Title: Control of Hazardous Energy. No.: PA Page: 1 of 53. Supersedes: 05/17 (Rev. 17) Document Revision Change Table

Transcription

1 No.: PA Page: 1 of 53 Document Revision Change Table Revision Revision Description Number 15 Updated clearing valves to remain open in per AIM incident 0126-CLD Clearing valves detailed on MIP DANGER Tags for ongoing work Audit of MIPs Attachment L MIP audit form Added single bleed verification for small systems 2.6-Removed Danger Tag-Not Used in Practice 2.8-Clarified Energy Isolation Device and Removed reference to use exchangers as isolation 4.6&4.9- Clearing Valve Requirements to identify clearing valves on P&ID and requires signature with 4 eyes verification General Review and Formatting. Update references to PA Boundary Isolation for External Boundary Isolations. Revised Revision By Date BLM 11/16 DLS 11/16 BLM MM SA 05/ added definition of Electrical Hazardous Energy 2.9 added definition of Electrically-Driven Equipment 2.27 One Plus (Tag Plus) requirements changed 2.28 Reference PA-P-ME-407 for non-operations energy control / Long term isolation requirements 4.4/4.13 communication to affected employees of status 4.6.5,7 Automatic valves w/out bleeds on each side PI tag to verify try on electrically-driven equipment One Plus (Tag Plus) requirements changed actions to take in the event of found missing tag(s) & Isolation/verification of zero energy requirements For Electrical Hazardous Energy vs. Electrically-Driven Equipment 4.20 changes made to elements of Periodic Review and Program Review LP 6/18

2 No.: PA Page: 2 of PURPOSE To establish minimum standard work practices and procedures for isolating and tagging out Hazardous Energy Sources and otherwise disabling machines or equipment (including third party equipment such as water treatment or process chemical injection systems) to prevent unexpected or unintentional energizing, startup, or release of stored energy that could cause personal injury or equipment damage. 2. DEFINITIONS 2.1. Acceptance An acceptance signature on a Master Isolation Plan (MIP) is acknowledgement by the person signing, that: The equipment specified on the isolation procedure is the equipment to be worked on. The MIP signed has the same number designation as the isolation tags used to isolate the equipment to be worked on. This shall be verified by auditing two or more isolation tags used for the isolation of the equipment. De-energization has been verified by checking two bleeds that are included in the MIP which are closest to the work to be performed. Note: for small isolations (e.g. single pump, skid, or small pipe runs) where only one bleed valve is present, it is acceptable to verify de-energization with only one bleed. The owner has communicated all information needed about the hazardous energy control. The MIP has all 4 signoffs required by Operations Affected Employee An employee whose job requires him/her to operate or use a machine or equipment on which servicing or maintenance is being performed under lockout or tagout, or whose job requires him/her to work in an area in which such servicing or maintenance is being performed Authorized Employee An employee who locks out or tags out machines or equipment in order to perform service or maintenance on that machine or equipment. The Authorized Employee and the Affected Employee may be the same under certain circumstances. (i.e. shop equipment, office equipment, etc.)

3 No.: PA Page: 3 of DEFINITIONS cont d 2.4. Contingent Employee (i.e. contractors brought in without their company supervision on site) 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 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 De-Energized Isolated or Disconnected from all Energy Sources and containing no residual or stored energy Designated Representative Authorized Employee that oversees or leads a work crew and is allowed to affix or remove Lockout/Tagout Devices on behalf of the Authorized Employees of the work crew Electrical Hazardous Energy Electricity of sufficient voltage and/or magnitude to cause injury; transmitted in electrical circuits and equipment including but not limited to transformers, breakers, heat tracing circuits, motors, field wiring, and other electrical components Electrically-Driven Equipment Equipment that is powered by electricity; including but not limited to pumps, fans, valves, compressors, and hoists Energy Isolating Device A device that physically prevents the transmission or release of energy, including but not limited to the following: Manually operated electrical circuit breaker; Block valve Disconnect switch; Radiation device lockout shutters. These must be tagged out by a Trained Radiation Gauge User (i.e. I/E Tech) or a Radiation Safety Officer (RSO) for confined space entries. A positive shutoff actuated valve if all the following conditions are met: It is a positive (i.e. tight) shutoff device and has no leak by (e.g. TSO XVs). Note: A process control valve is not considered a tight shutoff valve and cannot be used as an energy-isolating device since it is not a positive shut-off device.

4 No.: PA Page: 4 of DEFINITIONS cont d Energy Isolating Device cont d The fail-safe position is the desired position. The valve is disabled. The energy source has an energy-isolating device (blocking device) and is locked out or tagged out. Any similar device used to block or isolate energy, (e.g. blinds, pancakes with an isolation tag attached), air gaps (>12 ). Air gaps must also have an isolation tag attached to show that the air gap is being used as part of the isolation. All Blinds must have a pink streamer as a visual identifier in the field Four-eyes Principle The use of 2 or more individuals (equipment owner and other qualified person) to assess tasks to ensure that all hazards are identified and eliminated and/or controlled through safe work practices, use of PPE, communication and awareness, etc Hazards For this procedure, there are two types of hazards: Chemical hazards - Excessive chemical concentrations of mists, vapors, gases, liquids or solids in the form of dusts or fumes. Chemicals may enter the body through inhalation, skin contact, absorption, injection, and ingestion. Physical hazards Electrical (including electrical tracing), fire/explosion, noise, radiation, pressure, temperature, etc. Physical hazards can have immediate and cumulative health effects Hazardous Energy Control Isolation Sheet Documented method for accurately identifying all hazardous energy isolation control points and their proper positioning to ensure a safe de-energized condition is established Hazardous Energy Source Any source of electrical, mechanical, hydraulic, pneumatic, kinetic, chemical, thermal, radiation, or other energy, including stored, inertial or residual energy, that if unexpectedly or unintentionally released, could cause injury to personnel, or if introduced into a process could be hazardous Individual Release The initialing off on the Work Crew Accountability Form that the individual is no longer working on the specified job or behind the hazardous energy isolation.

5 No.: PA Page: 5 of DEFINITIONS cont d Isolation The process of preparing and positioning of equipment or components of equipment to segregate them from Hazardous Energy Sources. Energy isolation must be performed in accordance with equipment specific hazardous energy isolation procedures, and must achieve a Zero Energy State Isolation A procedure that includes the necessary steps for identifying hazardous energy sources and must include the following elements and be attached to the MIP: Sequence for shutdown; Clearing; Startup of equipment; Methods used to isolate each hazardous energy source; Steps to release stored energy; Verification/de-energization of automatically controlled or interlocked equipment Isolation - Approver The person who, after completing all steps and signoffs required for hazardous energy control, approves the Isolation for Isolation Verification. The procedure approver will confirm all required documents and requirements are included in the MIP documentation and sign the space provided on the MIP (Attachment E). This person will be identified by owning/operating department management Isolation Tag (Red, White, & Black) An Isolation tag and a means of attachment (plastic tie-wrap), which is securely fastened to an energy isolating device in accordance with an established procedure, to indicate that the energy isolating device and the equipment being controlled may not be operated until the lockout device is removed in accordance with established procedures Process Information Only Tags (Orange, Black, & White) Process Information Only tags are used to convey process information.

