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ZAKIR HUSSAIN
TRAINING AGENDA
THIS PROCEDURE DEALS WITH
-PLANNING & EXECUTION OF ALL LINE BREAKS
- LINE BREAK AT DESIGN STAGE
What is line break?
Line break—
Opening of cleared or unclear lines or equipment by actions that may
include, but are not limited to, the following:
Breaking flanges
Removing one or more bolts from flanges
Opening valves to the atmosphere
Removing valve bonnets and non-return (i.e.,check) valves
Turning spectacle plates (i.e., blanks/blinds)
Breaking pipe joints
What is line break?
Line break—
Opening of cleared or unclear lines or equipment by actions that may
include, but are not limited to, the following(Continued):
Removing slip plates (i.e., blanks/blinds), blind flanges, plugs, and caps
Disconnecting tubing
Disconnecting loading and unloading process hoses
Penetrating a line by mechanical or other means
Opening inspection ports
Making subtle adjustments (e.g., replacing packing on a valve)
What is line break?
Line break—
All systems prepared for line breaks shall be properly isolated according
to Company HSE procedure on Lockout/Tag out & as per HSEF Manual
Executing Line Break-Job Plan
The job plan shall include the following which will be done by Permit
Issuer & Engineer In Charge:
Specific identification of the hazards (Risk assessment).
Isolation, clearing, and flushing plans, (SOP with Isolation Diagram is
necessary) which may include isometric drawings.
Identification of valve to close, location to drain, and the lockout.
A description of the PPE to be used, when to wear it, and when to remove
it.
The specifications for and duties of a standby person, where appropriate.
Contingency plans if a single isolation device is used or if unprotected
personnel and/or the environment are potentially exposed.
Control of entry to the area affected by the line break.
Executing Line Break-Job Plan
The Completed Job Plan is a part of Line break work Permit.
The first break does not always verify that the system or equipment is
free of hazards.
Company experience has shown that incidents still occur after the first
break is completed.
These incidents have a variety of causes, including trapped pockets of
pressure or hazardous process material, not isolating all sources of
pressure or hazardous process material, or not draining the low point
and venting the high point.
Executing Line Break-System Preparation
All valves within the isolated system must be maintained in the open
position and the line cleared to prevent trapping process material in
the line/equipment.
On 8th August 1999 Para-xylene release through pump strainer due to improper
XV isolation procedure and no positive isolation.
Safety Contact - 1
SEQUENCE OF INCIDENTS
On 8/8/1999 19:30 hrs :-
P01 B was stopped and suction XV was closed by pushing emergency button from
local cabinet B . Discharge valve was also closed . Pump P01A was running at 240
C and 7 barg pressure.
8/8/1999 Night:-
The strainer element of P01 B was removed with an intention to use it in P01A.
Strainer flange, strainer drain flange and vent flange were left loosely bolted.
9/8/1999 day :-
Insulation work was going on pump suction line near XV push button.
Safety Contact - 1
SEQUENCE OF INCIDENTS
9/8/1999 14:35 hrs:-
SFE noticed insulation workers running away from the site.
He immediately went to the site and found a major release of xylene .