Site Function: Environmental, Health & Standard No.: BCF020.023 Page: Page 1 of 20 Site Representative Manager, Environ., Health & Record of Revisions Date Revision No. Details of Change 05/15/2018 9 4.5.3 (B) 3 rd bullet. Added monitoring requirements for hot work inside a welding enclosure.
Site Function: Environmental, Health & Standard No.: BCF020.023 Page: Page 2 of 20 Site Representative Manager, Environ., Health & 1.0 PURPOSE 1.1 The purpose of this document is to establish minimum standards for activities that can produce heat from flame, sparks or other sources of ignition with sufficient energy to ignite combustible materials or explosive atmospheres. 2.0 DEFINITIONS 2.1 Applicable Distance - For the site the distance is 35 feet (10.7 m). Unless otherwise stated, the Applicable Distance applies in all directions from the area. 2.2 Appreciable Combustibles or Flammables An amount of combustibles or flammables that could easily ignite and grow quickly into a fire that could not be extinguished with a single fire extinguisher. 2.3 Area Classifications - Class I Division I and Class I Division II are defined as potentially hazardous areas and will be classified as either a RED or YELLOW area. Maintenance Shops and other non-hazardous areas will be classified as BLUE areas. Area classifications will be shown on a plot plan in the plant. 2.4 Combustible - A material that could be ignited by coming into contact with open flames, heat or sparks. This includes such items as paper, wood, plastic, cloth, liquid with a closed cup flash point at or above 100 F (37.8 C), but below 200 F (93.3 C). 2.5 Combustible Dust - A combustible solid material composed of distinct particles or pieces that present a fire or explosion hazard when suspended in air or some other oxidizing medium over a range of concentrations. 2.6 Container - Any bag, barrel, bottle, box, can, cylinder, drum, reaction vessel, storage tank, piping, or the like 2.7 Contracted Employee - An individual or group of individuals for whom BASF Corporation (BC) provides direct supervision in their day-to-day activities and direction as to how an activity is to be performed. (i.e., contractors brought in without their company supervision on site) 2.8 Contractor Employee - An individual engaged by or through a third party to perform services principally for the third party. (i.e., nester, daily and shutdown contractors with supervision on site) 2.9 Electrically Classified Area - Locations where fire or explosion hazards may exist due to the presence of flammable gases, flammable liquid produced vapors, combustible liquid produced vapors, combustible dusts, or ignitable fibers/flyings. These areas are required to be classified by NFPA 70, Chapter 5 (Example: Class I, Division 1, Group A). 2.10 Fire Retardant Tarps Tarps used in shielding during hot work must be designed to contain sparks/slag and withstand the fire hazards present during the hot work to prevent it from creating a fire. Falling slag, grinding sparks, exposed hot equipment, or any other fire potential present during hot work activity must be considered.
Site Function: Environmental, Health & Standard No.: BCF020.023 Page: Page 3 of 20 Site Representative Manager, Environ., Health & 2.11 Fire Watch - A person, not performing the hot work, who is assigned the responsibility of watching for conditions that may produce a fire as a result of the hot work activities. Their duties are to: 2.11.1 Make sure that all shields are properly positioned to contain all sparks produced. 2.11.2 Have the appropriate amount of water hoses, with cut off valves at nozzle end on the job site. Where required, tarps must be kept wet and sparks quenched. 2.11.3 Have the specified type of fire extinguisher and other specified fire fighting equipment on the job site and be trained on their use and limitations. 2.11.4 Have an approved and tested combustible gas meter on the job site. Fire watch must be familiar with the operation of the meter. 2.11.5 Know how to shut off the gas supply or electric power to welding/burning/grinding machines. 2.11.6 Monitor the continuous combustible gas meter for any indication of an explosive gas mixture or fire hazard. 2.11.7 Stop the job if conditions under which the permit was issued change or sparks are escaping from the shielded area. 2.11.8 Know how to sound an alarm or get help, should problems arise where assistance is needed. 2.11.9 Be present at the area of hot work the entire time hot work is going on and remain on the job for 30 minutes after hot work has stopped to assure there are no smoldering fires. Fire watches are to check and shake out tarps during this period to prevent smoldering fire at a later time. 2.11.10 Have current BASF fire watch training and be briefed on potential hazards of the area. 2.12 Flammable - a material that falls into one of the following categories: 2.12.1 Aerosol, flammable" means an aerosol that can yield a flame projection exceeding 18 inches at full valve opening, or a flashback (a flame extending back to the valve) at any degree of valve opening; 2.12.2 "Gas, flammable" means: (A) A gas that, at ambient temperature and pressure, forms a flammable mixture with air at a concentration of thirteen (13) percent by volume or less; or (B) A gas that, at ambient temperature and pressure, forms a range of flammable mixtures with air more than twelve (12) percent by volume, regardless of the lower limit. 2.12.3 Gas, liquefied flammable means: a flammable gas that is handled in a liquid state by keeping it under pressure or at low temperatures. Class 1A flammable liquids, any material with an NFPA flammability rating of "4," and any material with an "F+" rating on the German Gefahrstoffliste are liquefied flammable gases. Process conditions will determine whether or not a material is to be considered a liquefied flammable gas. Any flammable liquid stored or handled significantly above its boiling point, but kept liquid by pressure is also considered a liquefied flammable gas. 2.12.4 "Liquid, flammable" means any liquid having a flashpoint below 100 deg. F (37.8 deg. C), except any mixture having components with flashpoints of 100 deg. F (37.8 deg. C) or higher, the total of which make up 99 percent or more of the total volume of the mixture.