6 No.: PA Page: 6 of DEFINITIONS cont d Locking/Lockout The placement of a Lockout Device(s) on an Energy Isolating Device, in accordance with an established equipment specific hazardous energy control procedure, to ensure the Energy Isolating Device and the equipment is controlled to a Zero Energy State and cannot be operated until the Lockout Device is removed Lockout Device A device that indicates or holds an Energy Isolating Device in a Safe Position and cannot be manipulated until the Lockout Device is removed per procedure. This can be a tag or lock. When locks are being used, they should be identifiable by the colors listed below. Locks require a Control of Hazardous Energy Tag whenever they are being used to control hazardous energy. High Voltage Technicians = Gold Instrumentation Technicians = Black Millwrights = Blue All Contractors = Green Operations = Red Radiation Officer = Silver Master Isolation Plan (MIP) Hazardous Energy Source control process that may be used for control of multiple isolation points/devices. Since the Master Isolation Plan relies primarily upon administrative means to control the release of potential hazardous energy, additional steps for Verification of Zero Energy State are required to ensure that protection comparable to Lockout is maintained during work covered by this procedure. There must also be a mechanism to achieve personal acceptance of the Hazardous Energy Isolation by each Authorized Employee (Work Crew Accountability Form - WCAF) MIP Developer A person who understands the complete work scope of a job that is requiring hazardous energy isolation and develops/gathers all required documents of an MIP (P&ID s, procedures, energy control, tagout sheet, etc.) together in one package. After the package is complete, this person will sign/date the procedure developed/drawn by portion of the MIP sheet.

7 No.: PA Page: 7 of DEFINITIONS cont d MIP Developer cont d This person will be considered qualified to be an MIP developer after having been qualified on a job by the owning/operating department manager. An MIP developer can only sign as the procedure developed/drawn by person in a job they have been qualified on Non-Incendiary Circuit (Intrinsically Safe Circuit) A circuit, other than field wiring, in which any arc or thermal effect produced under intended operating conditions of the equipment is not capable, under specified test conditions, of igniting the flammable gas air, vapor air, or dust air mixture. Devices with these features are always marked with a label that identifies them as being "Intrinsically Safe." One-Plus (Tag Plus) System utilizing a mechanism of physical protection to make equipment inoperative. This is intended to prevent unintentional operation of an Energy Isolation Device when Lockout cannot or is not used. All energy isolating devices (including valves) require one plus to secure them. Some examples include, but are not limited to: Removing an isolating circuit element; Taking off the valve handle; Chaining the valve handle; Using tie wraps to secure a valve in the proper position; Using tie wraps with cable to secure a valve in the proper position; Taping or securing non-lockable electrical breaker devices; Securing equipment shafts that could be rotated while being worked on. Electrical switchgear for isolating Electrically-Driven Equipment: multi-lock hasp with tag For isolating Electrical Hazardous Energy: multi-lock hasp with tag(s) AND lock by qualified electricians

8 No.: PA Page: 8 of DEFINITIONS cont d 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. Under certain documented circumstances individuals, departments, or companies that would not normally be considered members of the Operating/Owning Department (i.e. service and maintenance personnel) may be authorized to perform work under the permitting exemption described in this section. The following circumstances must be met to consider such individuals as Operating/Owning Department personnel: They must be trained and qualified to perform the subject activities; They must have a level of knowledge and experience with the operation/process (equipment, hazards, and controls) that is equal to any existing Operating/Owning Department personnel. They are specifically authorized by the OM/OD in writing (individually / department / company as appropriate) as a member of the Operating / Owning Department for the specific tasks they are to perform. Refer to PA-P-ME-407 (Maintenance Safe Work Permits Area of Responsibility) to determine energy control responsibility for non-operations equipment. Note: Control of Electrical Hazardous Energy must always be performed, verified, and authorized by a Qualified Electrician Qualified Electrician Person who has completed formal program of training (either classroom or on the job) and qualification and is familiar with the: Hazards of electricity. Skills and techniques needed to distinguish exposed live parts from other parts of electrical equipment. Skills and techniques needed to determine the nominal voltage of exposed live parts. Clearance/approach distances required and the corresponding voltages to which the qualified person will be exposed. Applicable electric codes. Hazardous area classification and its application to electrical installations. Safety-related electrical work practices pertaining to their respective job assignments. Electrical requirements included in operating and maintenance procedures (including hazardous energy control). Use, care, and limitations of personal protective equipment. See NOTE on following page.

9 No.: PA Page: 9 of DEFINITIONS cont d Qualified Electrician cont d NOTE: This will be verified by the person authorizing the electrician to work on site. If done by contractor service, the contractor is responsible. If brought in for specific job, the person authorizing their use is responsible to verify their qualifications Permit Issuer Personnel that have been trained, qualified, and authorized to issue or modify permits on behalf of the Operating/Owning Department Prior Contents Includes the previous chemical contents in the equipment before clearing and any chemical agents (i.e. soda blasting, soaps, etc.) used for cleaning Release A release signature on the Master Isolation Plan by the person who accepted the MIP that certifies that all personnel in his/her work group have stopped work, signed (initialed) off WCAF, and are clear of the equipment they were permitted to work on Removal Authorization Authorization to allow the hazardous energy control isolation to be removed from equipment that has been serviced. It signifies that the job is complete, all workers are off the job, and the hazardous energy control isolation can be removed. At the Port Arthur site, it is the Shift Supervisor Safe Position The specific position of an Energy Isolation Device that achieves a Zero Energy State and prevents unexpected energization of the equipment (i.e., open/closed, de-activated, blocked, removed, etc.) Tagout The placement of an Isolation Tag on an energy-isolating device, in accordance with an established procedure, to indicate that the energy isolating device and the equipment being controlled may not be operated until the Isolation Tag is removed in accordance with established procedures.

10 No.: PA Page: 10 of DEFINITIONS cont d Test/Position of Equipment Temporary re-energization of equipment and removal of Lockout devices to check operation or positioning prior to completion of the work. Testing is allowed only during the limited time necessary and only on the affected components. After completion of the testing, the equipment must be de-energized and all hazardous energy control requirements resumed Try The method used to ensure all energy sources have been removed and isolated. For example: opening of a bleed to ensure there is no pressure on a piping system; testing with a LEL meter to ensure all flammable gases have been removed; The physical action of trying to start or energize equipment after the hazardous energy isolation is complete. The purpose is to verify isolation and release of potential energy; this includes bypassing equipment interlocks if applicable Verification Means to ensure that Isolation has been achieved for each type of Hazardous Energy Source. Examples may include sampling with chemical indicating tubes, photo-ionization detectors or combustible gas indicators, measuring ph of wash water, checking voltage, checking equipment for potential rotation (ensure any other energy source such as wind on fans could cause them to rotate, etc.), attempting to operate a valve or switch, successful purge/flush, etc Work Crew Accountability Form (WCAF) A form that is attached to all Safe Work Permits serving several purposes: The administrative control to account for every individual working in the unit(s) who is not signed in on the Work Authorization Log (WAL) or is an approved member of the Daily Support Team (DST). The administrative control for every individual working behind a hazardous energy isolation. The verification that every individual worker has read and understands the conditions of the permit(s).

11 No.: PA Page: 11 of DEFINITIONS cont d Zero Energy State The point where all potential Hazardous Energy Sources have been verified to be De-Energized External Boundary Isolation Any battery limit isolation designated in the Boundary Isolation PA These are intended to capture streams that cross the plant fence line or otherwise represented by a third-party supplier. 3. SCOPE The requirements of this procedure apply to the BASF Port Arthur Site. This procedure applies to all activities (including third party equipment such as water treatment or process chemical injection systems) where there is a potential for exposure to Hazardous Energy Sources, unless specifically exempted below. NOTE: Project work may not be subject to this Control of Hazardous Energy procedure if the project is physically separated from the existing facility and any energy source. As the systems are connected to existing facility equipment (piping, electrical, or other systems) they must be locked out as appropriate This procedure does not apply to the following: Work on cord and plug connected electrical equipment for which exposure to the hazards of unexpected energization or startup of the equipment is controlled by the unplugging of the equipment from the Hazardous Energy Source if the plug is under the exclusive control of the employee performing the service or maintenance. The plug is under the exclusive control of the employee if: It is physically in the possession of the employee or It is in arm s reach and in the line of site of the employee or The employee has affixed a Lockout Device on the plug Activities on equipment that are considered non-incendiary circuits Operation and maintenance of electric power generation, control, transformation, transmission, distribution lines/equipment. These tasks require specific training, work practices, and employee protection from these special hazards presented by working with energized electrical equipment not identified in this procedure.

