JOSOP Hot Work Standard

Transcription

1 JOSOP Ht Wrk Standard Apprved 27 February 2008 Revisin 1.3 February 2013

2 Table f Cntents 1.0 Purpse, Objectives and Scpe Purpse Objective Scpe Requirements Terms and Definitins Rles, Respnsibilities and Training Requirements Initial Training Refresher Training Standard Instructins Ht Wrk Assciated with Tanks, Vessels, and Piping Designated Safe Ht Wrk Areas Dcumentatin Permit t Wrk Ht Wrk Certificate Permit Changes Permit Revalidatin Recrding Changes Permit Re-Evaluatin Cntractrs Jbsite and Equipment Preparatin Gas Testing Requirements Initial Gas Testing Wrk Delays Fllw-up Gas Testing Cnditins fr Wrk Stppage Fire Watch Wrk Cmpletin Recrds Required Recrds Retentin Requirements References Other Guidance Dcuments Dcument Cntrl Appendix A: JO Ht Wrk Certificate Appendix B: JO Gas Test Lg Appendix C: JO Ht Tap Checklist ii Versin C Psted 21 January 2010

3 1.0 Purpse, Objectives and Scpe 1.1 Purpse The purpse f this standard is t ensure that ht wrk is perfrmed in a safe and cntrlled manner. 1.2 Objective This standard establishes the requirements fr the safe perfrmance f ht wrk. 1.3 Scpe This Ht Wrk Safe Wrk Practice (SWP) Standard cvers wrk perfrmed by JO emplyees and their delegates and cntractrs within JO peratinal cntrl. 2.0 Requirements 1. Cnsider all cld wrk alternatives befre perfrming ht wrk. 2. A hazard analysis shall be perfrmed in accrdance with the U&G Standardized MSW Hazard Analysis OE Prcedure when planning wrk invlving ht wrk. 3. Hazards assciated with the ht wrk shall be identified and mitigated prir t beginning wrk. NOTE: Ht tapping requires additinal precautins. 4. Ht wrk shall nt be permitted in the presence f explsive atmspheres. 5. Hazardus (Classified) lcatins and safe ht wrk areas shall be designated and apprved by management. 6. Persnnel invlved in ht wrk activities shall be trained and cmpetent in the rles fr which they are respnsible. 7. A Jb Safety Analysis (JSA) shall be cnducted at the wrk site in accrdance with the U&G Standardized MSW Hazard Analysis OE Prcedure prir t cmmencing wrk invlving ht wrk. 8. A Qualified Gas Tester must cnduct gas testing prir t ht wrk, including but nt limited t: When there is a ptential fr flammable gases t be present When mtrized vehicles (battery r internal cmbustin) are being perated within areas where flammable vaprs may be present When the use f electrical r battery perated equipment r devices that are nt intrinsically safe r explsin prf in a Hazardus (Classified) Lcatin. 9. A dedicated fire Watch must be present where pen flame ht wrk is carried ut, except in designated safe welding areas. 10. The ht wrk must begin within 30 minutes after the Qualified Gas Tester has tested the area and cleared it fr ht wrk t start. Versin C Psted 21 January

