1. BASF Geismar Site Requirements
Safe Work, Hot Work, LOTO & Line Breaking

2. Safe Work Permits
Technically covers all “work” at the site, including operations, contractors, visitors, deliveries, etc.,
General Work in non-process areas no longer exempted
Contractor activities that are exempted:
Lawn care
Janitorial staff
Deliveries to non-process areas
Work performed in maintenance shops, designated fabrication areas for turnarounds or large maintenance project fabrication areas which are specifically demarcated or require other administrative measures to ensure all personnel can easily identify fabrication areas.
Use of the Safe Work Permit has been expanded to cover additional activities that may have previously been exempted at Geismar (ex. General Work in XA areas).

3. Safe Work Permits
Non-unit personnel only visiting a process area must now be issued a Safe Work Permit OR be authorized through use of an “authorization log”
Examples: Conducting an audit, a foreman reviewing a job, visitor, etc.
Not performing work!
Authorization Log
Set up in control room
Must sign in/out when entering a process area
Must receive approval from the Owning Department, the name of whom must be recorded on the log.
All contractors going into a process area must be covered by a Safe Work Permit or sign in/out on the Authorization Log. Each cluster is responsible for determining which approach to use.

4. Safe Work Permits
The Permit Issuer must meet with the Work Crew Representative at the specific work location, prior to permit issuance, to conduct a 4 Eyes Review:
Review the job scope
Review all applicable sections of the permit
Ensure that all necessary precautions have been taken
The following activities require a 4 Eyes Review:
Lockout/Tagout
Installation/removal of a pipe clamp
Line Breaking
Hot Work
Confined Space
Loading/unloading by non-BASF personnel (excluding fuels)
All contractor work to be done in electrical substations, even general work
Electrical work on equipment 480 V and above
Installation/maintenance/removal of temporary repairs (ex. clamp) to pressure equipment
The intent of the work site visit is to employ the “4 Eyes” principle…two people looking at a job is better than one. BASF needs to make sure that the work crew understands the job scope, the precautions that need to be taken, and review the permit. This requirement has been added as a result of prior incidents, many of which occurred at Geismar, where the Work Crew did not understand the job scope, worked on the wrong equipment, performed line breaking in the wrong place, etc.
The work site visit can include one or more Work Crew Representatives (ex. The foreman and a crew member) for jobs that involve Lockout/Tagout, Line Breaking, Hot Work, and Confined Space, but must include someone from the actual work crew.
How the paperwork is to be handled will not be mandated. Each cluster will need to decide what works best.

5. Expectations for the 4 Eyes Review
All Line Break locations have been identified and all Line Break precautions taken
Bleeders nearest each line break are open and unplugged
There is no pressure on the system
All purges are off
All piping/equipment is cool
Any associated Start/Stop switch has been tried. Note: If a local field switch is used to Try To Operate the equipment, the off-switch shall be activated immediately following the “try”. This is to help prevent startup of the equipment once the Servicing/Maintenance is complete and the switch gear is energized by the Equipment Owner.
Equipment has been verified as de-energized and is ready for work
The job scope is mutually agreed upon and documented as such on the SWP
If the work involves entry into a Confined Space, that a rescue plan has been established and that retrieval equipment is in place
‘Cut’ tape is in place, as applicable to the work.
Again, the intent is to ensure that the job is safe before work begins.

6. Color Code for Line Cuts and Demo Work
Prior incidents, in which contractor crews cut into wrong lines or still energized lines, resulted in the following requirements being implemented:
Locations where piping will be cut, in order to isolate from (ex. pipe demo) or tie into a process (ex. install tie point), must be marked with orange “cut” tape (Stores # ).
Applies to all services, including utilities.
The Owning Department is responsible for identifying where the pipe cuts will be made and ensuring that the “cut” tape is placed on these locations.
The Owning Department representative must initial the tape once it’s in place.
The 4 Eyes Review must verify that the tape is in place.
The Work Crew is responsible for cutting the pipe at the locations identified by the “cut” tape.
Note: Additional pipe cuts may be necessary to ensure safe removal of pipe sections (ex. for crane lift); however, such cut locations are not covered by #1 above.
Piping and equipment, which is to be demolished / removed, must be marked with Fluorescent Orange spray paint (Wilson #14285).
This applies to all process services, including utilities.
The spray paint should be applied by the Maintenance Planner or Foremen