12 No.: PA Page: 12 of SCOPE cont d 3.1. This procedure does not apply to the following: cont d Hot Taps that are covered by site-developed procedures. (Refer to PA Hot Work and PA Hot Tap ) The following procedures/processes may be exempted from a site s/unit s Hazardous Energy Source control program if a risk assessment has been documented and approved by BASF management identifying the risks and control measures necessary to protect personnel: Activities performed by Operating/Owning Department personnel where the work is routine, repetitive and integral to the use of the equipment for production and under the exclusive control of the individual(s) performing the work. Exclusive control means within 10 feet. One example of such an activity could be changing a filter on a filter pot with integrated isolation and proper draining. To meet this exclusion, an operations procedure is required. A. This does not exempt any PPE requirement outlined in the Port Arthur Line Breaking (PA ) or on the PPE grid. NOTE: Lab instrument servicing, maintenance, and repair can qualify for this exemption by following manufactures recommended installation, maintenance, and servicing procedures if the work is performed by operating/owning department. The isolation sources must be under the control of the servicing personnel, where applicable, for control of hazardous energy. B. Routine electrical tasks involving specific equipment that must be performed in an energized state and are conducted by a Qualified Electrician Removal of a blind flange/plug from a bleed valve and the operation of a bleed valve if the below items are complied with: A. Performed by Operating/Owning Department only. B. PPE grid identifies proper PPE for each potential exposure condition and is followed during each task. C. Personnel are instructed in and use proper defensive positioning techniques during tasks.

13 No.: PA Page: 13 of SCOPE cont d 3.1. This procedure does not apply to the following: cont d D. Personnel maintain direct control of the bleed valve during the blind flange/plug removal. NOTE: If a bleed valve s blind flange or plug is removed that is not included in the MIP, the valve must be tagged with a designated Open Ended Line tag and the Guidelines outlined in the OPEN-ENDED LINE AND WALK THE LINE PROGRAM must be followed Loading and unloading operations performed by Operating/Owning Department may be exempted from site s/unit s Hazardous Energy Source control program if they are using a BASF Manager approved procedure that covers all steps necessary to ensure personnel are not exposed to hazardous energy during the process of loading and/or unloading Gas bottles that supply lab instruments, cutting torches, or other equipment and the energy can be isolated at the bottle by person replacing the bottle Status of standby or idle equipment shall be communicated using Process Information Tags. Out of service equipment should be isolated using Management of Change process. 4. PROCEDURE 4.1. Authorization to Prepare and Approve Hazardous Energy Isolations Operating technicians who have been qualified for specific areas are approved to prepare and/or approve hazardous energy isolation procedures. These employees are knowledgeable of the system, energy sources, and other hazards associated with the equipment being isolated Control of Work involving Hazardous Energy Sources Personnel shall not perform activities involving the control of Hazardous Energy Sources without prior written authorization in the form of a safe work permit issued by a Permit Issuer (excluding Operating/Owning Department personnel when proper criteria are met (3.1)). The applicable equipment MIP number shall be referenced on the permit. To meet the requirements of the four eyes concept the permit issuer and the permit accepter cannot be the same person.

14 No.: PA Page: 14 of PROCEDURE cont d 4.3. Zero Energy State Verification All activities shall be performed, to the extent possible, under a Zero Energy State that has been verified, at a minimum, by Operating/Owning Department personnel. For permitted work, verification of Zero Energy State shall be documented on the Hazardous Energy Control Isolation sheet, as well as the permit. When Zero Energy State verification is not possible, proper PPE and/or additional administrative/engineering controls shall be utilized to minimize exposure to hazards Communication Prior to the performance of activities subject to this procedure, the Operating/Owning Department shall notify all Affected Employees of the work activities and any potential hazards/consequences associated with the work. In addition, all affected employees shall be notified prior to placing equipment back into service via at least one of the following: shift relief, shift log, shift meetings, night orders, electronic white board, documentation on the MIP itself New and Replacement Equipment Whenever replacements, major repair, renovation, modification of a machine or equipment is performed, and whenever new machines or equipment are installed, Energy Isolating Devices for such equipment shall be designed to accept a Lockout Device Preparation for Tag Out Preparation of equipment will be performed in accordance with specific equipment procedures and with the following: The system or equipment will be isolated with all energy sources having been secured All valves (manual, automatic, XVs, etc.) within the isolation shall be opened for clearing and shall remain open during the clearing process and detailed description provided in the Clearing (s). When these lineups are made for clearing, the valves opened for clearing will be highlighted and initialed by the person performing the clearing activities and an additional qualified person will check and initial the P&ID. Alternatively, a single signature on each individual P&ID by the individual responsible for clearing and the qualified reviewer can be used in lieu of initialing each individual valve in the MIP. No MIP will be approved or issued unless verification of these valves was performed.

15 No.: PA Page: 15 of PROCEDURE cont d 4.6. Preparation for Tag Out cont d A temporary deviation from this procedure, on a case by case basis, will be created for services that are normally open to atmosphere or in cases where all interior valves and components cannot be opened for clearing The position of the valves outlined in section may change after the initial clearing verification. This may include: Additional Isolations within the original isolation (e.g. Hot Work, etc.) Maintenance activities such as removing valves, etc. NOTE: All MIPs must be checked independently for zero energy Any automatic valves or XVs that are utilized for clearing purposes must have the same level of verification as stated in section Automatic valves requiring manual field by-pass, Triconex or DCS by-pass will additionally be tracked with the appropriate by-pass paperwork (see PA Bypassing Interlocks) and a copy is to be included in the MIP package. Automatic valves must be manually bypassed and set to the open position in all cases where an open bleed is not located on both sides of the automatic valve The system or equipment will be prepared as far as is absolutely possible by draining, de-pressuring, purging, flushing, and cleaning, etc Upon the completion of clearing activities, the Shift Supervisor or Production Leader has the option to authorize the release of any of the automatic valves not necessary to ensure the integrity of the MIP. (For example: performing maintenance on the valve/stroke testing, valve removal, additional MIP isolation points, etc.) Any control / automatic valve should be checked to ensure that bleeds are open on both sides of the valve before authorizing a change in valve position. NOTE: If changes to the by-pass paper work are made, the supervisor will replace the copy included in the MIP package with the current version Bleeders, vents, or drains shall be opened as necessary and checked to verify no pressure is present, and at a minimum, tagged in position with properly designated and completed hazardous energy isolation tags and included in the MIP.

