LINE BREAK, EQUIPMENT OPENING AND TIE-IN PROCEDURE

LINE BREAK,

EQUIPMENT OPENING

AND TIE-IN

PROCEDURE

1

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

3

SCOPENO WORK Shall be performed

“until”:

1. Known Identity of the

last contained substance

2. Review of the Safety Data Sheet (SDS – formerly MSDS)

4

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

6

DEFINITIONS

CLEARED LINES are lines or

equipment that have been:

A. Isolated, drained, vented,

flushed, and

B. Visually verified

7

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

9

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

11

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

12

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

14

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??


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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.

33

TIE-IN

2. Connecting by means of welding or bolting

3. Adding onto existing system


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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