LINE BREAK, EQUIPMENT OPENING AND TIE-IN PROCEDURE
Transcript of LINE BREAK, EQUIPMENT OPENING AND TIE-IN PROCEDURE
LINE BREAK,
EQUIPMENT OPENING
AND TIE-IN
PROCEDURE
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ST-055
December 19, 2019
INTRODUCTION
This “PROCEDURE” wasdeveloped as a guideline andestablishes the requirements for:
Line Breaks,
Equipment Openings
and Tie-ins2
PURPOSE
This procedure was developed to:
1. Safeguard Personnel
2. Prevent Exposure
3. Contain Contents
4. Avert Environmental Spills or releases
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SCOPENO WORK Shall be performed
“until”:
1. Known Identity of the
last contained substance
2. Review of the Safety Data Sheet (SDS – formerly MSDS)
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SCOPE
3. Potential RisksAnalyzed
4. Elimination or
Preventive measuresare established
5. Isolation of hazard5
SCOPE6. Double Block, and Bleed
“Preferred Method”
7. If Isolation is NOT Possible a Varianceis required
8. Trust – But – Verify
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DEFINITIONS
CLEARED LINES are lines or
equipment that have been:
A. Isolated, drained, vented,
flushed, and
B. Visually verified
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DEFINITIONS
CONTROL MARKING TOOL
(formerly Control Dot / Orange
Dot) is the control tool used by
Performance Contractors, Inc. to:
1. Identify the actual point
of line break, equipment
opening or tie-in8
DEFINITIONS
DOUBLE BLOCK & BLEED
Is the Preferred method of
isolation for line breaks❖ LOTO of 2 inline valves (A & C) and opening the
drain or vent valve (B)
A C
B
Break Point
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DEFINITIONS
ISOLATION is the
method or control
procedure used to
Prevent or Block
the release of
energy10
DEFINITIONS
IMMEDIATELY DANGEROUS TO LIFE OR HEALTH (IDLH)
Condition that poses an immediate or
delayed threat to life, OR
cause irreversible adverse health
effects
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DEFINITIONS
VARIANCE to this procedure is
required when isolation is NOT
possible:
1. Written Safe Work Plan
2. Identifies Hazards
3. Must be approved by Regional
Project & EHS Managers
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DEFINITIONS
WALK DOWN is physically
walking down the complete
system to verify safe
configuration, proper
isolation and
LOTO points
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STANDARD OPERATING
PROCEDURES (SOP)
Preplanning:
• Identify Last Contained
• Cleared line, system, or
equipment
• Isolation
• Flawless Execution Plan
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STANDARD OPERATING
PROCEDURES (SOP)
Preplanning:
Obtain a copy of the process
flow diagram, P&ID, isometric
drawing, to positively identify
the precise location of break,
opening or tie-in15
STANDARD OPERATING
PROCEDURES (SOP)Personnel Required Training
1. Confirm valid cards
2. Respirator Certified
3. Line Break, Equipment Opening and Tie-in Training
4. Confined Space Entry
5. Lockout / Tag Out (LOTO)
6. Fresh Air16
STANDARD OPERATING
PROCEDURES (SOP)
Job Planning
1. Isolation points marked
2. Selection of PPE
3. IDLH environment
4. Confined Space Entry
5. Hot Work
6. LOTO17
STANDARD OPERATING
PROCEDURES (SOP)
Job Planning
7. Other
A. Non-sparking tools required
B. Specialized PPE
C. Grade D Breathing Air Certificate or analysis
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STANDARD OPERATING
PROCEDURES (SOP)
Job Planning
D. Volume of contents
I. Vacuum truck
II. Catch pan
E. Containment (spill kit)
8. Emergency Plan
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STANDARD OPERATING
PROCEDURES (SOP)
PermittingRequest all necessary permits
1. Safe Work
2. Hot Work
3. LOTO
4. Line Break
5. Confined Space20
STANDARD OPERATING
PROCEDURES (SOP)
Control Documents1. Safety Data Sheet (SDS)
2. Permits
3. Line Break, Equipment Opening, and Tie-in Checklist (EHS-6.05)
4. Supplied Air Checklist (EHS-6.04)
5. Flawless Execution Plan (EHS-3.03)
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STANDARD OPERATING
PROCEDURES (SOP)
Control Documents
6.Final Walk down with
A. Crew – Isolation points
B. Review Documents
7.Control Marking Tape
8.Job Safety Analysis
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STANDARD OPERATING
PROCEDURES (SOP)
Perform Task
1. Set up at job site
2. Review Control Documents
3. Barricade area
4. Mark, sign, date and place Control Marking Tape
5. Work Safe23
OPERATIONS OR
MAINTENANCE
Are RESPONSIBLE for safely
preparing the system and / or
equipment by:
1. Clearing lines
2. Isolating hazards
3. Safely configuring valves
for maintenance or service24
LINE BREAKLINE BREAK means
1. Intentional opening of lines,
ducts, equipment, existing plant
process piping systems
2. Disconnecting flanges,
breaking pipe joints
3. Removing blinds, blanks, and
plugs or 25
LINE BREAK
4. Opening ports such as a
man-way, hatch, or cover
5. Penetrating a line by
mechanical or other means,
6. Any task that requires a worker to perform work on an existing process piping system
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LINE BREAK7. Intentional Opening that
could result in the releaseof the system contents.