16 No.: PA Page: 16 of PROCEDURE cont d 4.6. Preparation for Tag Out cont d Push buttons, selector switches, and other circuit type devices are not energy isolating devices, but are used as verification of zero energy on electrically-driven equipment, and will be tagged as part of the try step on the MIP using a Process Information Tag, indicating Try Verified All Vents and drains opened for any other purpose (i.e. not for hazardous energy isolation purposes) that are not included in the MIP (and tagged with an Isolation Tag) must follow the guidelines outlined in the OPEN-ENDED LINE AND WALK THE LINE PROGRAM The RSO or an individual trained as a Nuclear Gauge User shall close the shutter on radioactive devices that need isolation Owning/Operating Department Lockout Devices shall be the first applied in the procedure and the last removed Lockout Devices Lockout devices must have positive identification as to ownership by department or individual and shall not be used for any other purpose. When locks are being used, they should be identifiable by the colors listed below. Locks require a Control of Hazardous Energy Tag whenever they are being used to control hazardous energy. High Voltage Technicians = Gold Instrumentation Technicians = Black Millwrights = Blue All Contractors = Green Operations = Red Radiation Officer = Silver If an energy-isolating device is designed for a lockout device, then the lockout device will be attached at that point One Plus (Tag Plus) is the minimum requirement for an Energy Isolating Device. All valves must use One Plus for isolation Isolation tags must be the only tag used for controlling energy and shall not be used for any other purpose.

17 No.: PA Page: 17 of PROCEDURE cont d 4.7. Lockout Devices Isolation tags cont d Isolation tags must legibly include, with indelible ink: Associated MIP number The reason for tagging The tag sequential number that matches the Hazardous Energy Control Isolation sheet Energy isolating device instructions (do not open, do not close, do not energize, etc.) Equipment ID Person/Position who will authorize tag removal Name (printed legibly), date and department of person attaching the tag All Isolation tags must be attached with a fastener that is non-reusable, attachable by hand, self-locking and non-releasable with a minimum unlocking strength of 50 pounds The Isolation tags must be capable of withstanding inadvertent or accidental removal and can tolerate the environment and time period in which they will be used Isolation tag information must be legible and able to withstand environmental conditions In-use Isolation tags must be updated if they are no longer legible, but do not have renewal requirements based on time. If a piece of pipe or equipment is being removed, it may not have an isolation tag attached Equipment owners are responsible for ensuring that all Isolation tags are removed from equipment prior to that equipment being physically removed for maintenance, demolition, etc When tags are found missing from an isolation device: Work is to be stopped on the equipment, if known; And immediate investigation shall be performed including generation of an incident report Master Isolation Plan (MIP) (INTENT) The MIP system is made up of several items and steps which are used to control the tagout of multiple isolation points if it will afford both the Authorized and Affected Employees protection comparable to that of individual Lockout Devices.

18 No.: PA Page: 18 of PROCEDURE cont d 4.8. Master Isolation Plan (MIP) (INTENT) cont d The total count of tags is to be noted on the MIP The procedure developer will sign their name as the procedure developed/drawn by person and put the date of development. This is on the back of the MIP form All hazardous energy sources must be isolated and verified zero energy as per the requirements of this procedure before authorizing work under the protection of a MIP The person completing and authorizing work under a MIP must verify that all hazardous energy sources are properly isolated and verification methods have been performed An approved isolation procedure shall be on or attached to the respective MIP(s) The MIP number shall be written on all Isolation tags used for the isolation. The unique number on the top of the MIP form must be used and another number or name not substituted for it Safe Work Permits must reference the number of the MIP(s) controlling the isolation for the respective job(s). The person doing the work, or crew leader, will sign acceptance on the MIP to indicate that they are performing work under the protection of the MIP. Each isolation point will be documented by using the attached Hazardous Energy Control Isolation sheet. The Hazardous Energy Control Isolation sheet will reference the number of the MIP being used Lockout devices on equipment or on energy isolating devices referring to a MIP number cannot be removed until the respective MIP has been checked and all personnel have signed off the MIP Individual Authorized Employees must be given the opportunity to personally verify isolations, if they choose Approval of all MIPs must be by an authorized person designated by job description, Shift Supervisor, or the area OM. The MIP approver and the MIP developer cannot be the same person. This signature location is on the back of the MIP form.

19 No.: PA Page: 19 of PROCEDURE cont d 4.8. Master Isolation Plan (MIP) (INTENT) cont d MIPs that require external boundary isolation will be field verified by the Operations Coordinator, Shift Supervisor, or Production Leader. Refer to the Boundary Limit Isolation procedure PA for further instruction Additional sheets must be attached to the original MIP if more sign-on locations are needed Equipment Specific Isolation s All activities, subject to the requirements of this procedure, shall be performed by Owning/Operating Department using written equipment specific hazardous energy control procedures. These procedures shall be prepared for each piece of equipment or for each group of equipment Exemption Equipment specific energy control procedures are not required if all of the following eight conditions are met but must be documented using the Hazardous Energy Control Isolation Sheet: NOTE: These exemptions are for an individual servicing a machine such as a lathe or a trash compactor. The equipment has no potential for stored or residual energy or reaccumulation of stored energy after shut down that could endanger employees; Equipment has a single Hazardous Energy Source that can be readily identified and isolated; The Isolation and locking out/tagging out of the Hazardous Energy Source will completely de-energize and deactivate the equipment; The equipment is isolated from the Hazardous Energy Source and locked/tagged out during service/maintenance; A single lockout device will achieve a locked-out/tagged-out condition; The lockout device is under the exclusive control of the Authorized Employee performing the service or maintenance; The service/maintenance does not create hazards for other employees; and, The site/unit has had no incidents involving the unexpected activation or re-energization of the equipment during service/maintenance.

20 No.: PA Page: 20 of PROCEDURE cont d 4.9. Equipment Specific Isolation s cont d Isolation Sequence Overview The established procedures for the application of energy control shall cover the following elements and actions and shall be done in the following sequence: Preparation for shutdown. Before an authorized or affected employee turns off a machine or equipment, the authorized employee shall have knowledge of the type and magnitude of the energy, the hazards of the energy to be controlled, and the method or means to control the energy. Machine or equipment shutdown. The machine or equipment shall be turned off or shut down using the procedure established for the machine or equipment. An orderly shutdown must be utilized to avoid any additional or increased hazard(s) to employees because of the equipment stoppage. Machine or equipment isolation. All energy isolating devices that are needed to control the energy to the machine or equipment shall be physically located and operated in such a manner as to isolate the machine or equipment from the energy source(s). Lockout or tagout device application. Lockout or tagout devices shall be affixed to each energy isolating device by authorized employees. Lockout devices, where used, shall be affixed in a manner that will hold the energy isolating devices in a safe or off position. Tagout devices, where used, shall be affixed in such a manner as will clearly indicate that the operation or movement of energy isolating devices from the safe or off position is prohibited. Where tagout devices are used with energy isolating devices designed with the capability of being locked, the tag attachment shall be fastened at the same point at which the lock would have been attached. Stored energy Following the application of lockout or tagout devices to energy isolating devices, all potentially hazardous stored or residual energy shall be relieved, disconnected, restrained, and otherwise rendered safe. If there is a possibility of re-accumulation of stored energy to a hazardous level, verification of isolation shall be continued until the servicing or maintenance is completed, or until the possibility of such accumulation no longer exists.

21 No.: PA Page: 21 of PROCEDURE cont d 4.9. Equipment Specific Isolation s cont d Isolation Sequence Overview cont d Verification of isolation. Prior to starting work on machines or equipment that have been locked out or tagged out, the authorized employee shall verify that isolation and deenergization of the machine or equipment have been accomplished Isolation Guidelines When writing equipment specific hazardous energy control procedures, use the following, when applicable: Electrical power sources must be shut down. Heat tracing (steam and/or electrical) Process, utility, feed and/or discharge sources must be drained, depressured, purged, flushed or cleaned as much as possible to effectively remove the potential for injury. Additional precautions could include the blinding or physical disconnection of lines and/or lockout of valves. Hydraulic pressure sources must either be completely de-pressured or adequate blocking devices must be placed to prevent unintentional movement of the equipment. Inertial energy identification and verification steps i.e. gagging a fan blade to stop motion. All gags must be tagged as part of the isolation so that they may be identified as part of the hazardous energy control. Proper isolation of systems with remote start capabilities, including the ability of such systems to have multiple methods for energizing equipment (i.e. field start/stop and DCS) Capacitors will be fully discharged or removed. Any equipment operating at 13.8kv or above will be verified to be properly locked out and de-energized by a Qualified High Voltage Technician due to the technique required to disconnect the circuit Verification of Zero Energy State for Electrically-Driven Equipment will be verified using one-plus tag and Try method by the owning / operating department. Verification of Zero Energy State for work involving Electrical Hazardous Energy will be verified and signed off by a qualified electrician, and a lock must be used to hold the isolating device in the safe position where possible.