Site Function: Environmental, Health & Standard No.: BCF020.023 Page: Page 4 of 20 Site Representative Manager, Environ., Health & 2.12.5 Solid, flammable" means a solid, other than a blasting agent or explosive, that is liable to cause fire through friction, absorption of moisture, spontaneous chemical change, or retained heat from manufacturing or processing, or which can be ignited readily and when ignited burns so vigorously and persistently as to create a serious hazard. 2.13 Hot Tap - A procedure used in the repair, maintenance and services activities which involves welding on a piece of equipment (pipelines, vessels or tanks) under pressure, in order to install connections or appurtenances. It is commonly used to replace or add sections of pipeline without the interruption of service for air, gas, water, steam, and petrochemical distribution systems. 2.14 - An activity that falls into one of the following categories which are further defined below: flame-or spark-producing (high energy), non-rated electrical equipment (low energy), or vehicle access (low energy). 2.14.1 High Energy A. Flame- or Spark-Producing means an operation that can produce enough heat from flame, spark, or other means, such as friction, with sufficient energy to ignite Combustibles or Flammables. includes electric arc and gas welding, grinding, cutting, burning, brazing, soldering, and other spark-producing or heat-producing operations above 800 0 F. 2.14.2 Low Energy A. Non-rated Electrical Tools/Equipment includes the use of electric equipmet and electronic devices that are attended 100% of the time in Red and Yellow Hot Work Classified areas (100% attendance while plugged in) that are not Listed or Labeled for use in the Electrically Classified Area, unless the device is a Portable Electronic Product 1 (PEP1) device. B. Vehicle Access/Entry includes the operation of electric, gas, diesel, or internal combustion engines in Red and Yellow Classified Areas, unless the equipment has been approved for use in the area by a nationally recognized testing lab NOTE: Powered Industrial Trucks must be rated for the Electrically Classified Area. See also BC032.001, Powered Industrial Trucks. 2.15 Area Classifications 2.15.1 Red Area Classification A. Is an area within 50 ft. of where flammables OR COMBUSTIBLES USED AT TEMPERATURES ABOVE FLASH POINT are being used or stored. Quantities of 55 gallons or fewer can be moved. B. Is within 35 feet of an intra-plant ditch which could contain flammable orcombustible liquids.
Site Function: Environmental, Health & Standard No.: BCF020.023 Page: Page 5 of 20 Site Representative Manager, Environ., Health & C. Any other area designated by the Production Execution Manager 2.15.2 Yellow Area Classification A. Is within 35 feet of where combustible liquids are being stored or used unless the quantities are small enough that they can be moved. B. All other production areas, where combustible materials are processed, handled or stored. Pipe racks outside of Block limits are considered Yellow Areas, even though flammable materials are transferred. If an OSBL pipe rack is Red because of a sump or other hazard, it must be shown on the area classification drawing. C. Any other electrically classified area not already listed as a Red or Yellow area. 2.15.3 Blue Area Classification A. Includes all shop areas that meet the requirements in section 4.5.8 of this standard. Shops may be classified on Area Classification Drawing, by Production Execution Manager / Site Utilities/Infrastructure Asset Manager, that they do not require permitting due to meeting requirements in 4.3.5 for shops. Any electrically unclassified area which is outside block limits and no process hazards are within 35 feet. 2.16 Incipient Fire A fire that can easily be put out with a single fire extinguisher or water hose that does not require the use of any fire fighting equipment (fire hose 2 or greater, fire truck, foam cart, etc.). 2.17 Listed or Labeled - Equipment that meets identified standards or has been tested and is suitable for a specific use. Independent testing laboratories, such as UL, TUV, CSA, or others, assign a listing number and maintain a list of products that meet the identified standards requirements. The organization maintains periodic inspection of production of listed equipment. The listing organization will use some means to identify listed equipment, which can include labeling. 2.18 Lower Explosive Limit (LEL) - The minimum concentration of vapor to air below which propagations of a flame will not occur in the presence of an ignition source. Combustible gas meters measure the % concentration of vapor to air mixtures from 0 to 100 % of the LEL. 2.19 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. 2.20 Permanently Installed - Equipment that is hard-wired or equipment used without a person present 100% of the time it is in use. 2.21 Portable Electronic Product 1 (PEP1) - Battery powered or photovoltaic cell powered device worn in direct contact with the skin. Examples include electronic wristwatches worn in direct contact with the skin and hearing aids inserted in the ear. In order to be exempt from requirements of, a PEP1 device must meet all the following criteria:
Site Function: Environmental, Health & Standard No.: BCF020.023 Page: Page 6 of 20 Site Representative Manager, Environ., Health & A. No visible sparks or excessive temperature during normal operation. B. No motors, unless the motor incorporates non-arcing technology. C. No visible damage. D. Powered by a maximum of two button cells (battery). E. No electrical connections accessible outside the product. 2.22 Primary Isolating Device - An isolating device that is intended to withstand the rated pressure of the equipment. 2.23 Sewer/Seal Plug A tool/device used to seal against the inside of the pipe to ensure any residual vapors in the isolated line are secured from the weld location during welding. This is especially helpful in long transfer lines or odd configurations that make it difficult to ensure all vapors are cleared. Plumbers plugs, sewer plugs, seal plugs, Carber Isolation Tools, etc., that seal against the wall of the piping and have a method to ensure no pressure build-up behind the tool are acceptable for use. (tool/device must be able to comply with Attachment B requirements) 2.24 Stopple - A procedure for mechanically stopping flow in a line that cannot be blocked in because of a leaking valve or the absence of a valve. The installation of a stopple requires a hot tap procedure. 