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 are not exempt
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. Authorization Log
The Authorization Log is used to authorize entry into process area for activities that don’t require a Safe Work Permit.
Example activities: Safety contact / audit, job planning, job walk, etc.
Purpose is two-fold:
Authorize minor activities (i.e., those not requiring a Permit).
Account for personnel in event of emergency.
Expectations for use of Authorization Log (ex. going into another unit):
You must get authorization from a qualified Permit Issuer for the area you will be entering.
This can be via radio
Communicate the purpose for entry to ensure a Safe Work Permit is not needed.
Fully complete the log, including the name of the person granting authorization.
Sign out when leaving the area.
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 4 Eyes Review
Definition: The use of 2 or more individuals to review a job or task in the field to ensure all hazards are identified and eliminated/controlled through the use of safe work practices or PPE, communication/awareness, etc. At a minimum this must include a Permit Issuer and a Work Crew Representative.
The majority of contractor permits will require a 4 Eyes Review. The following work activities are excluded:
General work
Hot bolting
Vehicle Access
Someone doing the work must participate in the 4 Eyes Review.
The foreman may still participate but must also include a crew member who will be doing the work.
“Working foremen” must be assigned to one crew if they are only reps participating in 4 Eyes Review.
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 work activities with a 4 require a 4 Eyes Review.
Back of the permit includes guidance for completing a 4 Eyes Review based upon the specific work classification(s).
All boxes, as applicable to the work, shall be checked on the back of the permit.
The Owning Department Rep and Permit Acceptor shall legibly sign the back of the permit upon completion of the 4 Eyes Review.
Again, the intent is to ensure that the job is safe before work begins.

6. Expectations for Permit Acceptors
Understand the scope of the job
Review the permit, job scope, and safety precautions
Legibly sign the permit on behalf of the work crew
Walk the Tag Out and hang the Work Crew Lock/Tag, as applicable to the job
Review the permit details with the other work crew members
Ensure that the yellow copy of the permit is maintained at or near the work location.
For work on multiple decks by same crew, the permit may be kept at designated location (ex. job box, base of stairs, etc.).
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 Work Crew Lock/Tag
Return the permit for closeout at the conclusion of the job

7. 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.

8. Expectations for all Work Crew Members
Know the location of the permit
Understand the scope of the job and hazards involved with the work.
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.

9. Permit Revalidation Definition: When required:
The process of reusing an existing Safe Work Permit to authorize work by reviewing the work conditions specified on an existing permit with a permit acceptor to ensure the scope, conditions, and safety precautions listed on existing permit have not changed.
When required:
If the amount of time between the 4 Eyes Review and start of actual work exceeds two (2) hours;
Change in work scope or conditions which are not addressed by the existing permit;
Permit Acceptor changes;
Work stoppage due to an emergency that adversely affects the work area.
The prior definition required a 4 Eyes Review for every revalidation.
Eliminated a change in Permit Issuer as conditions for needing revalidation.
The Permit Acceptor is responsible for informing you if 1, 2, or 3 occur.

10. Permit Revalidation Minimum expectation for any revalidation:
All parts of the permit are reviewed
Initial permit conditions have not and will not change; or update accordingly
Permit Issuer and Permit Acceptor sign the permit
In addition, a 4 Eyes Review is required for revalidation of permits involving confined space entry, LOTO, line breaking, and/or flame/spark-producing hot work.

11. Line Breaking and Lockout/Tagout
Written job plans are 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 by Operations.
A copy of the drawing is not required to be provided to Work Crews, but should be made available upon request.

12. 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.
Each work crew member must individually sign on and off the back of the Safe Work Permit.