22 No.: PA Page: 22 of PROCEDURE cont d 4.9. Equipment Specific Isolation s cont d Isolation Development Equipment specific hazardous energy control isolation procedures shall, at a minimum, include the following elements: Be approved by an authorized employee Be included in the MIP Identify the equipment Include a detailed job description. Identify all hazardous energy sources Examples: o Marked up P&ID o Hand Drawing Sequence for shutdown, isolation, clearing, and start-up of the equipment Examples: o Shutdown procedure o Clearing procedure o Start-up procedure o Approved TSA o Approved work plan o All Interior Valves opened for Clearing (Highlighted and Initialed or P&ID Signed by 2 Qualified persons o Method used to isolate each hazardous energy source Examples: o Hazardous Energy Control Isolation sheet showing safe isolation position o Marked up drawing or P&ID Steps necessary to release the stored or contained energy after isolation Examples: o o Drained, de-pressured, grounded, vented, etc. Identification of and test method used to verify automatically controlled or interlocked equipment are truly de-energized (includes any applicable by-pass paperwork) o Cause and Effect table o Interlock by-pass form A list showing all the specific types, hazards and magnitudes of Hazardous Energy Sources immediately outside of the isolation and the specific steps/methods for verification

23 No.: PA Page: 23 of PROCEDURE cont d 4.9. Equipment Specific Isolation s cont d Isolation Development cont d Hazards - The specific hazard will be entered into the Energy Control section under Hazard such as: o Specific Chemical (naphtha, propylene, butane, acid, etc. o Specific Utility (SHP, MP, condensate, N 2, etc.) o Specific Mechanical (I.D. fan, blower motor, furnace box, etc.) Energy Type - The specific physical hazard will be entered into the Energy Control section under Energy Type such as: o Pressure, temperature, ph, radiation, electrical, flammable, etc. Energy Magnitude - The level of energy associated with the hazard and energy type such as: o 200 psi, 1000 degrees, 4 ph, 480 volts, etc. Method Used to Clear and/or release energy - How the piece of equipment was cleared and the energy released, such as: o Flushed, purged, steamed, grounded, cooled, isolated breaker, etc. Verification Retest Frequency - If possibilities of re-accumulation of stored energy exists, the retest frequency for this energy will be noted under this section. o Initial, daily, hourly, etc. Verification Method - The method used to verify the equipment has no contained hazardous energy such as: o ph test, LEL test, O 2 test, chemical concentration test (benzene, butadiene, etc.), voltage reading, rod out bleed/verify bleed open, pressure check, temperature check, etc. Specific methods and isolation locations(s) necessary for achieving Zero Energy State isolation o Example: Hazardous Energy Control Isolation sheet having a descriptive location and showing the safe valve position, blind location, air gap, etc. Include sign off for nuclear device isolation by Trained Radiation Gauge User (i.e. I/E Tech) or the Radiation Safety Officer. Include the date and signature of the person who gives the Iso- Approval in the Iso- approver blank on the MIP form

24 No.: PA Page: 24 of PROCEDURE cont d 4.9. Equipment Specific Isolation s cont d Isolation Development cont d The isolation must be verified. The person who walks the system down to verify that all requirements of the MIP have been met, must sign the MIP isolation verification section. By-pass paper work must be included for any automatic interior valves required to ensure a zero energy state Isolation Drawings Whenever equipment is to be isolated for work, an isolation drawing must be generated. A hand drawing or a P&ID may be used. The following information must be noted on the drawing: Valve position (open or closed) Isolation location Tags and/or locks, blinds and other isolating devices Legend for color codes, abbreviations, etc. All Interior Valves opened for Clearing (Highlighted and Initialed or P&ID Signed by 2 Qualified persons) The Isolation generator s name must be printed on the drawing along with the date Hazardous Energy Control Isolation sheet A Hazardous Energy Control Isolation sheet shall be generated to track the location of tags and/or locks, blinds, or any other isolating device placed on the equipment. Attachments E and F must be fully populated and completed prior to authorizing work activities. The Owning/Operating Department completes the Hazardous Energy Control Isolation sheet (attachment A ) with the following information: Equipment number MIP number Reason for Tag Out Date and Time of tagout Tag number The initials of the individual installing the lockout device to each specific isolation and the initials of the individual who verified the tag placement 4 eyes An indication if the isolating device is a blind The original position of the valve if applicable The safe position the valve is tagged for isolation

25 No.: PA Page: 25 of PROCEDURE cont d 4.9. Equipment Specific Isolation s cont d Hazardous Energy Control Isolation sheet cont d The initials of the person verifying the Zero Energy Verification (this includes all types of energy) A descriptive location of the isolation point The initials of the individual removing the lockout device from each specific isolation Tag Out remover s signature and date after total isolation is removed Application of Hazardous Energy Control When servicing department personnel are to perform work requiring that energy sources be isolated and tagged out, the following steps must be taken: A. The Owning/Operating Department must be aware of all personnel who will be working on the equipment and all affected employees must be notified of the intent to tagout the equipment or machinery. B. The Owning/Operating department will generate an MIP and all documentation that is to be attached. C. The Owning/Operating Department will follow all steps of the Isolation to ensure the equipment is safe for work. D. Owning/Operating Department Lockout Devices shall be the first Tags/Locks applied in the procedure and the last removed Verification of System De-energization A. After application of the Tag Out and prior to beginning of work, authorized personnel of the Owning/Operating Department will try the system as applicable to the situation by: Attempt to start or energize the equipment using all start devices (local and remote). Equipment interlocks, where applicable, must be verified that they are not preventing or interfering with the proper verification of Isolation. Opening a bleed or vent to verify the absence of chemicals, pressure, water, air or other types of energy. Conduct air monitoring at an open bleed or vent to assure no flammable or toxic liquids, vapors, or gases are present.

26 No.: PA Page: 26 of PROCEDURE cont d 4.9. Equipment Specific Isolation s cont d Verification of System De-energization cont d Permission to Work B. If possibilities of re-accumulation of stored energy exists, verification of isolation shall continue until servicing or maintenance is complete or until such re-accumulation hazards no longer exist. C. The Authorized Employee servicing the equipment must verify deenergization, at a minimum, two point(s) closest to the work to be performed, where the de-energization was verified, i.e., bleed, vent, start/stop switch, etc. per the MIP. D. For work on equipment that contains Electrical Hazardous Energy (i.e., pull leads from motor, replacing switch, work on electrical circuits or equipment, etc.) voltage will be tested, and zero energy state signed off by a Qualified Electrician to verify that the power is de-energized. Lock and tag must be used to prevent operation of devices controlling Electrical Hazardous Energy E. Other methods may be necessary to determine if energy sources have been isolated Work Authorization The Safe Work Permit must include an isolation procedure for the equipment to be worked on Worker or Crew Leader Responsibilities Prior to Work When the equipment has been properly isolated per department procedures, the person performing the work, or the crew leader, will for him/herself and/or his crew, determine that the provisions of the site/department procedures have been properly applied and: a. Sign Acceptance on the respective Master Isolation Plan; b. The contractor has the option to attach a lockout device to each energy isolation device on the equipment to be worked on, then sign acceptance on the MIP with a comment showing that lockout devices have been affixed to each energy isolation device; c. Include the date, company, permit number, task description, and any other needed information on the MIP form; d. Obtain a Safe Work Permit prior to performing any work.