3.0 SCOPE 3.1 This procedure applies to BASF Corporation in Texas. It is our policy not to perform "hot work" in potentially hazardous areas until all alternative methods are considered. After it has been established that no practical alternate methods exist, "" procedures and permits will be used. This standard is to be used in conjunction with Standard #1, Safe Work Standard. 3.2 Non-rated electrical equipment and vehicle access hot work (low energy hot work) requirements are covered in this procedure in Section 4.1. 3.3 Flame or spark producing hot work (high energy hot work) requirements are covered in this procedure in Section 4.2. 3.4 This procedure is not to be used to allow permanently installed electric equipment not listed or labeled for use in an electrically classified area. 4.0 PROCEDURES 4.1 LOW ENERGY HOT WORK (GENERAL REQUIREMENTS) 4.1.1 All personnel, including operating/owning department personnel, require a safe work permit to perform low energy hot work. 4.1.2 Routine non-rated electrical equipment and vehicle access hot work may be performed by operating/owning department personnel without a permit when current equipmentspecific operating procedures (e.g., TJAs, JSAs, SOPs) that cover the identification and control of hazards are used.
Site Function: Environmental, Health & Standard No.: BCF020.023 Page: Page 7 of 20 Site Representative Manager, Environ., Health & 4.1.3 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. 4.1.4 Field verification (risk assessment) with individual performing work and an approved permit issuer (4-Eyes) from operating/owning department must be performed with documentation of the following items on the permit: A. A Permit Issuer(s) must sign the permit to confirm the risk assessment is complete. B. A Permit Acceptor must sign the permit to acknowledge and agree to the conditions on the permit C. The equipment to be used is in satisfactory condition and in good repair. D. Personnel performing work are informed of potential hazardous conditions and emergency procedures. E. All other potentially affected work groups have received appropriate communications to ensure coordination of activities and prevent adverse effects. F. Verification of absence of explosive atmospheres in red or yellow hot work classified areas. (See Section 4.5) In addition to tests of the general area, tests must be made at the specific area where hot work will be conducted or where sparks or other ignition sources may occur. Low points (such as sumps, drains, trenches) within the 35 feet of the hot work location must be included in the testing locations The meter used (ID number) for verification of absence of an explosive atmosphere and the field readings shall be documented on the Safe Work Permit. 4.1.5 Low Energy LEL Monitoring Requirements A. Two hours is the maximum time between work area monitoring and the start of hot work. B. Areas must be periodically monitored at a minimum on issuance of permit and required every 2 hours. The meter ID number and readings shall be documented after the issuance of the Safe Work Permit or when Low energy Hotwork is on-going. Meter # and readings should be documented on a white board or electronic log book or any other means where information is readily available. C. Employees performing LEL monitoring must be an approve safe work permit issuer or an operating/owning employee approved by Production Execution Manager that has LEL meter training and has knowledge of the process, process areas, and process hazards that could relate to explosive atmospheres. 4.2 HIGH ENERGY HOT WORK GENERAL REQUIREMENTS 4.2.1 High Energy LEL Monitoring Requirements A. Field verification with an individual performing work and an approved permit issuer (4-Eyes) from operating/owning department must be performed. B. Two hours is the maximum time between work area monitoring and the start of hot work. C. Continuous monitoring by an approved fire watch is required in red and yellow hot work areas during hot work operations
Site Function: Environmental, Health & Standard No.: BCF020.023 Page: Page 8 of 20 Site Representative Manager, Environ., Health & D. Employees performing LEL monitoring for a hot work permit issuance must be an approved hot work permit issuer. E. The meter used to verify the absence of an explosive atmosphere number and the field readings shall be documented on the Procedure. See Attachment A. 4.2.2 Hot tap is covered by Standard 29. Procedures are based upon API Recommended Practice 2201, Safe Hot Tapping Practices in the Petroleum and Petrochemical Industries. 4.2.3 No hot work shall be performed in or on used drums, barrels, tanks, or other containers until they have been cleaned so thoroughly as to make absolutely certain there are no flammables present or any substances such as greases, tars, acids, or other materials which, when subjected to heat, might produce flammable or toxic vapors. 4.2.4 When Flame-or Spark-Producing is performed on a container such as a vessel, tank, piece of equipment, or a pipe, continuous LEL monitoring shall be conducted inside and outside the container prior to the start of and during the activity. Monitoring conducted inside the vessel should account for the potential pockets of trapped gases. The following exceptions may apply to continuously monitoring inside the container during a hot work activity Hot work on a container/pipe that has been inerted with N2 or other inert welding gas Hot work that is a final weld to close a container/pipe Hot work on new containers/pipe that has not been previously connected to process systems or coated with material that may become volatile under higher temperatures due to the hot work activity Hot work on a system that has never contained flammable material or any other material that may become volatile under higher temperatures due to welding, and is isolated from adjoining piping and systems including all process, drains, overflow and utility connections in order to ensure that liquids, solids, vapors, or gases do not enter the system where hot work is to be performed. The method of isolation must meet one the following criteria: o A pancake or spectacle blind that is bolted between the process or utility piping flanges NOTE: Pancakes and blinds used for a primary isolating device, or do not have a method to avoid pressure build up (by use of a bleed valve or air gap), must be rated to match size and pressure rating of the line or equipment. o An air gap (12 or greater) created by removing a spool piece or missaligning the process or utility piping so as to prevent liquids or vapors from entering the Permitted Confined Space. o A double block and bleed where the two block valves are closed; the bleed is open and locks/isolation tags are applied
