w. DOCUMENT CODE | SAF-wPuMs.020 | REV.# | 00 | REV.DATE| 11.0310 | PAGE | 1 of4 OIL WORK PROCEDURE TITLE: FIRST BREAK OF THE EQUIPMENT 4.0 PURPOSE: To define steps required to prevent personnel injuries and reduce release of products while making equipment breaks. 2.0 SCOPE This procedure is applicable to all instances when a sealed system is opened fo inspection, cleaning, repair or maintenance such that a possibility exists that ‘substance contained by the system or equipment may be unexpectedly released. ] / 3.0 DEFINITIONS / 3:1 Equipment refers to operational systems such as pumps, vessel, tan, ‘bri, valves and gauges, etc. 3.2 First Break is the physical opening of the system to the atmosphere to prove that process clearing has been completed. NOTE: Opening a drain or valve does not constitute First Break. 3.3. Clearing is the isolation of valves, electrical switches or other devices such as blind inserting to make the equipment inoperable and also removal of fluid spillage / splashing hazards from the equipment by de-pressurizng, drain 3.4 Work Group refers to either A ieesbsiora who pefforms the first- break task. 4.0 PROCEDURE | Preparations for and release of any ounce ar work mud sequence, i a. Clear equipment ee b. Electric Isolation . Wear appropriate personal protective equipment required d. Provide experienced standby personnel e. Issue valid work permit for First Break of the Equipment. f First break into equipment 9. Release the equipment to the work group. Issue @ relevant work permit for the job to be attended on the equipmentiine. 4.1 Clearing of Equipment ROUTE PREPARED BY REVIEWED BY ‘APPROVED BY REFERENCE ‘Name ‘Abdul Karim Noon | ljazHussginthan [ Qadeer Ahmed Khan | ion 4 ag Di uplo | W-3-10 QMS 4.2.1 (d)/ DOCUMENT CODE | SAF-wP4MS-020 | REV.# | 00 |REV.DATE| 11.03.10 | PAGE | 20f4 / 4.1.1 Pre-Reauisites: Develop a work plan to identify the hazards of the system, such as thermal, chemical, reactivity, toxicity, environmental etc. ‘including energy ‘sources such as heat tracing. Such information is typically available in MSDS Sheets. b. Involve the qualified individuals from Operations; Maintenance and E&l or any other group to prepare work plans in order to address the multi-dimensional hidden hazards ft. Identification of the equipment and the scope of the jobs are clear to |" all concerned. 2 gd ZZ jd. Ensure that all the persons involved in the line or equipment opening Qz Job are skilled and qualified on that task. Pay extra care on this while Sz Performing the first break on any line or equipment. = fe. The working team and / or team leader is qualified on work permit system. ‘Appropriate PPEs are available with the working team and their use is clear to all. 4.1.2. To perform work on equipment, a request for shutdown, clearance, and release will be made by Maintenance to the Operations group. Similar clearing of equipment may be necessary for operational reasons. 4.1.3 The Operations is responsible for making the correct equipment inoperable and safe 4.1.4 Positively isolate the required line. Strictly follow the relevant operating procedure to ensure all the requirements for isolations have been met. 4.1.5 Clear off the lines or equipment by effective flushing, purging with nitrogen or steam and venting. 4.1.6 Perform clearing of equipment by safe manners, i.e. use closed vent systems to vent the hazardous substances during purging, 4.1.7 Use N2 blanketing while performing cutting jobs where required. Strictly follow the relevant procedures. 4.1.8 Ensure the lines or equipment is not under pressure and hot. Open drains and depressurizing valves where applicable and ensure its safe to break the flange. 4.1.9 Ensure all the concemed powered equipment are stopped, electrically isolated and tried out. eck whether the line or equipment is cold enough to safely perform the lear off the lines which are insulated and / or heat traced with extra care af there may be a potential to transfer heat to the material that may remain “~Znlthe line and Jor equipment (including the clearing medium). 4.1.12 When doing clearing of lines, consideration must be taken on the possibility that even horizontal lines could have sags, however slight, that can trap ROUTE PREPARED BY REVIEWED BY APPROVED BY REFERENCE ‘Name ‘Abdul Karim Noon | ljazHussajn-Khan | Qadeer Ahmed Khan Hee aae Date Upte Ce W-3-10 Wa-me] Ap), (OMS 4.2.1 (d) [Desig. /Sign. | UM Safety DOJi [Documenr cone] sar-wraus-oao [reve [oo [Rev-oaTe] wicni0 [PAGE| sofa products. The location where the first break is done might not reveal this trapped material. 