27 No.: PA Page: 27 of PROCEDURE cont d Permission to Work cont d Worker or Crew Leader Responsibilities Prior to Work cont d e. Verify Zero Energy State f. Get crew to initial on the WCAF after their reading of the permit and understanding its conditions Changes Made to MIP after Work Has Begun When work is in progress and changes need to be made to the isolation procedure, the following steps must be taken: a. Remove employees from any work covered by the isolation procedure b. Have employees sign off (individual release) the Work Crew Accountability Form (WCAF) portion of the Safe Work Permit c. Have the work crew representative sign off (release) the existing Master Isolation Plan d. Change the isolation and revise the isolation procedure documentation, Safe Work Permit, Hazardous Energy Control Isolation sheet and/or Master Isolation Plan. Re-sign the Iso- Approval next to the current revision and indicate reason for revision and get the isolation reverified e. Communicate the changes to affected workers f. Have work crew representative sign on the MIP and have each worker sign on (acceptance of) the Work Crew Accountability Form (WCAF) portion of the Safe Work Permit prior to the resumption of work Test/Position of Equipment For situations in which Lockout Devices must be temporarily removed from the Energy Isolation Device and the machine or equipment energized to test or position the machine, equipment, or component, the following sequence of actions will be followed: a. Approval must be obtained from representatives the Operating/Owning Department and Authorized Employees. b. Machines or equipment must be cleared of non-essential tools and materials, and assurance made that components are operationally intact. c. Have employees initial off (release) the Work Crew Accountability Form (WCAF) portion of the Safe Work Permit and the acceptor signs off (release) the Master Isolation Plan.

28 No.: PA Page: 28 of PROCEDURE cont d Permission to Work cont d Testing shall be performed in this sequence: a. The work crew lockout devices are removed first, if attached. b. Operating/Owning Department lockout devices are then removed. c. Update the MIP with current changes. d. The Operating/Owning Department will then restore all valves, switches, etc. to their normal operating position and perform the test. e. Equipment/machines must be de-energized and energy control measures previously in place must be restored before servicing activities may resume. f. Update the MIP showing changes. g. Have work crew leader re-sign the MIP acceptance and then have each employee sign (initial) on the Work Crew Accountability Form (WCAF) portion of the Safe Work Permit prior to the resumption of work Work Crew Accountability All workers are required to be in control of the hazardous energy sources. The Work Crew Accountability Form (WCAF) serves as the administrative control to ensure the safety for every individual working behind hazardous energy sources. If the permit acceptor and signer of the MIP is the same person they are not required to sign on the WCAF The WCAF must reference all associated MIP s or energy isolations if the WCAF is on a separate sheet from the permit The permit acceptor will be responsible for ensuring that all affected workers sign (initial) on and off the WCAF The permit acceptor may not sign off (release) the MIP if all affected workers have not signed (initialed) off on the WCAF In the case where a tag or a lock or the WCAF or the MIP has not been removed or signed off by the person applying it or the owner cannot be identified, the Operating/Owning Department Supervision may remove the tag/lock/initial/signature only when all the following conditions are met: Positive verification that the employee responsible is not available; Notification to the employees Department/Company Supervision; Verification that the removal will not create an unsafe condition Completion of the Tag/Lock Removal Form.

29 No.: PA Page: 29 of PROCEDURE cont d Intra-Facility Tag Out When maintenance/servicing work requires isolation of common lines between BASF and an offsite facility outside of the immediate control of BTP, the Boundary Isolation (PA ) must be followed Removal of Lockout Devices after Completion of Work The work area will be inspected to ensure that nonessential items have been removed and to ensure that machine or equipment components are operationally intact The work area shall be checked to ensure that all employees have been safely positioned or removed from the unit. NOTE: Owning/Operating Department shall verify all workers on the WCAF have initialed off before allowing the acceptor to sign release on the associated MIP It must be verified that all individual workers have signed (initialed) off the WCAF, the "Release" section of the MIP must be signed, and the job status box checked complete. Before the isolation tags can be removed, the Shift Supervisor must review all paperwork, confirming the job is complete and all workers are off the job, then sign the removal authorization portion of the MIP releasing the equipment so the Tags/Locks can be removed. NOTE: If a worker or crew leader decided to attach a lockout device(s) to each energy isolating device, all lockout device(s) will be removed before allowing the acceptor to sign the MIP release All lockout devices shall then be removed by the person(s) applying them or the Designated Representative The Hazardous Energy Control Isolation sheet shall be updated (showing removed) as the Tag Out removal is ongoing until all isolation tags have been removed. Then the Hazardous Energy Control Isolation sheet shall be dated and signed all tags removed by person completing the tag removal The person who signs the Hazardous Energy Control Isolation sheet all tags removed will print their name on the MIP (remover s name) indicating isolation removal.

30 No.: PA Page: 30 of PROCEDURE cont d Removal of Lockout Devices after Work Completed cont d After lockout devices have been removed and before a machine or piece of equipment is started, affected employees shall be notified that the lockout device(s) have been removed All deviations and/or interlock by-passes will be reinstated All valves opened for clearing will be returned to original position and signed off on the valves opened for clearing sheet. Any Purple Lock that has been manipulated during the isolation must be placed back in its original safe service position upon removal of the isolation All blind flanges/plugs will be reinstalled and signed off on the blind flanges/plugs removed sheet The startup procedure will then be used to either ready the equipment for startup or to actually startup the equipment. When this is complete, the close out date on the MIP will be entered indicating job completion The MIP and all related documentation will then be turned into the Shift Supervisor. It shall be kept for 30 days In the case where a tag or a lock or the WCAF or the MIP has not been removed or signed off by the person applying it or the owner cannot be identified, the Operating/Owning Department Supervision may remove the tag/lock/initial/signature only when all the following conditions are met: Positive verification that the employee responsible is not available; Notification to the employees Department/Company Supervision; Verification that the removal will not create an unsafe condition; Completion of the Tag/Lock Removal Form. NOTE: All Affected Employees shall be informed before equipment is placed back into service via at least one of the following: shift relief, shift log, shift meetings, night orders, electronic white board, documentation on the MIP itself If the job is not complete, the Owning/Operating Department lockout devices will be left in place and the release section of the MIP must be signed and the job status box checked Incomplete. If a worker or crew leader decided to attach a lockout device(s) to each energy isolating device, all lockout device(s) will be removed before allowing the acceptor to sign the MIP release.