13. Individual Yellow Tags
Each individual will hang their own Maintenance Tag (not lock) at the designated location.
Individual tags to be removed at the end of each day.
Work Crew lock / tag to be removed at the conclusion of the job, unless ‘release for testing’ is needed by Ops.
Individual tags must be completely and legibly filled out.
Contact #: Who BASF will call from your company if your tag is left in the field.
Individual tags can be used multiple times (i.e., there is no date)

14. Individual Yellow Tags
Each individual tag must be removed by the person who applied it.
Work crew foreman cannot remove on their behalf.
We expect all tags to be removed as required.
Tags that are left will be treated just like a lock left on equipment.
BASF will contact the work crew leader to see if the individual is still on-site.
If “yes”, then the individual will be responsible for removing their tag.
If “no” but work crew supervision is on-site, then the work crew supervisor will be responsible for removing the tag.
If no work crew representatives are on-site, then BASF will verify that it is safe to remove the tag before doing so.

15. Scenario: Job involving no electrical energy source, extends over shift with no Release for Testing (changes in red)
Permit acceptor hangs work crew Maintenance Tag at designated valve during 4 Eyes.
Each crew member hangs their own Maintenance Tag at the designated valve before starting work within the LOTO.
At conclusion of the permitted shift, each crew member removes their individual Maintenance Tag. Work crew tag remains in place.
Each crew member hangs their own Maintenance Tag at the designated valve when they return the next day.
At completion of the job, each crew member removes their individual tag and the designated crew member removes the work crew tag.
Final Release the Tagout Sheet.
Ops verifies all Maintenance Tags are removed before removing any Red Tag related to the Tagout Sheet.
Only those individuals performing work needs to have their own tag in place.
No change in the permitting process from an Ops perspective. The additional tags only come into play when the work crew starts work.

16. Scenario: Job involving no electrical energy source, extends over shift with Release for Testing (changes in red)
Permit acceptor hangs work crew Maintenance Tag at designated valve during 4 Eyes.
Each crew member hangs their own Maintenance Tag at the designated valve before starting work within the LOTO.
At conclusion of the permitted shift, each crew member removes their individual Maintenance Tag. Work crew tag remains in place.
Each crew member hangs their own Maintenance Tag at the designated valve when they return for the next permitted shift(s).
Ops requests Release for Testing:
Each crew member removes their individual tag and the designated crew member removes the work crew tag
Release for Testing section of Tagout Sheet is completed
Ops performs Testing and ultimately reissues the Tagout Sheet.
Steps 1-2 by work crew
At completion of the job, each crew member removes their individual tag and the designated crew member removes the work crew tag.
Final Release the Tagout Sheet
Ops verifies all Maintenance Tags are removed before removing any Red Tag related to the Tagout Sheet

17. Scenario: Tagout Involving Electrical Source (changes in red)
Permit acceptor hangs work crew Maintenance Tag and yellow lock at designated breaker during 4 Eyes.
Each crew member hangs their own Maintenance Tag on the designated breaker before beginning work.
Note: The individual tags should be hung with cable ties on either the work crew lock or available hasp
At conclusion of the permitted shift, each crew member removes their individual Maintenance Tag. Work crew lock and tag remains in place.
Individual tags are replaced on subsequent shifts
At completion of the job, each crew member removes their individual tag and the designated crew member removes the work crew lock / tag.
Final Release the Tagout Sheet
Ops verifies all Maintenance Tags are removed before removing any Red Tag related to the Tagout Sheet
Hanging the individual tags to the work crew lock keeps all related tags on the same lock

18. Line Breaking and Lockout/Tagout
One-Plus isolation is required for:
Any valve tagged in closed position.
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.

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

20. Red Tags Applied by Operations

21. Electrical Tags

22. Instrument Tags

23. Tag Placed by Maintenance Crew

24. Tag Placed by Individual Worker

25. 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.

26. 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.

27. 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
Pneumatic wrenches
Generators, etc.

28. 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.

29. 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.

30. Completion of Work / End of Shift
If the job is not complete, but the Work Crew is finished for the shift then:
Each individual will remove their individual yellow tag.
Complete the Closeout section of the permit
Return the unsigned Tag Out Sheet to the Equipment Owner.
The Work Crew Yellow Tag(s) / lock(s) shall be pulled or left in place as directed by the permit issuer.
If the job is complete then all yellow tags must be pulled and the Tag Out Sheet completed by initialing the Final Release section.
Completed Safe Work Permits, along with other associated documents (ex. Tag Out Sheet, Confined Space Permit, etc.) must be returned to the Owning Department.
This must be done face-to-face. Do not just drop permit off and leave.