4 11. When the wrk has been cmpleted accrding t the jb scpe, the Wrk Team Leader must clse ut and return the Ht Wrk Certificate and permit-related dcuments t the permit apprver after: The jbsite has been left in a safe, clean and rderly cnditin. Adequate time (30 minutes) has elapsed fr the Fire Watch t verify the cnditin f the jbsite. The wrk that was perfrmed meets the required scpe and specificatins. 12. If wrk is interrupted by Stp Wrk Authrity, weather cnditins, alarms r unfreseen dangerus cnditins, the Ht Wrk Certificate must be revalidated befre wrk can be restarted. 13. Ht tapping is nt cvered under this Standard. It is cnsidered a high risk activity which requires Subject Matter Expert input, written prcedures and a high level f management apprval. 3.0 Terms and Definitins The fllwing terms and definitins apply t the JO Safe Wrk Practice (SWP) Standard fr Ht Wrk: Classified Hazardus Area Any area classified as a hazardus zne area (Zne 0, 1 r 2 r Class I, Divisin 1 r 2) in accrdance with API RP 505/API RP 500 r ther equivalent lcal standards. Classified Hazardus Areas shall be apprved by management. Cnfined Space A space that: Is large enugh and s cnfigured that an emplyee can bdily enter and perfrm assigned wrk Has limited r restricted means fr entry r exit (fr example, tanks, vessels, sils, strage bins, hppers, vaults and pits are spaces that may have limited means f entry) Is nt designed fr cntinuus emplyee ccupancy Fire Watch An individual wh is cmpetent in basic firefighting and whse rle is t bserve cnditins in the immediate and adjacent areas f ht wrk t ensure it is perfrmed safely, and t sund the alarm if necessary. The Fire Watch will extinguish any incipient fire that ccurs, if safe t d s. Gas Testing Use f prtable detectin equipment by the Qualified Gas Tester, including detectr tubes and cmbustible gas indicatrs, t determine levels f xygen and flammable r txic vaprs and gases. A prcess whereby the required gas tests are cntinuusly r intermittently mnitred. Cntinuus r intermittent gas testing is nrmally required when there is a likelihd f changing gas cncentratins and/r there is a high risk t wrkers if the gas cncentratin changes unexpectedly. Hazardus Atmsphere Atmsphere(s) that expse persnnel t the risk f death, incapacitatin, impaired ability t self-rescue, injury, r acute r chrnic illness that may be caused by any f the fllwing: 4 Versin C Psted 21 January 2010

5 An atmspheric cncentratin f any substance in excess f the permissible expsure limit (PEL) that culd result in emplyee expsure, fr example, t benzene r hydrgen sulfide. Flammable gas, vapr r mist in excess f 10 percent f its lwer explsive limit (LEL). An atmspheric xygen cncentratin less than 19.5 percent r abve 23 percent. Any ther atmspheric cnditin that is immediately dangerus t life r health (IDLH). Ht Tap A prcedure used in repair, maintenance and service activities that invlves welding n and then cutting an pening int a piece f equipment (pipelines, vessels r tanks) that is under pressure r in service, fr the purpse f installing cnnectins r appurtenances. A special prcedure is required t weld a cnnectin nt a pipe, vessel r tank that is in service withut leaking any f the cntents r causing an explsin r fire. Ht Wrk Any wrk activities that intrduce a ptential ignitin surce f any kind t the jbsite in a Classified Area. Open flame surces include, but are nt limited t, activities such as welding, cutting, brazing, burning and grit-blasting. Clsed flame surces may include battery-perated persnal electrnic devices and prtable internal cmbustin engines (thse that are nt a prperly designed and permanently installed part f the facility). Driving vehicles int a classified hazardus area, fr example, tank impunding basins, is anther surce f clsed flame ignitin. Ht Wrk Certificate A certificate issued in additin t a Permit t Wrk t grant the Cmpany and/r cntractr emplyees permissin t perfrm ht wrk. Inert Atmsphere An atmsphere cnsisting primarily f an inert gas such as nitrgen r carbn dixide that is effectively xygen-free. Initial Gas Testing Gas test, r tests, that are cnducted prir t beginning wrk and that are designed t determine the fllwing: Requirements fr cnfined space entry Whether the area is safe fr ht wrk The tests may be cnducted in tw parts: testing a cnfined space initially frm the utside and then testing again n the inside t determine if it is safe fr wrk t cmmence. Lwer Explsive Limit (LEL) The lwest mixture f hydrcarbn vapr and air that will supprt cmbustin. Typically indicated n gas testing equipment as 100%, it is smetimes referred t as lwer flammable limit (LFL). Qualified Gas Tester A persn wh is cmpetent in the use f prtable gas-testing equipment and has successfully demnstrated use f the equipment in the field. This persn must als be cmpetent in recgnizing risks inherent t ht wrk and cnfined space entry. 4.0 Rles, Respnsibilities and Training Requirements There must be clearly defined rles, and persnnel must meet the training and cmpetency requirements f this standard prir t starting wrk. JO is respnsible fr establishing the methdlgy t achieve cmpetence. Versin C Psted 21 January