4.2 Electric Isolation The identified equipment must be electrically isolated, tagged and checked by both the Operations and the Work Group involved. This must be done according to Electric Isolation Procedure. 4.3 Wear appropriate Personal Protective Equipment 4.3.1. Operations will review the appropriate personal protective equipment and standby personnel requirements. 4.3.2 In all cases, minimum personal protective equipment is Safety Helmet, safety shoes, ear plugs, safety goggles and appropriate gloves. NOTE: Operations personnel are responsible for ‘first break’ control and should be present at each ‘first-break’. Personnel assigned to perform the ‘first break’ should be familiar with the risk and precautions to be taken. a 4.4 Provide Experienced Standby Personnel A standby person, if required, must be assigned by the Operations. The primary function of the standby personnel is to serve as a rescue man on site. He must be ‘equipped with the following items: a. Walkie-talkie, if available, for emergency communication ORIGINAL | b. Have the required PPE on standby for rescue purpose. WHEN IN RED. c. Knowledge of location of safety showers & emergency actiofs- J d. Aware of hazardous properties of chemicals involved. 4.5 First Break into Equipment 4.5.1 The Operations personnel must determine the location of the first break to ensure that the work will be done on the correct equipment. 4.5.2 The Operational personnel will define the limits into which the first break is to be made such as sections of piping or equipment systems. Input from the Work Group Supervisor should be used in defining the limits. 4.5.3 The Work Group Supervisor is responsible for ensuring that those Participating in the first break are familiar with breaking job. 4.5.4 Work Permit Issuer & Receiver involved in a first break share a joint responsibility to ensure that the hazards are understood and the appropriate protective equipment and standby requirements are present and utilized during a first break. 4.5.5 Th first break should be made at the appropriate point away from the i 00P_—-wotkers body, and the equipment allowed to drain before starting the job. Instruct maintenance person to first loosen the bolts to ensure no pockets Vapors of hazardous substances have been trapped within the line or equipment. ROUTE PREPARED BY REVIEWED BY APPROVED BY REFERENCE Name Abdul Karim Noon jaz Hussail jan Qadeer Ahmed Khan HSE: 4.46 Date mst Lyi Jy [ies-en0 Ms 42:1 (¢) [Desig. Sign. | UM Safety ‘SPM re DO/ 46 47 / [posunenr cose] sarwrmnsom [Reve] m [Rey ome] vem [pace | 40 | Caution: Breaks shall be made away from the body. When performing a break ‘one should be conscious of body positioning such that if there is a release of material from the break there is limited body contact and that there is egress / escape opportunity. Safety Risk and Pollution Prevention 4.6.1 Break locations should be inspected thoroughly before startup 4.6.2 Precautions must be taken at first break locations to prevent ground contamination, and/or bystander exposure. The existence of ignition sources in the vicinity should be considered when opening a system that may possibly release a flammable material 4.8.3 If there is risk of ignition by sparks from falling tools, lay a noncombustible fabric on the concrete floor or wet the floor. 4.8.4 Signs and / or barricades, if necessary, should be used to eliminate potential exposure to passerby. Caution: During the course of job, if conditions affecting health, safety, and environment differ from the expected (e.g. drain valve plugged or line cannot be cleared), the job shall be stopped and the work plan revised to address the additional hazards of the situation. Release of Equipment 4.7.1. The Operations will release the equipment or system for work only AFTER the first break is COMPLETED and the equipment system is cleared of hazards and/or gas freed. 4.7.2. When work on cleared equipment is to last over an extended time, or where the hazards of the material warrants, open lines should be bianked or capped. . 5.0 REFERENCE | ~OR'GWaL 5.1 Procedure No. Electric Isolation Procedure. [_ WHEN IN RED 7 Name PREPARED BY. REVIEWED BY APPROVED BY REFERENCE ‘Abdul Karim Noon | jaz HussaipKhan | Qader Ahmed Khan HSE: 4.4.6 Date Desig. ‘Sign. Didi N-3-10 Tassie TOs, | omsaztie UM Safety SPM DO et