Site Function: Environmental, Health & Standard No.: BCF020.023 Page: Page 9 of 20 Site Representative Manager, Environ., Health & o The block valves in a line to jackets, coils, reboilers and similar items which in themselves are not open to the area in which work is to be performed are closed and tag out applied. A hot tap is being performed Hot taps should follow the hot tap procedure 4.2.6 Fire watches are required where hot work is performed in locations where other than an incipient fire might develop or if any of the following conditions exist: A. Appreciable Combustibles or Flammables, in building construction or contents, are closer than 35 to the point of Flame- or Spark-Producing hot Work, or B. Appreciable Combustibles or Flammables are more than 35 away from the point of Flame- or Spark-Producing hot Work, but may be easily ignited by sparks, or C. Wall or floor openings within 35 of exposed combustibles or flammables in adjacent areas including concealed spaces in walls or floors, or D. Combustibles or flammables are adjacent to the opposite side of metal partitions, walls, ceilings, or roofs and are likely to be ignited by conduction or radiation. 4.2.7 All hollow spaces, cavities, or containers shall be vented to protect against overpressure due to thermal expansion before preheating, cutting or welding. 4.2.8 Special precaution must be taken to prevent packing fires within a vessel. A. Hot work may not be performed on the outside of a vessel shell with packing inside the vessel, if the packing is within three feet of the area that the hot work will be performed. B. Packing must be removed from the inside of the vessel prior to hot work inside a vessel to prevent ignition from falling sparks or slag. C. Exception to above rules may be approved by MOC generated that addresses the safety hazards and is approved by Site Leader, Manufacturing Director/VP, and Pressure Vessel Group. Note: Heat transferred from the hot work site can cause internal packing to combust, this includes metal packing. Greater clearance distances may be required based on type of packing and amount of potential heat transfer through vessel shell. 4.3 HOT WORK AUTHORIZATION 4.3.1 Owning/Operating Department management must specify in writing authorized Permit Issuers. 4.3.2 No personnel, including operating/owning department personnel, shall perform hot work without the prior written authorization in the form of a permit issued by a permit issuer. The permit issuer must be a different individual from the permit acceptor. 4.3.3 Before the performance of any hot work, the permit issuer, with an individual who will perform the hot work, shall verify in the field that all applicable fire prevention precautions found in hot work procedure have been implemented and documented on the permit or hot work procedure before beginning hot work. (Use Attachment A Procedure Form.)
Site Function: Environmental, Health & Standard No.: BCF020.023 Page: Page 10 of 20 Site Representative Manager, Environ., Health & 4.3.4 In areas such as permanent maintenance shops and fabrication areas, where hot work may be routinely performed, a permit issuer can waive the requirement to obtain a hot work permit as long as the following requirements are satisfied: A. The area is designated as not requiring a hot work permit in the unit s hot work area classification drawings. B. The hot work is conducted in a manner that ensures protection equal to the safeguards a permit would have required. C. These areas are included in the annual unit review to ensure necessary fire prevention precautions are adequate and remain effective. 4.3.5 Temporary fabrication areas set up for turnarounds or plant construction activities must be initially reviewed and approved by EHS. These areas must be inspected at least every 30 days for the duration of use to ensure necessary fire prevention precautions are adequate and remain effective. A. A risk assessment on the a temporary fabrication area will be conducted and approved for use and documemted using the MOC process. If the temporary area is still in place after 30 days the inspections will be documented in the MOC used for the temporary area. B. The must be conducted in a manner that ensures protection equal to the safeguards a permit would have required. 4.3.6 Hot work shall not be permitted in the following situations: A. In areas not authorized by a permit issuer B. In buildings with sprinklers while such protection is impaired C. In the presence of explosive atmospheres D. Where explosive atmospheres may develop inside unclean or improperly prepared tanks or equipment that have previously contained flammables or combustible dusts with air E. Where explosive atmospheres may develop in areas with an accumulation of combustible dusts F. In areas near the storage of large quantities of exposed, combustible, or flammable material 4.3.7 When the Applicable Distance for Flame or Spark Producing extends beyond the Permit Issuer s Owning/Operating Department, a Permit Issuer from each respective Owning/Operating Department must authorize the work, ensure necessary fire prevention precautions in their unit are implemented and maintained for the duration of the work and co-sign the permit. 4.4 PERMIT REQUIREMENTS 4.4.1 A permit to perform hot work does not authorize smoking in an area where smoking is otherwise prohibited. 4.4.2 Any hot work requires a safe work permit to be issued before the start of work.
