Title:

Line/Equipment Breaking

Function: Environmental, Health, and Safety

Freeport Site
Standard No.: BCF020.039 Page: 1 of 11
Reviewed: 03/15 Effective: 08/15 Supersedes: 10/09
Preparer: Owner: Approver:
Site Safety Representative Manager, Environ, Health & VP and Gen. Mgr., Freeport
Safety

RECORD OF REVISION
Date Revision Details of Change
Number
03/15 7  1. Purpose Statement revised to align with corporate standard
BC032.015 Line Break
 2.3 Changed BC to BASF
 2.7 Added To Definition to align with corporate standard BC032.015
 2.10 Changed Line and Equipment Break to Line Breaking and
changed wording for clarification.
 2.12 Added Definition for Permit Acceptor
 2.14 Added 4 Eyes Principal
 4.1.1 Added Note 2
 4.1.2 Added ‘Preparation’ to Title, added Note 1,2,3, added
requirement to test for toxic concentrations and added ‘Where present,
pressure gauges should be checked for pressure readings and bleeds
should be opened and cleared.’
 4.1.3 Added Examples for Verification
 4.2.2 Rephrased language to emphasize requirement for wearing
chemical googles as minimum PPE
 Title:
Line/Equipment Breaking

Function: Environmental, Health, and Safety

Freeport Site
Standard No.: BCF020.039 Page: 2 of 11
Reviewed: 03/15 Effective: 08/15 Supersedes: 10/09
Preparer: Owner: Approver:
Site Safety Representative Manager, Environ, Health & VP and Gen. Mgr., Freeport
Safety

1. PURPOSE

To establish minimum standard work practices and procedures for initial safe opening and
ensuing work on flanges, pipes, and equipment which contained or may have contained
hazardous material, thermal hazards (hot or cold) or been under pressure.

2. DEFINITIONS

2.1. Cleared
Lines/equipment that have had hazardous materials removed through washing,
purging, neutralizing, and/or inerting.

2.2. Contracted Employee (i.e. contractors brought in without their company supervision on site)
An individual or group of individuals for whom BASF provides direct supervision
in their day-to-day activities and direction as to how an activity is to be
performed.

2.3. Contractor Employee (i.e. Nestor, daily and shutdown contractors with supervision on site)
An individual engaged by or through a third party to perform services principally
for the third party.

2.4. Defensive Position

 Anticipating the likely direction of potential release of material and placing one’s
body and equipment out of the anticipated plane of release
 Loosening bolts farthest away (to avoid a spray, etc.); then loosening bolts on
either side, prying open the side farthest away from oneself.
 Loosening pipe unions cautiously and then flexing away from oneself.
 Being aware of pinch points due to spring-back and shrinkage

2.5. Drained/ Depressured

The emptying/evacuation of hazardous products and/or stored energy through
draining or venting. Verification that lines/equipment have been drained/de-
pressured shall be through the opening of available bleeds or vents and
ascertaining that all are clear and flowing.

2.6. Hazardous Material/Energy Source

Any electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other
energy (e.g. radiation), including stored or residual energy, that if unexpectedly or
inadvertently released, could cause injury to personnel, or if introduced into a
process could be hazardous or pose a risk of one of the following:
 Title:
Line/Equipment Breaking

Function: Environmental, Health, and Safety

Freeport Site
Standard No.: BCF020.039 Page: 3 of 11
Reviewed: 03/15 Effective: 08/15 Supersedes: 10/09
Preparer: Owner: Approver:
Site Safety Representative Manager, Environ, Health & VP and Gen. Mgr., Freeport
Safety

 Health, physical, or environmental hazard,

 Cryogenic hazards,
 High temperature exposures (greater than 120 degrees Fahrenheit),
 High Pressure hazards.

2.7. Isolation
The preparation of a line(s) or piece(s) of equipment as per the requirements of
BCF 020.012, Control of Hazardous Energy Sources.

Note: Reference BCF 020.002, Confined Space Entry, if work involves a

confined space.