31 No.: PA Page: 31 of PROCEDURE cont d Removal of Lockout Devices after Work Completed cont d Long-Term Isolations: MIP s should not remain in effect nor should energy isolation tags be left on equipment that is idle or bottled-up for use at a later time. Status of such equipment should be communicated in the field using Process Information tags (see sec. 4.14). Out of service equipment should be evaluated for potential risks and isolated from other equipment using the Management of Change process Process Information Only Tags Process Information Only tags are used to convey process information. They can show material status, equipment out of service, or any specific instructions needed to be communicated at a given position in the process. A comment section is provided for more detail information. No time-based renewal requirements apply to this tag Violations Violations of tagging and/or hazardous energy isolation control procedures must result in disciplinary action up to and including termination of employment Training General Each department shall provide training to ensure that the purpose and function of this procedure is understood; and that adequate knowledge and skills are developed and maintained for the safe application and removal of energy isolation techniques Training Content A. BASF and Contingent Employees performing work as Authorized Employees shall receive training on the following: Content of this standard; Recognition of applicable Hazardous Energy Sources and their hazards; Type and magnitude of Energy Sources in the workplace; Use of adequate methods and means to control these sources, and the limitations of a Tagout system; Tags are essentially warning devices affixed to energy isolating devices, and do not provide the physical restraint on those devices that is provided by a lock;

32 No.: PA Page: 32 of PROCEDURE cont d Training cont d Training Content cont d When a tag is attached to an energy isolating device, it is not to be removed without authorization of the person responsible for it and it is never to be by-passed, ignored, or otherwise defeated; Tags must be legible and understandable by all employees Tags may evoke a false sense of security, and their meaning needs to be understood as part of the overall hazardous energy control program Use of equipment specific hazardous energy control procedures; The requirements for issuing a permit, and the necessary means to safeguard against the hazards posed during these activities. B. BASF and Contingent Affected Employees shall receive training in: The purpose and use of the site energy control program and how it may affect their specific work operation; The limitations of a Tagout system (see A. for details) C. BASF and Contractors Not Directly involved in the site s hazardous energy control program: Personnel not directly involved in the hazardous energy control program will receive awareness training for this and other safe work practices in accordance with the EHS curriculum assignment process Training Frequency for Affected Employees and Authorized Employees Training shall be delivered in accordance with the EHS curriculum assignment process. Retraining of an employee is required whenever: There is a change in job assignment affecting the level of participation in the program (i.e. an employee changes from an Affected Employee to an Authorized Employee). Deviations or inadequacies in an individual s performance of an applicable procedure indicate that lack of knowledge is a cause. An applicable equipment specific hazardous energy isolation procedure has been changed due to equipment or process changes or a new hazard is introduced.

33 No.: PA Page: 33 of PROCEDURE cont d Documentation for BASF and Contracted Employees Training will be documented, including: 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 Contractor Employees Refer to BC and PA for BASF Contractor EHS Management for requirements Management System Review Program Review Each site/unit shall review the effectiveness of the site/unit s program at least annually to ensure that the RCMS management systems are properly implemented and the elements adequately control exposures to Hazardous Energy. As a minimum, the following management system elements shall be included in the review: a review of the site/unit procedure and records to ensure that all currently required elements are included a review of all incidents and other non-conformance reports involving Hazardous Energy control activities that have occurred since the last management system annual review; review shall verify that root causes have been properly identified and that appropriate corrective actions have been implemented results of Periodic Inspections (Section ) for the energy control procedures Periodic Inspection (Using Attachment C Periodic Inspection Form) Periodic inspections shall be performed at least annually, based on twelvemonth intervals, to verify that each energy control procedure is adequate and being properly applied. Energy control procedures used less frequently than once a year need be inspected only when used. Energy control procedures or practices that are not required to be written per the exemption stated in Section still need to be inspected and reviewed to ensure that they are adequate and being properly utilized. The periodic inspection shall be performed by an Authorized Employee who is not currently involved in the being inspected (inspector).

34 No.: PA Page: 34 of PROCEDURE cont d Management System Review cont d Periodic inspection cont d For the purposes of Periodic Inspection, energy control procedures may be grouped together. Periodic Inspections shall be documented and include: An inspection of each Energy Control used during the service and maintenance activity A review of each employee s responsibilities under the inspected including interviews with Authorized Employees regarding their responsibilities, discussion of limitations or concerns with specified isolation methods, and determination if the procedure is adequate to provide the necessary protection; if not, what modifications are needed. A comparison of the procedure(s) against existing equipment design and layout A comparison of the procedure(s) against actual practices (i.e., observe the process as it is being performed) Name of inspector and Authorized Employees included in inspection Date of inspection Equipment-specific hazardous energy control procedure(s) inspected and on which machine/equipment procedure was used. Findings and corrective action, where applicable, of any deviations or deficiencies identified during the inspection NOTE: The inspector cannot apply any energy control devices or associated tags on the Energy Control (MIP) under inspection. The inspector must not sign off Lockout/Isolation Device Installed field on attachment A, nor sign off Iso Approval on attachment E Unit Review Requirements Notify site safety of all incidents involving the failure to control hazardous energy sources. Site safety must be notified of these incidents to meet annual review requirements Action Item Tracking Corrective actions resulting from the inspections shall be tracked to completion utilizing a tracking system and must be communicated to all Authorized and Affected Employees.

35 No.: PA Page: 35 of RESPONSIBILITIES 5.1. Site Manager The Site Manager has responsibility for ensuring the implementation of this procedure EHS Manager/Team Leader The EHS Manager/Team Leader has the primary responsibility for issuing, reviewing, administration, and/or interpretation of this procedure Operations and Maintenance Managers Implement the requirements of this procedure. Ensure that the requirements are being followed in their areas of responsibility. Ensure that training as per requirements is provided. Ensure that identified deficiencies are corrected and forwarded to site safety for review. Authorize, in writing, personnel, departments, and companies who can prepare and approve equipment isolation procedures in their areas. Verify they have training on this and other applicable BASF safety standards and have procedures to comply with them. Verify they are trained and qualified to perform the subject activities Verify they have a level of knowledge and experience with the operation/process (equipment, hazards, and controls) that is equal to any existing Operating/Owning Department personnel Permit Writer Ensure all applicable requirements in this standard are met prior to issuing Safe Work Permit. When issuing a SWP to a Designated Owner/Operator verify that they have procedures to meet the requirements of this standard, just as if they were the normal owner/operator (i.e. MIP, TSA, SOP, that addresses all aspects of this standard) Employees Prepare and approve isolation procedures if authorized. Isolate and verify isolations of equipment per procedure/requirements. Assign/issue MIP s. Communicate to acceptor of MIP the following: Positive I.D. of equipment. Isolation and method(s) used. Verification (testing) methods used. Any known potential hazards, safety precautions and requirements for the job.

36 No.: PA Page: 36 of RELATED DOCUMENTS OSHA 29 CFR N-ID-OSA 014 BASF Corporate Control of Hazardous Energy Sources PA Safe Work Permit PA Port Arthur Line Breaking PA Port Arthur Confined Space PA Bypassing Interlocks PA Safety System Valve Lockout PA Boundary Isolation EHS Plan OPEN-ENDED LINE AND WALK THE LINE PROGRAM Attachment A Hazardous Energy Control Isolation Sheet Attachment A Additional Hazardous Energy Control Isolation sheet Attachment B Lockout Device/WCAF Initial/MIP Signature Removal Form Attachment C Control of Hazardous Energy Inspection Form Attachment D Annual PA Review Form Attachment E Master Isolation Plan (MIP) Attachment F Energy Control addition sheet Attachment F MIP additional sign on sheet Attachment G Valves Open for Clearing and Blind Flange/Plug Removal Form Attachment H Work Crew Accountability Form (WCAF) Attachment I Isolation Tag PVC Attachment J Process Information Tag PVC N-R-OSA-001-EN-M Occupational Safety and Industrial Hygiene