31. Application of Cut Tape & Permitting
BASF cut tape must be placed at locations where piping will be cut to isolate from or tie into process and/or utility services.
The cut tape may be applied at any time prior to start of work (ex. Planners).
If piping is insulated, the tape must be applied after the insulation has been removed.
Each cut tape location must be initialed by a representative from the Owning Department.
This must be done during the 4 EYES Review with the contractor representative
Initialing of the cut tape only indicates the location for the cut is within the boundaries of the Tagout.
Every BASF cut tape location must include a unique identification number based on the tie point location number that is included in the job plan. If no tie point location is identified in the job plan, the Tag Out Sheet number will be used (ex. Tagout Sheet #1234-1, , etc.).
This information must be documented in section 1 of the Safe Work Permit under ‘Description of work authorized by the permit’.
The Work Crew Representative must initial each BASF cut tape location during the 4 Eyes Review and then apply their own physical marker (ex. tape, tag, etc.) at each location identified by the BASF cut tape.

32. BASF Cut Tape Stores # 8516337 ← B A S F C U T L I N E← B
BASF APPROVER:______________ A S
CONTRACTOR APPROVER:________ F
BASF CUT LOCATION #:___________ C U T L I N E
Stores #
10/13/2019

33. Permitting for Line Cutting

34. Exception to Applying BASF Cut Tape at Every Cut Point
When additional line cuts are needed to execute the work (ex. cut into sections for removal), the Work Crew may make additional cuts within the boundaries of the first/last BASF cut tape as long as:
The piping to be cut is clearly identifiable between the BASF cut tape locations;
The piping has been marked with fluorescent orange paint;
The additional cut locations have been approved by a BASF Owning Department representative; and
The Work Crew applies their own physical marker (ex. tape, tag, etc.) at each additional cut location.
Fluorescent orange paint may only be applied to lines that have been verified cleaned, de-pressured, isolated and ready for the permit to be issued.

35. Responsibilities for Line Cutting / Cut Tape
The Owning Department is responsible for:
Ensuring that the BASF ‘cut’ tape is placed at locations where line cuts need to be made.
Initialing each BASF cut tape location once the tape is in place.
Assigning a unique identifier to each BASF cut tape location.
Referencing the unique identifier(s) for each cut location on the Safe Work Permit issued to execute the work.
Conducting a 4 Eyes Review with the work crew to ensure that the work is safe to execute.
Approving additional cut locations needed to execute work (ex. demolition) between the identified BASF cut tape locations.
The Work Crew is responsible for:
Having the Work Crew Representative initial the BASF cut tape at each identified cut location.
Applying their company’s physical marker (ex. tape, tag, etc.) at each cut location identified by the BASF cut tape.
Cutting only at the location(s) identified by the BASF cut tape
Applying their company’s physical marker (ex. tape, tag, etc.) at additional locations necessary to facilitate the work, as approved by the BASF Owning Department.

36. Line Cutting Work Execution
For piping systems in flammable service which have no verifiable clearing bleeds in the immediate area, a 1/8” hole should be drilled into the pipe to verify that no flammable content is in the pipe before cutting the pipe. If drilling a hole is not reasonably possible, an exception may be written on the Safe Work Permit and must include why the hole cannot be drilled and what alternate method has been used to verify clearing.
The Work Crew may not make a cut any location unless the following criteria have been met:
A 4 Eyes Review has been completed between the permit issuer and the work crew.
Orange cut tag is present at each cut location, or the pipe has been marked according to the exception.
The orange cut tag identification number(s) matches the number(s) indicated on the Safe Work Permit.
The work crew marking tool (e.g., tape, tag, etc.) is present at each cut location.
If upon work execution it is determined that additional cuts need to be made, which have not been identified on the Safe Work Permit, the job must be stopped and BASF cut tape applied at each new location.
The Safe Work Permit must be updated to include the new cut locations.

37. Example Scenario

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