammable and/or toxic liquids or gases, test with a properly calibrated combustible gas indicator initially and intermittently during work. Use cold cutting methods to cut a line that contained flammables. Consider purging the line with nitrogen to minimize possibility of fire. Connect both side of the area to be cut with ground straps before cutting to minimize ignition potential..

[Audio] Analyze hazards and identify means of control Survey the worksite and look for potential sources of ignition if the line opening involves flammable materials. Ignition sources could include hot equipment surfaces, vehicles or hot work being performed in the area, including above and below. Ensure that where work is performed on elevated piping or equipment, the area below the work will be barricaded and splash pans/spark containment provided as needed..

[Audio] Understand operational status Understand operational status Recognize changes in process conditions Line or equipment openings that last over several hours or days need to be secured by installing blind flanges or in-line blinds to prevent unexpected releases. Treat disconnecting a blind flange as a line opening..

[Audio] Ensure resources to adequately assess safe work activities Time pressure and/or task complexity on authorizing personnel to get permits issued can compromise the safety process through the adoption of a "seems OK to be" process. Assure that there are enough resources to properly inspect the line opening site and positively identify the location of the line opening before permit is issued..

[Audio] Create safe environment Require proper PPE to protect personnel during initial line breaking. Personnel breaking lines must place themselves in a defensive position to avoid a spray of liquid or release when attempting the initial opening. Identify location of the nearest safety shower and eye wash to be used in case of an emergency. Install blind flanges on lines in hazardous service when equipment is removed for maintenance..

[Audio] Ensure that all workers are competent to execute their responsibilities Provide training to all personnel in Line/Equipment breaking policies and procedures. Ensuring contractors have required craft qualifications. Closely supervise all contractors to ensure they are aware of all hazards and how to respond to emergencies..

[Audio] Continuous monitoring of the envi-ronment; stopping work if hazardous material is detected in the line Line or equipment opening work should be stopped if presence of hazardous material is detected. Hazard evaluation should be completed to determine how the work should proceed or if it should be postponed..

[Audio] Communication is essential between the control room, the Operating personnel and the people conducting the work Communication with the control room at all times is essential. If an emergency alarm is sounded, all line opening work must cease immediately. Area should be re-inspected and line opening permit re-issued after emergency is resolved..