2.8. Learning Objective(s)

Specific knowledge, skills, or attitudes the training participant is intended to have
learned at the conclusion of the training program. As a minimum, the learning
objectives will include applicable regulatory training elements.

2.9. Line Breaking

The actual opening/separation/removal of equipment containing or having
previously contained a Hazardous Material/Energy source. Equipment includes
but is not limited to all types of flanges, threaded plugs, pumps, manways/hatches,
screwed pipe, fittings, exchanger tube plugs, valves, tubing, hoses, sanitary
connections, or other types of connections/openings in process or utility service.

Note: If sampling does not require a line break activity (i.e. plug removal) and the
valving system(s) has been designed and maintained (example: valves are
not leaking by and are easily operated) so that the personnel sampling can
control the release of energy to the point it does not pose a hazard the
activities fall out of the scope of Line/Equipment Break Standard and would
therefore not have to have a TJA or be permitted.

Note: Loading and unloading operations performed by PST, Logistics, or

Operating Owning Department may be exempted from site’s/unit’s Line
Break program if they are using a BASF Manager approved TJA that
covers all steps necessary to ensure personnel are not exposed to
hazardous energy during the process of loading and/or unloading.
 Title:
Line/Equipment Breaking

Function: Environmental, Health, and Safety

Freeport Site
Standard No.: BCF020.039 Page: 4 of 11
Reviewed: 03/15 Effective: 08/15 Supersedes: 10/09
Preparer: Owner: Approver:
Site Safety Representative Manager, Environ, Health & VP and Gen. Mgr., Freeport
Safety

2.10. Operating/Owning Department

The BASF unit or department that operates or is responsible for the daily
operation of the process, area or facility where work is being conducted.

2.11. Permit Acceptor

Person responsible for obtaining approval to do work.

2.12. Permit Issuer

Personnel that have been trained qualified and authorized to issue or modify
permits on behalf of the Operating/Owning Department.

2.13. 4 Eyes Principal

The use of two or more individuals (equipment operator/owner and individuals(s)
performing the work) to assess tasks in order to ensure that all hazards are
identified and eliminated or controlled through safe work practices, use of PPE,
communication.

3. SCOPE

This procedure applies to BASF Corporation’s Freeport Site.

This procedure only applies to Line Breaking on equipment where there is the potential
for a Hazardous Material/Energy Source.

4. PROCEDURE

4.1. General Requirements for Line Breaking Activity

4.1.1. Line Breaking Authorization

No personnel, including Operating/Owning Department personnel, shall
perform a Line Break without the prior written authorization in the form of a
permit issued by a Permit Issuer. The Permit Issuer must be a different
individual than the individual performing the Line Breaking activity.

Where exceptions to permits have been allowed, the work must be

performed using mechanisms that provide protection equal to safeguards
that would have been required by a permit.

Permit Exception: Routine activities (e.g., filter cleaning, hose connection or

disconnection, and process sampling.) may be performed
by trained Operating/Owning Department personnel
 Title:
Line/Equipment Breaking

Function: Environmental, Health, and Safety

Freeport Site
Standard No.: BCF020.039 Page: 5 of 11
Reviewed: 03/15 Effective: 08/15 Supersedes: 10/09
Preparer: Owner: Approver:
Site Safety Representative Manager, Environ, Health & VP and Gen. Mgr., Freeport
Safety

without a permit provided that current equipment-specific

operating procedures (e.g., TJAs, JSAs, SOPs) are
utilized which cover the identification and control of
hazards.

NOTE 1: BCF020.039A4 WI has been written as a Freeport Site procedure to

exempt Operating/Owning Dept. from permitting for removal or a
plug/blind flange from a bleed valve.