7. Color Code for Line Cuts
Cut tape is available from Stores
7/9/2007
INTERNAL

8. Color Code for Line Cuts and Demo Work – Practical Implications
The cut tape is only needed at those locations when the piping is still connected to a “live” service.
This may be one or more locations depending on the scope of work.
Additional cuts needed to facilitate the work (ex. break the pipe into smaller sections for removal), do not need our cut tape.
The cut tape can be placed at the required locations at any time (ex. during planning process, during equipment isolation, during 4 Eyes review), but should be verified as in place during the 4 Eyes review.
The tape can be physically placed by other groups (ex. Planner, work crew foreman, etc.) under the direction of the Owning Department, but the Owning Department representative must initial the tape once it’s in place.
Do not need to initial every blank on the tape, but just where it’s clearly visible to the work crew.
7/9/2007
INTERNAL

9. Expectations for Permit Acceptors
Understand the scope of the job
Go to the work location with the Permit Issuer to review the permit, job scope, and precautions to make the job safe
Sign the permit on behalf of the work crew
Walk the Tag Out and hang the Maintenance Lock/Tag, as applicable to the job
Review the permit details with the other work crew members
Maintain work crew headcount during the job
Return the permit if any job conditions, precautions, etc., change that could affect the safety of the job…such changes may require the permit to be revalidated
Report any incidents
Remove the Maintenance Lock/Tag
Return the permit for closeout at the conclusion of the job
This must be face-to-face

10. Expectations for Permit Acceptors
Statement on the Permit Acceptance section:
I understand the scope of work that is to be done and the requirements of this permit, and will inform others on this job of this information. I will ensure that all workers know how to use the equipment and PPE necessary for this job. I will inform the Owning Department of any changes to the permit conditions or any incidents that occur.
I also understand that this permit gives me the authority and responsibility to stop and/or shutdown a job if any unsafe condition exists or unsafe act occurs.

11. Expectations for all Work Crew Members
Understand the scope of the job
Sign on/off the back of the permit for the following types of jobs:
Non-System Tag Out, Hot Tap, Interdepartmental Tag Out, Confined Space, System Tag Out, Electrical Tag, Line Breaking, and GAMA Tag Out
Follow all permit conditions (ex. Precautions, PPE, etc.)
Clean up the work area before returning the permit
Report any incidents
Stop work if any unsafe conditions, unsafe behaviors, or hazards are observed.
Work crew accountability must be done by each individual…someone else cannot do it for you.

12. Line Breaking and Lockout/Tagout
Written job plans are now required for work on process equipment, which involves energy isolation or line breaking.
The details of the job plan will be determined by the job planner or Maintenance Coordinator based upon the complexity of the work activity.
Job plans must be available for review by the unit personnel for use in developing isolation strategies and Safe Work Permits for the work.
Whenever equipment is to be isolated for Servicing/Maintenance, a drawing showing the location of each isolation device must be generated.
A hand drawing, ISO drawing or P&ID may be used.
This drawing should be used in conjunction with the Tag Out Sheet to ensure all isolation points are identified for Hazardous Energy Sources.

13. Line Breaking and Lockout/Tagout
BASF will issue a copy of the Tag Out Sheet to each work crew. The Tag Out Sheet will identify all energy isolation devices that will be locked and/or tagged by BASF.
The Tag Out Sheet will also identify a location where each crew must hang a yellow Maintenance Tag.
The BASF permit issuer will provide copies of the tags if needed.
Each work crew member must individually sign on and off the back of the Safe Work Permit.
Your signature, along with the Maintenance Tag, is our mechanism for accounting for you on the lockout job.