Site Function: Environmental, Health & Standard No.: BCF020.023 Page: Page 11 of 20 Site Representative Manager, Environ., Health & A. Exception: hot work that takes place in areas designated on the hot work area classification drawings as no safe work or hot work permit needed. 4.4.3 Hot work permit issuers must be authorized in writing by the production execution manager, site utilities/infrastructure asset manager, power distribution manager, site & area logistic manager, or lab manager. 4.4.4 A Permit shall include the following minimum elements: A. A unique identifier, such as a number, to identify each permit B. Date authorized for, including the start and end time C. An accurate description of the work, the location, and where applicable, the object on which is performed D. Identification of specific hazards and required control/mitigation measures. E. Verification the applicable fire prevention precautions were implemented prior to beginning. When applicable, the permit shall document monitoring/testing requirements and results. F. Signature lines for Permit Issuer and Permit Acceptor. NOTE: Where conditions exist as described in 4.3.7, signature space for additional Permit Issuer(s). G. The permit forms must be in duplicate. One copy will stay with the Permit Issuer or in a controlled location, such as a control room, and the other copy shall either be posted in the immediate work area of the authorized work or be with one of the workers involved in the authorized work. 4.4.5 Hot work in red or yellow hot work designated areas requires the use of a hot work procedure that is attached to the field copy of the SWP. (Use Attachment A Procedure Form.) 4.4.6 Permit Duration A. A permit is valid as long as the following do not change: The Permit Issuer The Permit Acceptor If any of the above change, a Permit Issuer must issue a new permit or Revalidate the original permit. B. The maximum time between the start and end time is 16 continuous hours. After the maximum time, a Permit Issuer must issue a new permit. C. If the scope (specific job) or type of (Flame- or Spark Producing vs. Non rated Electrical Equipment) changes, a new permit must be issued. 4.4.7 Permit and Emergency Conditions A. If, during the course of hot work, an emergency condition occurs that adversely affects the safety of the area, permits will be automatically and immediately voided.
Site Function: Environmental, Health & Standard No.: BCF020.023 Page: Page 12 of 20 Site Representative Manager, Environ., Health & B. After these conditions have been resolved, the permit must be reissued or revalidated before hot work can be continued. 4.4.8 Permit Accessibility A. The completed copy of the permit with work authorization signatures and Hotwork procedure shall be available at the job site for the duration of the job. 4.4.9 Closing Out the Permit A. All permits are to be returned to a permit Issuer following the permit duration or at completion of the work. B. The permit will be closed out by reviewing the status of the work and discussing any hazards encountered or left in the workplace. C. The person(s) performing the hot work or a representative of the person performing the hot work, and a permit issuer will close out the permit by signing the permit. If conditions in 4.3.7 exist, the the permit issuer shall notify all stakeholders of the completion of Hotwork activities. 4.4.10 Closed permits shall be retained for the period necessary to facilitate the program review in 5.0, but no longer than one year. A. As a means to limit the number of closed permits that must be retained, more frequent reviews of a representative sample of the closed permits can take place. B. After the closed permit review described in 4.4.10(A), the closed permits no longer need to be retained, but documentation of the review results and corrective measures must be maintained until the entire program review described in 5.0. is completed. 4.4.11 When an incident occurs during activities, the hot work permit issued for that job shall be retained for at least one year from the date of the incident. The permit can also be scanned and added to the incident report. 4.5 HOT WORK AREA VERIFICATION REQUIREMENTS 4.5.1 When hot work is performed in red or yellow classified areas, verification of the absence of an explosive atmosphere in the work area must be performed. 4.5.2 For combustible dusts, a visual inspection of the area where hot work will be performed must identify any accumulations and airborne dispersions. A. Accumulations of dust on any surfaces within 35 feet must be removed before beginning hot work. Surfaces should be cleaned in a way that prevents dust cloud formation. The source of the dust should be eliminated for the duration of the hot work. B. Where airborne dispersions exist, hot work shall not be conducted until the source is eliminated, the airborne dispersion settles, and the accumulated dust is removed from the area.