6 A single individual may fulfill mre than ne rle as lng as he r she meets the cmpetency requirements and is able t fully meet multiple respnsibilities. When selecting persnnel fr these psitins, cnsider the candidate s level f experience and past perfrmance. The fllwing rles and respnsibilities are specific t ht wrk and are further defined in JO - Training Requirements Tl. Qualified Gas Tester Cnduct necessary tests as required in accrdance with the SWP Gas Detectin Standard (tests may be required as part f permit prcess, JSA requirements r frm ther business needs) Be familiar with the instrument they are using and the instrument handbk Inspect and zer the instrument befre each use Cnduct instrument field calibratin checks Anticipates where gases and vaprs may ccur and/r accumulate Enter Gas Test results n the relevant dcumentatin, including the date and time, and then sign the permit in the gas testing sectin If required t enter a cnfined space t cnduct gas tests, must als meet all the requirements f an Authrized Entrant Stps the wrk if unsafe cnditins develp te: Only qualified gas testers are permitted t cnduct gas test Fr updates refer t JO_MSW_TrainingRequirementsTl.dc Fire Watch Knws the wrk planned and the hazards invlved Inspects the jb site prir t Ht Wrk activities and ensures that cmbustibles are remved r cvered Ensures that any nearby penings are sealed r cvered with fire safe materials Observes cnditins in the immediate and adjacent areas f ht wrk t ensure that the wrk is perfrmed safely and that any requisite cnditins n the permits t wrk are cmplied with Raises an alarm shuld a prblem ccur Extinguishes any incipient fire, if it is safe t d s Maintains watch at the area fr at least 30 minutes after cmpletin f ht wrk and inspects adjacent areas where sparks r flame may have traveled fr signs f cmbustin Stps the wrk if unsafe cnditins develp te: Only qualified gas testers are permitted t cnduct gas test Fr updates refer t JO_MSW_TrainingRequirementsTl.dc Persn Perfrming Ht Wrk Knws hw t perfrm the wrk prcedures and the hazards invlved Only perfrms ht wrk when the requisite wrk permits are in place Stps the wrk if unsafe cnditins develp Fr updates refer t JO_MSW_TrainingRequirementsTl.dc 4.1 Initial Training Persnnel must meet the cmpetency requirements f this standardized safe wrk practice prir t starting wrk. Refer t the JO Training Requirements Tl. The SBU shall maintain dcumentatin f emplyees and cntractrs authrized t perfrm high-risk r pen-flame ht wrk. 6 Versin C Psted 21 January 2010

7 4.2 Refresher Training Refresher training must be prvided as fllws: As required by applicable regulatins r JO plicy As needed when identified by: verificatin, inspectins, incidents r audits 5.0 Standard Instructins Ht wrk must be permitted and managed in accrdance with the JO - Managing Safe Wrk Prcess. When cnsidering wrk that invlves ht wrk in a Classified Hazardus area, always cnsider whether there is a viable alternative, fr example, using a hand r pneumatic saw fr cld cutting rather than using a cutting trch, r mving the item utside f the Classified Hazardus area. The fllwing are examples f ht wrk: Using nn-explsin-prf electrical equipment r battery perated electrnic devices (including mbile phnes, inspectin and testing equipment, such as ultrasund and X-ray) in a hazardus area if the equipment is nt certified intrinsically safe Operating mtrized vehicles (battery perated r internal cmbustin) within a hazardus area r diked area where flammable vaprs may be present Burning acetylene r gas Welding, brazing, cutting, grinding r chipping Sldering Using electric resistance heaters Perfrming abrasin blasting, using high-pressure hydr-jet, etc. Using battery, electric r air-driven pwer tls capable f causing ht sparks r enugh energy t ignite a flammable mixture (i.e., jack hammers, rattle guns, air cmpressrs, generatr sets and drilling etc.) Using any equipment that generates an expsed flame r ht filament 5.1 Ht Wrk Assciated with Tanks, Vessels, and Piping Welding n any tank, vessel, r any piping cnnected t the tank r vessel while the tank r vessel is in service is a deviatin frm this ht wrk standard. It requires Subject Matter Expert input, written prcedures, and a high level f management apprval. NEVER d ht wrk abve the liquid level n the shell f any tank, vessel r piping that is nt islated, regardless f service. Ht wrk n the shell f a tank, vessel r piping attached t a tank r vessel requires at least 1 meter (3 feet) f liquid cverage abve the area f the ht wrk. ALWAYS discnnect r blind piping frm the tank (r ther equipment) befre perfrming ht wrk n the piping. ALWAYS assume that the vapr space f any tank that is in service is in the flammable range when planning and cnducting ht wrk activities clse t tanks. Gas testing by Versin C Psted 21 January