NOTE 2: Lines or equipment that have been previously opened under Line
Breaking, and then subsequently closed shall be treated as a new
Line Breaking activity before lines or equipment can be re-opened.
All requirements of a new Line Breaking activity are applicable.
This requirement also applies to lines and equipment that have not
been

4.1.2. Line Breaking Preparation and Pre-work

Prior to the performance of any Line Breaking, the Permit Issuer together
with the individual that will perform the Line Break shall verify in the field that
the following items have been completed or are in place according to the 4-
Eyes Principle. The Permit Issuer shall document field verification of all
required pre-work on the permit. If a permit is not required, the following
must still be performed/ verified by the Operating/Owning Department
personnel that will perform the line breaking activities:

 All affected lines or equipment have been emptied, purged, flushed,

drained, vented, isolated (including flow and pressure), and tagged as
applicable to ensure the system is free of Hazardous Material/Energy
Sources.

NOTE 1: Opening of a bleed valve does NOT constitute an initial break.

The opening of the bleed can be used to de-pressure, drain, and
prove zero energy, but the line breaking activities are not
complete until at minimum a low point connection like a flange
and a high point vent are opened/disconnected. The high point
vent can be a vent valve.

 Process or equipment is assessed for the potential to trap or contain

hazards at various locations when Line Breaking occurs at several points
within a system.
 Title:
Line/Equipment Breaking

Function: Environmental, Health, and Safety

Freeport Site
Standard No.: BCF020.039 Page: 6 of 11
Reviewed: 03/15 Effective: 08/15 Supersedes: 10/09
Preparer: Owner: Approver:
Site Safety Representative Manager, Environ, Health & VP and Gen. Mgr., Freeport
Safety

 Permit for Line Breaking activities, where applicable, has been completed,
signed (by the Permit Issuer and the individual(s) that will perform the
Line Break), and maintained at the work area.
 All other applicable permits/procedures; such as, Control of Hazardous
Energy Sources, Confined Space Entry, Hot Work and Safe Work, are
properly completed, in use and maintained in the work area.
 De-pressurization of lines or equipment and absence of material has been
accomplished, when possible, by opening and clearing vents and drains.
Where present, pressure gauges should be checked for pressure
readings and bleeds should be opened and cleared.
 Testing with properly calibrated direct reading instrument or indicator is
preformed on lines and equipment which contained flammable (Flash
Point Below 100oF or 37.8oC) or toxic liquids or gases before and
intermittently during the line breaking activity. (See section 4.4.3 for a list
of acceptable testing methods)

NOTE 2: If testing for toxic liquids or gases inside of the equipment cannot
take place before the line breaking activity starts, full PPE must be
worn and cannot be downgraded until atmosphere can be tested,
and toxic readings are below established Occupational limits.

NOTE 3: If testing for flammable liquids or gases inside of the equipment

cannot not take place, extra steps such as increased
flushing/purging through the equipment must be completed and
continuous LEL monitoring at the line break location must be in
place during the line breaking activity. IF LEL is detected, then the
line breaking activity must stop and immediate actions taken to
clear the system of remaining LEL.

 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.
 Personnel performing the work are fully informed of any potential hazards,
special safety precautions and the location of nearest safety shower/eye
wash stations.
 All groups involved in or potentially affected by the Line Breaking activities
communicate appropriately to assure the coordination of activities.
 The level of personal protection for the various Line Breaking tasks shall
be clearly defined, available at the job location and communicated to
personnel performing the work.
Job plan includes:
 Title:
Line/Equipment Breaking

Function: Environmental, Health, and Safety

Freeport Site
Standard No.: BCF020.039 Page: 7 of 11
Reviewed: 03/15 Effective: 08/15 Supersedes: 10/09
Preparer: Owner: Approver:
Site Safety Representative Manager, Environ, Health & VP and Gen. Mgr., Freeport
Safety

o The use of defensive positioning in order to avoid a spray or release

when attempting the Break.
o Breaking of flanges on the opposite side of the piping from the
employee.
o The use of required PPE until the first Break has been completed and
until it is verified there is no Line Breaking hazard.