Site Function: Environmental, Health & Standard No.: BCF020.023 Page: Page 13 of 20 Site Representative Manager, Environ., Health & 4.5.3 For Flammable Gases or Flammable vapors, a properly calibrated and functional combustible gas meter must be used. If a measurable level is detected using a combustible gas meter operating in the percent range of sensitivity, is not allowed or must cease until the source is found, eliminated and subsequent testing meets requirements. A. Combustible Gas Meter Requirements Instruments are to be maintained according to manufacturer s specifications. Instrument calibration shall be documented indicating when the instrument was calibrated and who performed the calibration. Instruments are to be functionally tested by exposing the sensor to a known gas concentration before each use or daily, whichever is less frequent. (Response should be within ~10% of test gas value.) The minimum oxygen concentration specified in the manufacturer s instructions must be present when conducting combustible gas monitoring. Failure to have adequate oxygen content can give a false LEL reading. B. Combustible Gas Testing Locations In addition to tests of the general area, tests must be made at the specific area where hot work will be conducted or where sparks or other ignition sources may occur. Low points (such as sumps, drains, trenches) within 35 feet of the hot work location must be included in the testing locations. When hot work is taking place inside a welding enclosure (Hooch) all connections (ie. Flanges, beed valves with plugs, unions, etc ) and open ended lines inside the enclosure will be checked for LEL to verify that there are no leaks of any other material, which could be ignited while the hot work activites are taking place. 4.5.4 CONFINED SPACE HOT WORK A. When arc welding is suspended for more than 30 minutes, all electrodes shall be removed from the holders and the holders carefully located so that accidental contact cannot occur and the machine is disconnected from the power source. B. To eliminate the possibility of gas escaping through leaks or improperly closed valves, when using a gas for welding or cutting, the valves shall be closed at some point outside the confined area whenever the hoses are not to be used for more than 30 minutes. Where practicable, the hoses shall also be removed from the confined space. C. When welding inside a confined space, each welder must be provided 2000 scfm in the breathing zone or supplied air respiratory protection must be used. D. Welding inside of confined spaces on materials containing chrome (stainless steel, other alloys, etc) must comply with hexavalent chromium requirements BCF020.056. E. All other confined space entry requirements apply as specified in BCF020.002. 4.5.5 RED/YELLOW AREA PROCEDURE
Site Function: Environmental, Health & Standard No.: BCF020.023 Page: Page 14 of 20 Site Representative Manager, Environ., Health & A. The production execution manager, site utilities/infrastructure asset manager, power distribution manager, or site & area logistics manager (or his designee in his absence) must approve to perform hot work in red areas. Verbal approval may be given. The person receiving the verbal approval must sign for the manager, noting this on the hot work procedure. B. The shift supervisor or approved DST member must approve hot work in yellow areas. C. The hot work procedure must be attached to the safe work permit for "hot work." (Use Attachment A Procedure Form.) All sections of the form must be filled out. The Approval to do section is intended to define location, scope of work, and approval to do hot work in a red or yellow hot work area. This is to ensure that we do not perform unnecessary hot work in classified areas and requires a supervisory approval. The Procedure and Isolation Requirements section is to specify isolation requirement for equipment and safety precautions needed to perform hot work. If an MIP# is used to provide isolation point it must state the Rev. # that is to be used for hot work. If the Rev. # is changed, the procedure must be re-approved. This prevents modifications to the MIP that may not meet the hot work isolation requirements for this hot work job. The Field Verification Checklist section must be filled out in the field with a member of the hot work crew. This section along with the safe work permit meets all of the field verification requirements. The Procedure Acceptance section of the procedure is to document that all parties responsible for the hot work job are aware of the requirements of the hot work job. D. Hot work procedures that involve identical work may be reused by updating and obtaining the required signatures. E. The trained fire watch must review this procedure before the start of the job, and they must initial it to show their understanding of responsibilities. F. The following items must be done before issuing a permit to perform "hot work:" All lines or equipment must be isolated by pancakes, double blocks and bleeds, or air gaps of 12" or more. Pancakes used for a primary isolating device, hydrostatic testing, or do not have a method to bleed pressure off prior to them (bleed or air gap) must be rated to match size and pressure rating of equipment. (For special cases use of a sewer plug is allowed to prevent vapor migration, see Attachment B.) Other alternatives to isolating must be agreed to by the Sr. Production Manager/Director, Site Utilities/Infrastructure Asset Manager, Power Distribution Manager, or Site & Area Logistics Manager,and Site Team Leader. In red and yellow areas, ALL welding, cutting and grinding sparks must be contained by using fire retardant shields/tarps. At a minimum, one water hose and a fire extinguisher will be required at hot work location. In remote locations or under special circumstances (2) 20# fire extinguishers can be substituted for a water hose if approved by production execution manager.