8 itself des nt guarantee that the entire vapr space is nt in the flammable range. Special precautins may be required t separate the tank and attached piping frm the lcatin f the ht wrk. Gas testing by a Qualified Gas Tester is mandatry at any penings and within any enclsed spaces anywhere belw the lcatin where ht wrk is being cnducted. Gas testing is als required at any penings within 15 meters (50 feet) hrizntally f where the ht wrk is being cnducted. All penings and gaps int equipment, tanks, r piping within 15 meters (50 feet) shall be sealed by using sand bags, drain cvers, fire blankets, r ther means that prevent sparks frm entering the pening r gap befre allwing ht wrk t cmmence. 5.2 Designated Safe Ht Wrk Areas Specific area(s) can be designated t be Safe Ht Wrk Areas. These areas must be preapprved by facility Management in cnsultatin and endrsement with Health, Envirnment and Safety subject matter experts. These areas vary frm facility t facility, and generally have the fllwing characteristics: D nt cntain cmbustible and flammable material within 10 meters (35 feet) f the area Free f flammable atmspheres Ht Wrk carried ut in the designated Safe Ht Wrk Area des nt require a Ht Wrk Certificate, except when ht wrk is being perfrmed n equipment which may have cntained a flammable gas r liquid. NOTE: When persnnel are carrying nly nn-intrinsically safe devices (e.g., battery perated equipment r ccupatinal hygiene mnitring equipment), these persnnel must als carry a cntinuusly mnitring gas detectr. If the gas detectr alarm sunds, they must immediately stp wrk and vacate the area and infrm facility persnnel f the alarm. Fire Watch is required in these situatins. 5.3 Dcumentatin Permit t Wrk All ht wrk requires permit authrizatin. Refer t the JO Permit t Wrk Standard fr instructins Ht Wrk Certificate Ht Wrk Certificates must be used in cnjunctin with a Permit t Wrk. Ht Wrk Certificates are distinguishable frm ther certificates. The certificates must have a duplicate cpy at a minimum. The certificate and assciated dcumentatin must be available in the language apprpriate fr the Permit Apprvers and Wrk Team Leaders. T ensure a Ht Wrk Certificate cnsistent with this Standard refer t Appendix A: JO Ht Wrk Certificate and Guidance fr Specialized Wrk Permits (certificates). The Ht Wrk Certificate shuld include the infrmatin fund n the sample certificate in Appendix A and any additinal infrmatin JO deems necessary. The Ht Wrk Certificate must include the infrmatin fund n the sample certificate in Appendix A and any additinal infrmatin that JO deems necessary. 8 Versin C Psted 21 January 2010

9 5.4 Permit Changes Permits are revalidated in accrdance with the JO Permit t Wrk Standard. In all cases, befre a Ht Wrk Certificate can be extended, there must be a valid Permit t Wrk in place fr the perid t be cvered by the revalidatin Permit Revalidatin Shuld site cnditins change the Ht Wrk Certificate with the General wrk Permit must be revalidated befre wrk can be restarted. Revalidatin requires the Wrk Team Leader and/r the Area Cntrller t verify that all cnditins and requirements n the permit remain in effect. The wrk may be resumed nly after the Permit Apprver has given apprval t restart the permitted wrk. NOTE: If wrk is stpped fr mre than 30 minutes withut a Fire Watch present t ensure cnditins d nt change, the Ht Wrk Certificate must be revalidated. Befre the Ht Wrk Certificate is revalidated the Permit Apprver r designee must cnfirm the fllwing: The Wrk Team Leader has nt changed. The entire wrk crew has nt changed. All cnditins, requirements, and cntrls required by the Ht Wrk Certificate, the related Permit t Wrk and the JSAs remain in place. The n-duty Qualified Gas Tester has cnducted the required gas testing. Zer percent LEL is present. A valid Permit t Wrk is in place. The apprved dedicated fire Watch is assigned and present in the ht wrk area. The required dedicated fire-fighting equipment is n hand and in gd perating cnditin. The Permit Apprver and Wrk Team Leader have discussed the jbsite cnditins and are in agreement that the wrk can be cntinued safely. The Permit Apprver and Wrk Team Leader have authrized the Ht Wrk Certificate in the revalidatin sectin. All cpies f the Ht Wrk Certificate have been updated. NOTE: The extensin r renewal f a Ht Wrk Certificate may be perfrmed nly by the Permit Apprver during the shift(s) fr which they are respnsible fr Ht Wrk Recrding Changes Only the Permit Apprver can make changes t the infrmatin n the permit. Any changes made must be dcumented n all cpies f the permit and cmmunicated t the Wrk Team Leader Permit Re-Evaluatin Wrk must be stpped and the permit, with certificate, re-evaluated under any f the fllwing cnditins: Versin C Psted 21 January