4.1.3. Atmospheric Testing and Termination of Line Breaking Activities

All applicable pre-work and PPE requirements shall remain in effect until it is
positively verified and documented on the Safe Work Permit that Hazardous
Energy Sources are no longer present or are controlled to the extent that
they no longer pose a hazard to personnel. Verification shall be made
through one or more of the following methods:

 Testing (i.e., neutral pH of flush water)

 The creation of a minimum ½” air gap between flanges
 Establishing a purge out an open drain valve adjacent to the planned
line break
 Atmospheric monitoring for flammable, and/or toxic gas or vapor
 Monitoring for oxygenated atmosphere when working on lines
containing asphyxiates
 Other methods approved by the sit appropriate for the Hazardous
Material or Energy Source

4.1.4. Additional Line Breaking Requirements

 Line Breaking occurs during the opening of bleeders, flanges, vents, etc.
to verify a line or vessel is clear of chemicals and pressure, as part of the
equipment clearing process or during troubleshooting activities; AND to
the initial separation/removal of equipment.
 Line Breaking may occur at several points along a given system
depending on layout and the potential for trapped or contained hazards
to be present at various locations.

4.1.5. Relief Device Removal

A Relief Device Removal Tag shall be hung on all pressure relief devices
after they have been properly isolated and verified. Only pressure relief
devices tagged with the Relief Device Removal Tag shall be removed. See
BCF020.012: Control of Hazardous Energy Sources section 5.3 for details.
 Title:
Line/Equipment Breaking

Function: Environmental, Health, and Safety

Freeport Site
Standard No.: BCF020.039 Page: 8 of 11
Reviewed: 03/15 Effective: 08/15 Supersedes: 10/09
Preparer: Owner: Approver:
Site Safety Representative Manager, Environ, Health & VP and Gen. Mgr., Freeport
Safety

4.2. Personal Protective Equipment (PPE)

4.2.1. Hazard Assessment

The appropriate type of PPE employed in a given Line Breaking situation
will vary with the hazards associated with the material, equipment, location,
and ability to verify that the equipment/line is clear. Reference Unit’s PPE
Grid (Table #1 BCF020.019) for Unit/Department’s hazard assessment for
appropriate PPE requirements.

Because of the hazardous nature of Concentrated Sulfuric Acid, 50%

Sodium Hydroxide and Ammonia, work on systems handling these
products is covered in Work Instructions. See:

 BCF020.039A2 WI, Clearing Concentrated Sulfuric Acid Systems

 BCF020.039A3 WI, Clearing Concentrated Caustic Systems
 BCF020.039A4 WI, Clearing Ammonia Systems

4.2.2. Minimum PPE (regardless of whether a permit is required or not)

The minimum protective equipment in any Line Breaking situation shall be:
 Chemical, thermal and/or other appropriately protective gloves per the
Unit/Department’s PPE hazard assessment
 Full-face protection (face shield or full-faced respirator) if there is
potential for splashing or spraying in the face
 Chemical goggles are required for eye irritants.

In addition, the minimum protection for Line Breaking involving equipment that
contains or previously contained corrosives, skin absorbable materials, sensitizers
or materials that could pose a significant thermal hazard shall be:
 Chemical goggles (unless wearing a full faced respirator, fully encapsulating
suit, hood or other PPE that provides equivalent protection).
 Chemical/thermal resistant boots
 Appropriate chemical/thermal resistant clothing
 When activities have the potential to drip, spray or pour downward onto
individuals performing the work, additional measure may include the taping of
glove/clothing openings, the use of hooded clothing or other measures to
ensure materials do not come into contact with the skin

NOTE: PPE may NOT be downgraded until Line Breaking activities have been
properly terminated per section 4.1.3.
 Title:
Line/Equipment Breaking

Function: Environmental, Health, and Safety

Freeport Site
Standard No.: BCF020.039 Page: 9 of 11
Reviewed: 03/15 Effective: 08/15 Supersedes: 10/09
Preparer: Owner: Approver:
Site Safety Representative Manager, Environ, Health & VP and Gen. Mgr., Freeport
Safety

4.2.3. Respiratory Protection

Where a potential for vapor or gas exposure exists, respiratory protection
will be selected and practices followed as provided in the site Respiratory
Protection program and the Unit’s PPE hazard assessment.