Site Function: Environmental, Health & Standard No.: BCF020.023 Page: Page 15 of 20 Site Representative Manager, Environ., Health & Precautions should be taken to prevent tarp and/or scaffold board fires. This can be by use of fire retardant tarps and/or wetted surfaces. Welders must be protected from electric shock when on wet surfaces. Ditches, drains, or vents must be covered or protected from falling sparks under hot work areas. These sources of flammable materials must be covered within distances sparks may be able to travel to the source(s). The tarps must be kept wet, and care should be taken not to allow gas pockets to form below the tarps. A continuous combustible gas meter must be tested per manufacturer s testing or calibration requirements. A permit can only be issued if the area tested is "0"% LEL (Lower Explosive Limit). A combustible gas meter will be with each fire watch, and placed upwind of work. The permit issued must verify that the fire watch has been trained on use of the combustible gas meter. A trained fire watch must be used in red or yellow areas. In red/yellow areas, a BASF DOT/DST person trained in that unit/technology and with fire watch training must periodically survey the job. (red areas - once each hour, yellow areas - periodically, as needed). There is a space on the hot work procedure to sign on when fire watch visit the job. A fire watch can cover more than one crew when the crews are welding next to each other, provided that the fire watch can maintain all of his duties, as shown in definitions (2.11). NOTE: Some jobs in elevated process areas may require two fire watches. This will be determined by person(s) approving hot work and issuing permits. The safe work permit for "hot work" must be issued by an authorized person who visually checks the area to see that all items on HW permit and procedure have been satisfied. The person performing the work (i.e., pipefitter, welder) and the fire watch on duty must also sign the permit and procedure. One procedure may be written for each job, but a "hot work" safe work permit must be written for each welding crew if conditions for the work differ. Fire watch s must be trained initially by fire watch training guidelines. Refresher training must be given every three (3) years. Proof of firewatch training is by a firewatch sticker, with a number that is listed on the training documentation. Stickers are received from the Department. 4.5.6 BLUE AREA PROCEDURE A. This pertains to hot work in shops or other than red or yellow areas. B. Any pipe, vessel, or equipment that has been removed from a process for hot work must be clean before hot work can be performed. The owner will be responsible for thoroughly cleaning the equipment before removal and tagging the equipment with a process information tag that states, Equipment has been cleaned. C. No hot work procedure is required for blue area hot work. D. A safe work permit is required unless there is a designation on hot work area classification drawings specifying that the SWP requirement is waived. This would be for certain shops or areas that meet criteria in 4.5.8 of this standard. 4.5.7 CONSTRUCTION SITE PROCEDURE
Site Function: Environmental, Health & Standard No.: BCF020.023 Page: Page 16 of 20 Site Representative Manager, Environ., Health & A. Construction sites in red or yellow areas may have a single procedure written for the work in the area if steps have been taken to shield the area from flammables or combustibles and no tie-ins have been made to the operating process. The senior production manager/director and site safety team leader must agree on hot work procedures and level of fire protection for these areas. B. Construction that is in a red or yellow area and has had no process tie-ins must be provided with adequate fire protection to cover all hazard potentials throughout the construction phases. Procedures being used must be updated on a daily basis or as necessary to compensate for changing conditions. The senior production manager/director, project engineer, and the Department team member must ackingagree upon procedures and fire protection requirements. 4.5.8 BUILDING HOT WORK REQUIREMENTS A. Where combustibles are on the floor, the floor shall be swept clean for 35 feet and the following criteria shall also be met: Combustible floors shall be kept wet, covered with damp sand, or protected by noncombustible or fire-retardant shields. Where floors have been wet down, personnel operating arc-welding equipment or cutting equipment shall be protected from possible shock. B. Openings or cracks in walls or floors within 35 feet of the flame- or spark-producing hot work location shall be tightly covered with fire retardant or noncombustible material to prevent the passage of sparks to adjacent areas. C. Ducts and conveyor systems that might carry sparks to distant combustibles or flammables shall be shielded or shut down or both. D. If hot work is done near walls, partitions, ceilings, or roofs of combustible construction, fire retardant shields or guards shall be provided to prevent ignition. E. If hot work is done on one side of a metal wall, partition, ceiling, or roof, one of the following criteria shall be met: Precautions shall be taken to prevent ignition of combustibles or flammables on the other side by relocating the materials. If it is impractical to relocate materials, a fire watch shall be provided on the side opposite from where the work is being performed. F. Hot work shall not be attempted on a metal partition, wall, ceiling, or roof having a combustible covering or insulation or on walls or partitions of combustible sandwichtype construction. G. Hot work that is performed on pipes or other metal that is in contact with combustible walls, partitions, ceilings, roofs, or other combustibles, shall not be undertaken if the work is close enough to cause ignition by conduction. 4.5.9 SPECIAL PRECAUTIONS A. Personnel shall be protected from arc welding rays, falling slag, sparking, or other dangerous conditions while performing hot work. 5.0 PROGRAM REVIEW