10 Change f the entire wrk crew. Change f Wrk Team Leader. qualified Fire Watch designated fr the ht wrk. Change in jbsite cnditins (e.g. a leak r spill in the area, envirnmental cnditins change, r if there are cnditins that g beynd thse apprved in the permit). Serius injury, incident r near lss (near miss) at the jbsite. 5.5 Cntractrs Cntractrs shall use JO s prcedures unless they have been reviewed by JO (usually thrugh the CHESM prcess) t use their wn prcedure(s). 5.6 Jbsite and Equipment Preparatin Cmpetent persnnel must cmplete the steps needed t prperly and safely prepare the jbsite and equipment fr the start f wrk. Typical preparatins that are specific t ht wrk may include, but are nt limited t, the fllwing: Remving cmbustible materials within 10 meters (35 feet) f the ht wrk area. If cmbustible materials can nt be remved, they must be prtected by fire-resistant cverings r shields, r kept wet. Sealing drains within 15 meters (50 feet) f the ht wrk by plugging and filling with water, r by anther equivalent methd, t frm a seal. Vents in the vicinity f (including vents n the decks abve and belw) ht wrk shall be ruted away frm the vicinity f the ht wrk, r the input surce t the vents shall be safely islated. Barricade and mark the area. Arranging fr cntinuus ventilatin during ht wrk. Psitining dedicated fire-fighting equipment. tifying facility persnnel. Ensuring there is a designated Fire Watch at the jbsite. Inspecting all ht wrk equipment and ensure that it is safe t use. Gas-testing the jbsite and the surrunding 15 meters (50 feet) by a Qualified Gas Tester. Cmmunicating t all affected parties thrugh a pre-jb briefing. Additinal preparatins specific t pening equipment may include, but are nt limited t, the fllwing: Ensuring psitive islatin (refer t JO Islatin f Hazardus Energy Standard) Depressurizing Purging, flushing, draining r venting 10 Versin C Psted 21 January 2010

11 5.7 Gas Testing Requirements Gas testing is required prir t ht wrk (where there is a ptential fr flammable gasses, immediately dangerus t life r health (IDLH) atmspheres r ther hazardus atmspheres) except in designated Safe Ht Wrk Areas. Gas testing must be perfrmed by a Qualified Gas Tester. The frequency f gas testing shall be stated in the Permit t Wrk fr apprval Initial Gas Testing Initial gas testing must include testing fr xygen and flammable vapr r ther txic gases and vaprs as identified in the hazard analysis. The types and frequency f gas testing required must be based n the lcatin f the ht wrk and ptential hazards. The results f such a test will be used t determine: Whether the area is safe fr ht wrk Whether additinal vessel purging is necessary Time limitatins fr ht wrk t be cnducted Initial testing must be perfrmed after the ht wrk jbsite and equipment have been prperly islated and prepared. Gas testing fr LEL must be perfrmed in the surrunding area fr a distance f 15 meters (50 feet). Ht wrk must nt be perfrmed if the LEL is greater than zer percent and/r if residues f cmbustible liquids are present except fr ht tapping, fr which specific precautins must be taken. If gas test results indicate greater than zer percent LEL, the surce f the flammable gas r vapr must be identified and actins must be taken t eliminate it. NOTE: If, at any time during the perfrmance f the ht wrk, subsequent gas testing reveals an LEL f greater than zer percent, then the ht wrk is t be immediately stpped and the Ht Wrk Certificate must be re-evaluated. The Ht Wrk Certificate may nt be reissued until the surce f the flammable vapr is determined and eliminated and further gas testing indicates a zer percent LEL Wrk Delays The ht wrk must ccur within an agreed perid f time after the wrk is authrized. In all cases, if the ht wrk did nt start within 30 minutes after the Qualified Gas Tester has tested the area and cleared it fr ht wrk t start, the Ht Wrk Certificate must be revalidated befre ht wrk can begin again Fllw-up Gas Testing The Qualified Gas Tester will determine the frequency f fllw-up gas testing based n the ptential identified hazards. The required frequency f gas testing must be nted n the Ht Wrk Certificate. NOTE: Any ht wrk perfrmed inside a cnfined space requires cntinuus gas testing in the area f the Ht Wrk. 5.8 Cnditins fr Wrk Stppage During any nn-emergency wrk stppage, wrk site must be left in a safe cnditin, fr example, nn-essential equipment must be turned ff and secured. Wrk must be stpped and the Permit Apprver and Wrk Team Leader must reevaluate the Ht Wrk Certificate if the jbsite is left unattended and/r under any f the fllwing cnditins: Versin C Psted 21 January