4.3. Training

4.3.1. BASF and Contracted Employees Involved in Line Breaking Activities

 Operating/Owning Department and service/maintenance personnel shall
receive training on how to recognize the applicability of Line Breaking
situations, the requirements for issuing a permit, and the necessary
means to safeguard against the hazards posed during these activities.
 Training shall be delivered in accordance with the EHS curriculum
assignment process.
Retraining of an employee is required whenever:
 Deviations or inadequacies in an employee’s performance of an
applicable procedure indicate that lack of knowledge is a cause.
 An applicable procedure has been changed.

4.3.2. BASF and Contracted Employees Not Directly Involved in Line

Breaking Activities:
 Personnel not directly involved in Line Breaking will receive awareness
training for this and other safe work practices in accordance with the
EHS curriculum assignment process.

4.3.3. Documentation for BASF and Contracted Employees

Training will be documented including:
 each Trainee's name,
 date(s) of attendance,
 Means to verify understanding
 Learning Objectives for the course
 Documentation shall be maintained according to BC037, Record
Retention Policy and the applicable record retention schedule.

4.3.4. Contractor Employees

Refer to BC032.002 Contractor EHS Qualification and Oversight for
requirements.
 Title:
Line/Equipment Breaking

Function: Environmental, Health, and Safety

Freeport Site
Standard No.: BCF020.039 Page: 10 of 11
Reviewed: 03/15 Effective: 08/15 Supersedes: 10/09
Preparer: Owner: Approver:
Site Safety Representative Manager, Environ, Health & VP and Gen. Mgr., Freeport
Safety

5. RESPONSIBILITIES

5.4. Site Manager

The Site Manager has responsibility for ensuring the implementation of this
procedure.

5.5. Occupational Safety/Industrial Hygiene Team Leader

The Team Leader of Occupational Safety/Industrial Hygiene has the primary
responsibility for issuing, reviewing, administration, and/or interpretation of this
procedure.

5.6. Production Execution Manager, Site and Area Logistics Managers

Have the responsibility for:
 Ensuring this procedure is followed
 Participating in the annual Management Review

5.7. Sr. Production Manager/ Director

Has the responsibility for:
 ensuring the annual Management Review (section 6) is conducted

6. MANAGEMENT SYSTEM REVIEW

A review of the effectiveness of Line Break practices shall be conducted at least annually
to ensure that the Line Break management system is properly implemented and the
elements adequately control Line Break activities.

As a minimum, the following elements of the Line Break management system shall be
included in the review:

 A comparison of the site procedure and site permit to the corporate procedure and
corporate permit requirements.
 A review of incident reports involving Line Breaking activities that have occurred since
the last management system annual review.
 Inspection of at least one Line Breaking job-in-progress to ensure all applicable
precautions were indicated on the permit and implemented in the field.
 Interviews with Permit issuers, persons performing Line Breaks, and other affected
Employees, including Contractor and Contracted Employees where applicable.
 A review of applicable equipment and instrument maintenance and calibration
records.
 Title:
Line/Equipment Breaking

Function: Environmental, Health, and Safety

Freeport Site
Standard No.: BCF020.039 Page: 11 of 11
Reviewed: 03/15 Effective: 08/15 Supersedes: 10/09
Preparer: Owner: Approver:
Site Safety Representative Manager, Environ, Health & VP and Gen. Mgr., Freeport
Safety

The review shall be documented. For an example, see the Line Break Management
Review Checklist in Attachment 1.

7. RELATED DOCUMENTS
BC032.015 - Line Breaking
BC032.007 - Personal Protective Equipment
BCF020.019 -Personal Protective Equipment
BCF020.002 - Confined Space Entry
BCF020.012 - Control of Hazardous Energy Sources
BCF020.001 - Safe Work Procedures

8. ATTACHMENTS:
Attachment 1 039A1 Line Break Management Review Checklist
Attachment 2 039A2 WI Clearing Concentrated Sulfuric Acid Systems
Attachment 3 039A3 WI Clearing Concentrated Caustic Systems
Attachment 4 039A4 WI Clearing Ammonia Systems
Attachment 5 039A5 WI Plug/Blind Flange Removal from Bleed Valve