Site Function: Environmental, Health & Standard No.: BCF020.023 Page: Page 17 of 20 Site Representative Manager, Environ., Health & 5.1 The effectiveness of hot work practices must be reviewed at least annually to ensure that the hot work management system is properly implemented and the elements adequately control hot work activities. 5.2 Review Requirements 5.2.1 Site Review A. Review the site procedure and permit to ensure that all currently required elements are included. B. A review of all incidents and other nonconformance reports involving hot work activities that have occurred since the last hot work management system annual review. C. The review should verify that root causes have been properly identified and that appropriate corrective actions have been implemented. 5.2.2 Unit Review A. Owning/Operating Department management review the results of the program review, direct corrective actions, and ensure corrective actions are implemented. B. A review of a representative sample of the closed permits issued since the last Hot Work management system review to determine the effectiveness, completeness, and accuracy of the permit system. C. Inspection of at least one hot work job-in-progress to verify site practices comply with the site procedure. Verify that training personnel involved in this job-in-progress have received training. D. Interview a representative number of permit issuers, persons performing hot work, Fire Watch and other affected employees, including contractor and contracted employees where applicable, to verify that they understand their roles/responsibilities. E. Review applicable equipment and instrument maintenance and calibration records. F. A review of permanent work areas (see 4.3.4) and temporary work areas (see 4.3.5) where permits are waived to ensure minimum requirements are implemented. G. Units will notify Site of all incidents involving hot work. H. The review shall be documented. For an example, see the Management Review Checklist in Appendix C. I. Corrective actions resulting from the reviews shall be tracked to completion using a tracking system and must be communicated to all authorized and affected employees. 5.3 Results of review will be reported to MAT. 6.0 TRAINING 6.1 BASF and Contracted Employees Involved In Activities 6.1.1 Permit issuers, Permit Acceptors, Fire Watch personnel and personnel performing hot work shall receive training on how to recognize the applicability of hot work situations, the
Site Function: Environmental, Health & Standard No.: BCF020.023 Page: Page 18 of 20 Site Representative Manager, Environ., Health & requirements for issuing a permit, and the necessary means to safeguard against the hazards posed during these activities. 6.1.2 Training shall be delivered in accordance with the EHS curriculum assignment process. 6.1.3 Retraining of an individual is required whenever: A. Deviations or inadequacies in an individual s performance of an applicable procedure indicate that lack of knowledge is a cause. B. An applicable procedure has been changed. 6.2 BASF and contracted employees not directly involved in hot work will receive awareness training for this and other safe work practices in accordance with the EHS curriculum assignment process. 6.3 Training Documentation for BASF and Contracted Employees 6.3.1 Training must be documented, including all of the following: A. each trainee s name B. date(s) of attendance C. means used to verify understanding D. learning objective(s) for the course 6.3.2 Documentation shall be maintained according to BC037, Record Retention Policy, and the applicable record retention schedule. 6.4 Contractor employees shall be trained in accordance with BC032.002, Contractor EHS Qualification and Oversight for training requirements. 7.0 RESPONSIBILITIES 7.1 SVP and General Manager The Site Manager has responsibility for ensuring the implementation of this procedure. 7.2 Site Team Leader 7.2.1 The Site Team Leader has the primary responsibility for issuing, reviewing, administrating, and/or interpreting this procedure. 7.3 Sr. Production Manager/Director 7.3.1 aprove any additional isolation methods with site team leader 7.3.2 ensure that annual unit reviews are conducted and action items tracked and completed 7.4 Production Execution Manager, Site Utilities/Infrastructure Asset Manager, Power Distribution Manager, Site and Area Logistics Manager, and Lab Manager 7.4.1 Determine if hot work is necessary. 7.4.2 Approve hot work in red areas, in writing, those persons who have the authority to: A. approve the hot work procedure B. issue hot work permits
Site Function: Environmental, Health & Standard No.: BCF020.023 Page: Page 19 of 20 Site Representative Manager, Environ., Health & 7.4.3 Initiate initial and any subsequent changes or updates of the hot work area classification drawing. Site safety team approval is also required. 7.4.4 Approve the use of two 20# fire extinguishers for a water hose is special cases. 7.4 Authorized/Designated DST/DOT/Construction Members 7.4.1 Approve performing hot work in yellow areas. 7.4.2 Approve isolation procedures. 7.4.3 Issue hot work permits. 7.4.4 Ensure that all tests are conducted. 7.4.5 Ensure that all fire protection is provided. 7.4.6 Ensure that needed safeguards are in place for potential hazards that may exist. 7.5 Permit Acceptors Hot work permit acceptors have the responsibility to conform to the requirements given in the hot work procedure and hot work permit and to report any unusual conditions that may arise during the course of the work. 7.6 Project Engineers/Construction Supervision Project engineers and construction supervision have the responsibility to ensure that all hot work in construction areas meets the requirements of this standard. 8.0 RELATED DOCUMENTS BC032.016 - Corporate BCF020.001 - Safe Work BCF020.002 - Confined Space BCF020.029 - Hot Tap Procedures BCF020.056 - Hexavalent Chromium VI 29 CFR 1910.252 - General Requirements for Welding, Cutting, and Brazing 29 CFR 1910.119(k) Permit Process Management 40 CFR 68.85 Permit Risk Management Plan American Petroleum Institute (API) Recommended Practice 2009, Safe Welding, Cutting, and Practices in the Petroleum and Petrochemical Industries API Recommended Practice 2201, Safe Hot Tapping Practices in the Petroleum and Petrochemical Industries
Site Function: Environmental, Health & Standard No.: BCF020.023 Page: Page 20 of 20 Site Representative Manager, Environ., Health & American National Standards Institute (ANSI)/National Fire Protection Association (NFPA) 70 National Electrical Code ANSI Z49.1-2005 in Welding and Cutting and Allied Processes, (American Welding Society) BC037, Record Retention Policy G-S-CL 100 M - Minimum and Health Requirements Civil and Structure Work Instrument Society of America (ISA) RP12.12.03-2002 - Recommended Practice for Portable Electronic Products Suitable for Use in Class I and II, Division 2, Class I Zone 2, and Class III, Division 1 and 2 Hazardous (Classified) Locations National Fire Protection Association (NFPA) Standard 51B, Fire Prevention in the Use of Cutting and Welding Processes National Fire Protection Association (NFPA) Standard 654, Standard for the Prevention of Fire and Dust Explosions from the Manufacturing, Processing, and Handling of Combustible Particulate Solids 9.0 ATTACHMENTS Attachment A Procedure Attachment B Sewer Plug Requirements Attachment C Management System Review Checklist Attachment D RACI Chart