12 Changes in jbsite cnditin(s) that present a risk after permit issuance LEL greater than zer percent is detected Prtable r cntinuus gas test equipment failure (fr example, battery depleted) Change in scpe f wrk, such as additinal wrk nt riginally anticipated A safety cncern has been raised by a wrker r cmpany representative Occurrence f a minr incident r near lss during a jb task The jb is left unattended When the envirnmental cnditins change The Fire Watch leaves the ht wrk area The riginal finish time listed n the Ht Wrk Certificate has been reached The Permit t Wrk is n lnger valid 5.9 Fire Watch A dedicated persn must be designated t act as a Fire Watch. They must be cmpetent and equipped t perfrm Fire Watch duties. Fire Watch duties must be maintained fr at least 30 minutes after ht wrk ceases. During this time, the Fire Watch must inspect the adjacent areas where sparks r flames may have traveled and lk fr signs f cmbustin. NOTE: When persnnel are carrying nly nn-intrinsically safe devices (e.g., battery perated equipment r ccupatinal hygiene mnitring equipment) these persnnel must als carry a cntinuusly mnitring gas detectr. If the gas detectr alarm sunds they must immediately stp wrk and vacate the area and infrm facility persnnel f the alarm. Fire Watch is required in these situatins Wrk Cmpletin When the wrk has been cmpleted, the Wrk Team Leader must return the Ht Wrk Certificate and permit-related dcuments t the permit apprver. The permit apprver r designee must review the jbsite t ensure that the fllwing cnditins have been met: The jbsite has been left in a safe, clean and rderly cnditin. At least 30 minutes has elapsed fr the Fire Watch t verify the cnditin f the jbsite. The wrk perfrmed meets the required scpe and specificatins. If the abve cnditins have been met, the permit apprver r designee must sign and date the Ht Wrk Certificate t signify cmpletin. 6.0 Recrds 6.1 Required Recrds The fllwing recrds will be kept: Cpies f permits and assciated dcumentatin shall be maintained in accrdance with the JO Permit t Wrk Standard. 12 Versin C Psted 21 January 2010

13 6.2 Retentin Requirements Dcumentatin shall be retained as required by lcal regulatin, JO plicy, r fr a minimum f six mnths, whichever is greater. 7.0 References The fllwing is a cmplete list f the dcuments referenced by this standard: Table 1. Dcument List Title JO Training Requirements Tl File Name JO_MSW_TrainingRequirementsTl.dc JO Permit t Wrk Standard JO_MSW_PermittWrkStandard.dc JO Islatin f Hazardus Energy Standard Guidance fr Specialized Wrk Permits (certificates). JO_MSW_IslatinfHazardusEnergyStandard.dc Guidance fr Specialized Permits (certificates).dc 8.0 Other Guidance Dcuments Table 2. Dcument List Title American Petrleum Institute (API) Recmmended Practice (RP): 505 Recmmended Practice fr Classificatin f Lcatins fr Electrical Installatins at Petrleum Facilities Classified as Class I, Zne 0, and Zne Recmmended Practice fr Classificatin f Lcatins fr Electrical Installatins at Petrleum Facilities Classified as Class I, Divisin 1 and Divisin 2 American Petrleum Institute (API) Recmmended Practice (RP): 2201, Prcedures fr Welding r Ht Tapping n Equipment Cntaining Flammables Chevrn Energy Research and Technlgy Cmpany Open and n-pen Flame File / Link Name American Petrleum Institute (API) NOTE: Yu may need a subscriptin t access API dcumentatin. If s, cnsult a librarian listed n the hme page. American Petrleum Institute (API) NOTE: Yu may need a subscriptin t access API dcumentatin. If s, cnsult a librarian listed n the hme page. Chevrn Energy Research and Technlgy Cmpany Open and n-pen Versin C Psted 21 January