14. Line Breaking and Lockout/Tagout
One-Plus isolation is required in the following situations:
¼ turn valves on Hazardous Energy Sources that are tagged “closed”; regardless of handle type
Remove handle (by supervisor approval only)
Chain or cable
Valve cover or locking arm
Cable lock
Tie wrap (minimum tensile strength of 125 lb)
Non-lockable electrical sources
Chain-actuated valves
Secure chains out of the way or together at a height of 7 feet or more
During walkout of the Tag Out Sheet, you should notify Ops if you observe valves that do not have One Plus as required above .
If you see where One Plus is not properly applied then report it to the Permit Issuer before proceeding with work.

15. Do not tamper or attempt to operate any equipment with the following tag(s) attached…

16. Red Tags Applied by Operations

17. Electrician’s Tags

18. Instrument Technician Tags

19. Tag Placed by Maintenance Crew

20. Line Breaking
Any relaxing of Line Breaking precautions (ex. Downgrading of PPE) must be approved by the Permit Issuer and documented on the Safe Work Permit.
If a system or piece of equipment is closed and then subsequently reopened, after it has undergone a Line Break but not put back into service, the subsequent reopening is considered a new Line Break and must adhere to all the requirements of the initial Line Break.
Each line break has to be considered as if it contains hazardous materials. Depending upon the complexity of the equipment, each line break may have to require full PPE. The Owning Department is responsible for determining when PPE can be downgraded.
Geismar previously had an incident where equipment had been worked on then closed back up. The next the equipment had to be reopened, but the proper line breaking PPE was not worn. A valve leaked through and some contractor employees were exposed.

21. Line Breaking Precautions to be taken:
Restrict access using barricades and barrier tape when work is elevated or over grated platforms.
Use splash or drain pans, as needed, to protect personnel and equipment below.
Ensure that each work crew member is fully informed of any potential hazards, special safety precautions and the location of nearest safety shower/eye wash stations.
Coordinate/communicate with adjacent work groups to ensure everyone is aware of the line breaking activities.
Use defensive positioning in order to avoid a spray or release when attempting each line break.
Break flanges on the opposite side of the piping from the employee.
Continue to use required PPE until the equipment can be verified free of hazardous contaminants and Operations approves, in writing, the downgrading of any PPE.
Specified PPE must be worn by all personnel in immediate vicinity of the line break
These have been added to the back of the permit for your review
The work crew performing the line break is responsible for ensuring that this precautions are taken as applicable to the work. There have been multiple incidents at Geismar which could have been prevented if these precautions had been applied.

22. Hot Work At BASF Hot Work includes:
Flame / spark-producing activities, such as welding, burning, grinding, etc.
Vehicle access into process areas that may contain flammable atmospheres (ex. Class I, Div. II)
Use of tools and equipment that can be potential ignition sources in areas that may contain flammable atmospheres. Such tools & equipment include:
Portable electrical tools
Cameras
Generators, etc.

23. Hot Work
The 4 Eyes Review for Flame or Spark Producing Hot Work must ensure that applicable fire prevention precautions have been verified by the BASF Permit Issuer before the start of Hot Work.
The BASF Permit Issuer is responsible for communicating how this will be done.
The maximum amount of time between the 4 Eyes Review and start of actual work must not exceed two (2) hours. The permit must be revalidated or reissued, including the 4 Eyes Review, if two hours is exceeded.
The Hot Work Permit must be reissued or revalidated in the following situations:.
Change in work scope or conditions which are not addressed by the existing permit;
The Permit Acceptor changes.

24. Hot Work
Permits are not required for Hot Work conducted in designated areas (ex. Maintenance shops, fab areas, etc.); however, BASF Safety must approve any temporary fab area where hot work will be performed.
Adequate Hot Work precautions must be used to prevent the start of fires.
These areas must be audited each year to ensure that Hot Work practices are being followed.

25. This completes the overview of BASF Geismar’s Lockout/Tagout requirements.