8. Secondary containment
(spill or catch pan)
9. Minimum 2 workers wearing face shield and mono-goggles
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LINE BREAK10. IDLH?? Performance utilizes fresh air only as a precautionary measure for any potential hazards that may remain in lines or equipment.
At NO TIME will we intentionally perform work in known IDLH environments. We often create IDLH atmospheres by inertingand purging for welding.
We do NOT train nor have personnel for IDLH environments!
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LINE BREAK
11. Proper Flange Breaking
Protocol
12. Can’t Hot Bolt Flanges
with only 4 bolts
NOTE: Confirm site
requirements
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EQUIPMENT OPENING
EQUIPMENT OPENING is:
1. Opening process equipment such as tanks, vessels, drums, or exchangers, etc.
2. Disconnecting flanges,
3. Removing blinds, blanks,
and plugs30
EQUIPMENT OPENING
4. Opening ports such as a man-way, cover, hatch, or head to open equipment.
5. Breaking the imaginary plane is considered
“Entry”!
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EQUIPMENT OPENING
6. Equipment contents
IDLH??
7. Secondary containment
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TIE-IN
TIE-IN is any task that requires a
worker to:
1. Install a new component on or to an existing process piping system that could
result in the release of the
system contents.
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TIE-IN
2. Connecting by means of welding or bolting
3. Adding onto existing system
4. Secondary containment
5. Tie-in # / Tag
NOTE: This does notinclude a “Hot Tap”.
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CONTROL MARKING TAPEControl Marking Tape is the
Control Tool used to Identify the
specific location of the line break,
equipment opening or tie-in
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CONTROL MARKING TAPE• 2 complete 360° wraps around
pipe, flange, etc.
• Arrows facing each other
Signing
1. Place at identified location
2. Foreman & Crew performing task
3. Sign and Date
4. Only good for designated permit time
and crew that signed it for that shift36
--
cut
--
CONTROL MARKING TAPE
5. If the client or site require
other procedures, such as
cut tape to be followed,
YOU MUST STILL
FOLLOW THIS
PROCEDURE!37
CONTROL MARKING TAPE
Demolition: Control Marking
Tape shall be used to:
1. Mark line(s) to be demoed
2. Spray paint orange
3. Placed tape at every cut of
the demo line
NOTE: For a Unit demo, get a
variance.38
SUPERVISOR
Must follow the Standard Operating Procedure for:
LINE BREAK, EQUIPMENT OPENING or TIE-IN
NOTE:1. IDLH??
2. Secondary Containment
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SUPERVISOR
Must IDENTIFY the LAST
CONTAINED SUBSTANCE in
the LINE or EQUIPMENT!
“ANY POTENTIAL” that maycause injury or illness
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SUPERVISOR
1. Obtain Necessary Permits
2. Copy of Safety Data Sheet
(formerly MSDS)
3. Select PPE based on the
Hazards
4. Confirm line break, equipment
opening or tie-in points41
SUPERVISOR
5. Control Documents
6. Consider the “VOLUME” that
may be discharged (Catch Pan /
Vacuum Truck)
7. Identify and Review
Locations of:
A. Safety Shower42
SUPERVISOR
B. Eye Wash Station
C. Emergency Exits
8. Restrict Area Access –
NOTE: Barricade and account
for Wind carriage
9. Follow LOTO, Confined Space,
IDLH, etc. procedures43
SAFETY PERSON
Provides 2nd level adherence to:
“Same as Competent Person” • Line Break, Equipment Opening and
Tie-in Procedure
❖ Use of Control Marking Tape
❖ Training of Employees
❖ Isolation is completed
• Sign the Line Break Checklist & Flawless Execution Plan
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COMPETENT PERSONProvides 3rd level adherence to:• Line Break, Equipment Opening and
Tie-in Procedure
• Follow Standard Operating Procedure for site
• Conduct a system walk down
• Verify “Zero Energy” for LOTO
• Sign the Line Break Checklist & Flawless Execution Plan
NOTE: Final approval to verify safety systems are in place
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EMPLOYEES
Employees Trained in:1. Lockout / Tagout – LOTO
2. Line Break, Equipment Opening, or Tie-in
3. Knowledge of potential hazardsand preventive measures
4. Standard Operating Procedures
5. May require – if applicable Confined Space Entry, Fresh Air, Respiratory, Fit Testing, etc.
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EMPLOYEES
❖ Wear Required PPE
• Review Documentation
Review Safety Data
Sheet (formerly MSDS)
➢ Use the Buddy System
✓ Verify zero energy
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EMPLOYEES
• TRUST “BUT” VERIFY
YOUR LIFE
equals
YOUR RESPONSIBILITY
1. YOU – Confirm Isolation
2. YOU – WALK OUT the system
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EMPLOYEES
3. YOU – Verify isolating
devices
4. YOU – Test and Try prior to
beginning task to ensure that
energy source is properly shut off
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CONCLUSION
Use this Line Break, Equipment Opening, and Tie-in Procedure
Follow all LOTO, Confined Space Entry, IDLH, etc. requirements.
TRUSTthat the procedures are correct
BUT VERIFYthat they are!
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