14 Title Ignitin Surce Cntrl Guidance File / Link Name Flame Ignitin Surce Cntrl Guidance (101KB) 9.0 Dcument Cntrl Table 1: Dcument Cntrl Infrmatin Descriptin GU Cmmn SBU-Specific Apprval Date 27 February December 2008 Next Revisin Due 27 February December 2011 Cntrl Number Table 2: Dcument Histry Versin Number Date tes February 2008 Initial Release August 2008 Align Requirement 2 with ther GU SWP Standards December 2008 Added bkmarks fr OE Mentr December 2008 SAC Adptin A 29 March 2008 JO Versin Created B 21 January 2010 Call numbers n permits updated June 2012 Updated t include Crprate Required MSW Prcess Requirements 14 Versin C Psted 21 January 2010

15 Appendix A: JO Ht Wrk Certificate Sectin 1-5 t be cmpleted by the Wrk Team Leader r designate and Sectin 6-7 t be cmpleted by Apprver r designate Assciated general wrk permit n.. 1. Wrk Lcatin. Area/ Unit / Equipment Etc. 6. SITE PREPARATION (Tick which ever is applicable) NA Area tested initially fr cmbustible gas and test t be dne Every hurs. Or Cntinuusly ( Attach Gas test Lg) 2. Issue Date Equipment islated, drained, blinded, vented, flushed/purged and gas freed 3. Permissin granted t : Name f the divisin/ sectin/ cntractr Sewers, Drains and vents sealed within 15 Meters f wrk Cmbustibles remved frm the area Cver nearby equipment with fireprf blankets 4. Descriptin f wrk Fire extinguisher at wrk site Pressurized fire hse at jb site. Fire watch at jb site Cmmunicatin equipment with Fire Watch Ht tap checklist ( attached) Fire department site review 5. Tls/Equipment t be used Special prtective equipment and clthing (specify) Vehicles, engines with special safety certificate Other restrictin r special precautins if any ( mentin) Versin C Psted 21 January

16 Appendix B: JO Gas Test Lg JOINT OPERATIONS HOT WORK GAS TEST LOG Initial Gas test recrded n frnt side f permit Recrd subsequent test results here as per the frequency indicated. Fr cntinuus testing recrd the results every 30 minutes. Gas Detectrs are required t be calibrated quarterly r as recmmended by Manufacturer. Check the calibratin date befre use. Ht wrk certificate reference n. Gas detectr type ( make, mdel ) Gas Tester S.. Calibratin date Start-up OK? GAS TEST FREQUNECY Cntinuus Others ( Specify ) Date / Time Lcatin Cnducted by Result (% LEL) Must be 0% 16 Versin C Psted 21 January 2010

17 Appendix C: JO Ht Tap Checklist HOT TAP CHECK LIST This Checklist is a necessary cmpnent f the Ht Tap Plan required fr any ht tapping and shall be attached t ht wrk certificate. The Checklist shuld be prgressively cmpleted during the planning and executin stages f the ht tap. The Divisin that des the ht tap shuld maintain the cmpleted checklist n file with the Ht Tap Plan. Item Respnse, Cmments Verified by SECTION 1: BEFORE DECIDING TO HOT TAP 1. Can the cntents be safely ht tapped? What are the special cnsideratins? 2. What is the wall thickness f the line r vessel? Is burnthrugh r weld-cracking the primary cncern? 3. What will the line temperature be during the ht tap? 4. Based n the thickness f the line r vessel and the perating cnditins, shuld the flw be maintained, reduced r stpped? maintained reduced stpped 5. Will hydrtesting the branch line (befre drilling int the parent line) cllapse the parent line? 6. Has the metallurgy f the line r vessel been determined? a) Are there special welding cnsideratins fr the line r vessel? b) Has it been determined that pst-weld heat treating f the ht tap welds is nt required? 7. Is there adequate histing and supprt equipment fr the tapping machine and subsequent piping? 8. Is there sufficient rm fr peratinal and emergency access? 9. Has a prcedure been prepared t islate the wrk area in the event f failure? SECTION 2: BEFORE STARTING THE HOT TAP 10. Is a Ht Tap Plan cmpleted and apprved? 11. Cmbustible and txic gas tests have been taken, and safe levels exist. 12. A Permit t Wrk has been issued and is at the wrk site. Versin C Psted 21 January

18 Item Respnse, Cmments Verified by 13. The exact lcatin f the ht tap n the line r vessel has been marked. 14. Fr tanks and vessels, the ht tap lcatin is lcated at least 1 meter belw the liquid level. 15. The area t be welded has been inspected fr thickness and freedm frm laminatin, hydrgen attack, and ther metallurgical imperfectins. 16. The branch cnnectin and welding electrde have been selected t match the metallurgy f the line r vessel. 17. The flanges, blts, gaskets, pipe, and valves t be installed meet the pipeline, piping, tank r pressure vessel cde fr the line r vessel t be ht tapped. 18. Stress relieving f the welding area is nt required. 19. If required, suitable prtective equipment has been prvided t all expsed persnnel in the ht tapping area. 20. Fire-fighting equipment has been prvided. 21. The prpsed ht tapping machine has suitable temperature and pressure ratings. 22. Sufficient external clearance exists t accmmdate the peratin f the ht tap machine. 23. The ht tap fitting is f the prper length t accmmdate the peratin f the ht tap machine. 24. The tapping machine has adequate cutter travel fr this jb. 25. Sufficient internal clearance exists t retract the cutter thrugh the valve. 26. The ht tap valve is repacked, and the valve guide is either grund ff t allw free passage f the cutter r a full prt straight thrugh valve is used. SECTION 3: BEFORE WELDING 27. The weld area has been preheated, if required. 28. An apprved welding prcedure is n hand. It is in accrdance with the apprpriate cde and requires lw hydrgen electrdes and the temper bead weld pass sequence. 18 Versin C Psted 21 January 2010

19 Item Respnse, Cmments Verified by 29. The welders are qualified in accrdance with the apprpriate cde, have experience welding n pressurized flwing lines, and are aware that the line is under pressure and the type f risks invlved. 30. The fitting is prperly psitined s the ht tap machine will nt be misaligned. 31. The flw rate has been reduced r stpped t minimize the risk f weld cracking. 32. If the ht tap is being dne n a tank, all valves n the tank have been clsed, lcked, and tagged. SECTION 4: BEFORE CUTTING 33. Welds have been nn-destructively examined. 34. Ht tap valve, packing, gasket, and blts have been checked fr pssible leakage. 35. If the ht tapping plan requires that the ht tap cnnectin be hydr tested, the system has been checked fr the crrect hydr test pressure. The test pressure shuld nt exceed the cllapse pressure f the main run, the flange rating, r the rupture pressure f the reinfrcement sleeve. 36. The packing r seals n the ht tap machine have been checked and are suitable fr the temperature and the cntents in the line. 37. The bleed-ff valve has been checked t be sure it has the crrect pressure rating, is perative, and is nt bstructed. 38. All blts n the cutter and pilt bit are tight. 39. The cupn catcher is n the pilt bit. 40. The valve is centered n the flange. 41. The cutting depth has been calculated t avid cutting the ppsite side f the pipe. 42. The cutter stem is marked t indicate pints at which the cut will be cmpleted and at which the cutter is retracted past the valve seats. 43. The bring bar has been run thrugh the valve t ensure free passage. Versin C Psted 21 January

20 Item Respnse, Cmments Verified by 44. The cutter can be fully retracted s that the ht tap valve can be clsed. SECTION 5: BEFORE REMOVING THE HOT TAP MACHINE 45. The manufacturer's instructins have been fllwed t be sure the bring bar is fully retracted befre the ht tap valve is clsed. 46. The ht tap valve has been clsed and the bleeder valve pened. 47. The ht tap valve is hlding. 48. All pressure has been bled ff the ht tap machine befre remving blts frm the flange. SECTION 6: BEFORE RETURNING THE LINE TO SERVICE AND COMPLETING THE JOB 49. All valves that were clsed, lcked and tagged have been returned t service and all lcks and tags have been remved. 50. The pressure and flw rate have returned t nrmal. 20 Versin C Psted 21 January 2010