37 PA Hazardous Energy Control Isolation Sheet Attachment A Item Tagged/Locked Out MIP# Reason for Tag/Lock Out Sheet of Date: Time: Tag Number Tagout/Lockout Isolation Device Blind Valve Original Position Valve Tagged Installed Verified Y N Open Closed Open Closed 0 Energy Verified (bleeds, vents, breakers)* Location Tagout/Lockout Isolation Device Applied Blinds Plugs Reinstated Tagout/Lockout Isolation Device Removed By *Initials of the person verifying Zero Energy State in this column indicate the energy source has been de-energized. All Hand/Off/Auto switches should be placed in the off position and all DCS start permissives should be removed after the try step has been completed and prior to equipment being re-energized. SPECIAL INSTRUCTIONS/PRECAUTIONS: Tag Out Removal Owning/Operating Dept. - All tags removed Date: Effective: 07/2018 Approved by: EHS Manager

38 PA Additional Hazardous Energy Control Isolation Sheet Attachment A MIP# Sheet of Tag Number Tagout/Lockout Isolation Device Blind Valve Original Position Valve Tagged Installed Verified Y N Open Closed Open Closed 0 Energy Verified (bleeds, vents, breakers)* Location Tagout/Lockout Isolation Device Applied Blinds Plugs Reinstated Tagout/Lockout Isolation Device Removed By *Initials of the person verifying Zero Energy State in this column indicate the energy source has been de-energized. All Hand/Off/Auto switches should be placed in the off position and all DCS start permissives should be removed after the try step has been completed and prior to equipment being re-energized. Effective: 07/2018 Approved by: EHS Manager

39 PA Lockout Device/WCAF Initial/MIP Signature Removal Form Attachment B Date: Time: Location: Equipment Locked Out: Tag/Lock Owner: Supervisor (if a non-basf servicing crew): Date/Time Servicing Crew Supervisor Notified (if applicable): Attempt made to notify employee? Date/Time Attempted to Notify Employee: Area checked prior to equipment startup? Maintenance Coordinator consulted? Shift Supervisor Signature: Operations Coordinator Signature: Verbal Approval: Date: Time: Maintenance Coordinator Signature: Verbal Approval: Date: Time: Tagout/Lockout Device/WCAF Initial/MIP Signature Removed by: (Print and Sign) Tagout/Lockout Device/WCAF Initial/MIP Signature owners signature upon notification that they were removed: Comments: Effective: 03/08/11 Approved by: EHS Manager

40 PA SITE: Control of Hazardous Energy Sources Periodic Inspection Form DATE: Attachment C EQUIPMENT / MACHINE(S): PRODUCTION OPERATOR / SUPERVISOR: SERVICING DEPARTMENT (NAMES): INSPECTOR(S) (must be an authorized employee and not involved in the current Lockout under inspection) A check mark in the yes box for an item indicates that item is in place and effective. A check mark in the no box for an item indicates there is a deficiency related to that item. The details column should record what was examined in order to indicate yes or no. When no yes or no indication is given for an item, an explanation must be given in the details column indicating why the item was not applicable. All nonconformances must be entered into site non-conformance tracking database for follow-up through closure. Verify By Review of Work-in-Progress Yes No Item Details 1 Were the necessary permit(s) and instructions available in work area? 2 After examination of the active permit, was work approval authorization documented on permit? 3 After examination of the work area and discussion with affected employees, was the pre-isolation activity notification to affected stakeholders adequate (shift meeting, night orders, E-log, verbal instruction, etc.)? 4 For work that is exempted from permitting, was the isolation and control completed per the equipment specific hazardous energy control procedure? Did the procedure adequately address all the applicable hazards and verify zero energy? Were the procedure and all precautions in place and implemented as intended? 5 After review of the active permit and discussion with personnel involved in the work activity, was the permit issuance process in the site procedure followed? For example, did the Permit Issuer and the individual(s) performing the work meet at the work site and review the permit? Was isolation verified per the equipment specific hazardous energy control procedure prior to the work being authorized, etc.? Effective: 05/31/18 Approved by: EHS Manager

41 PA Control of Hazardous Energy Sources Periodic Inspection Form Attachment C Yes No Item Details 6 Does the procedure specify steps for the following? Shutting down Isolating Blocking Securing, Dissipating stored energy, and Verification? 7 Does the procedure specify steps for the placement, removal, and transfer of lockout or tagout devices and the responsibility for them? 8 When drawings or other documents were used to determine the isolation or preparation plan, did the documents reflect as-is conditions? 9 After examination of the work area and the active permit, was the equipment specific hazardous energy control procedure adequately performed? Was proper verification of the zero-energy state per the equipment specific hazardous energy control procedure indicated on the permit? Were these safeguards in place prior to beginning the work? 10 Are provisions to ensure continuity of Tagout among changes in Personnel or shifts adequate? Is MIP verified & approved by owning/operating department prior to acceptance by servicing group(s)? MIP released as complete by all servicing groups prior to removal authorization by shift supervisor? Is remover s name and date signed to signify close-out of the MIP? 11 After examination of the work area and discussion with affected employees, was there proper notification to those affected prior to putting equipment back into service? 12 Based on interview, do stakeholders (Permit Issuers, persons performing the work, affected employees,) understand their roles and responsibilities? 13 Based on interview, do stakeholders communicate any limitations or concerns with the isolation methods specified by the procedure? 14 Based on interview, is the procedure adequate to provide necessary protection, and if inadequate, what modification(s) is needed? Effective: 05/31/18 Approved by: EHS Manager

42 PA Annual PA Review Form Attachment D SITE: Control of Hazardous Energy Sources Review Checklist DATE: A Management System is a collection of programs, operations, people, documents, policies, guidelines, procedures, facilities, and equipment implemented to effectively satisfy an objective. It is independent of an individual expertise and contains checks and balance to ensure sustainability. PLAN DO CHECK ACT/REPORT BC , Control of Hazardous Energy Sources; Site procedure for Isolation activities; Permits for isolation activities Examples (all may not be applicable): Pre-work area assessments and evaluations; prework isolation and preparation techniques; permit issuance and work authorization process; work-in-progress review; coordination and communication among affected stakeholders. Examples (all may not be applicable): Closed permit reviews, including documentation and retention; training verification; previous site management system review; equipment calibration and maintenance records. Correct deficiencies; assess and review effectiveness; report to stakeholders A check mark in the yes box for an item indicates that item is in place and effective. A check mark in the no box for an item indicates there is a deficiency related to that item. The details column should record what was examined in order to indicate yes or no. When no yes or no indication is given for an item, an explanation must be given in the details column indicating why the item was not applicable. All non-conformances of the Line Breaking management system must be entered into site non-conformance tracking database for follow-up through closure. PLAN Yes No Item Details Has the corporate procedure been revised since the last annual review? If the corporate procedure requirements are found in more than one site procedure, all site procedures must be reviewed. Have any advisories or alerts been issued since the last annual review? If so, does the current site procedure contain all required elements? If the advisory or alert requirements are found in more than one site procedure, all site procedures must be reviewed. Have changes taken place at the site since the last annual review that affect the site isolation procedure? If so, is the current site procedure accurate? Are affected stakeholders involved in the development and/or revision of the site procedure(s)? Is the current site permit thorough, accurate, and reflective of the site procedure requirements? If the site uses more than one permit for isolation activities, as defined in the corporate procedure, all site permits must be reviewed. Is there evidence to show only the current version of the site safe work permit(s) and other records related to isolation are in use? Effective: 05/31/18 Approved by: EHS Manager

43 PA Annual PA Review Form PLAN Are there means to provide opportunity for feedback and communication with affected stakeholders, including contractor and contracted employees? Examples include permit debriefing after work is complete; start-of-shift safety talks; safety meetings; etc. Do stakeholders (Permit Issuers, persons performing the work, affected employees, EHS) understand their roles and responsibilities? Attachment D DO Verify by review of work-in-progress Yes No Item Details Were the necessary permit(s) available in work area? Permit # for work-in progress reviewed: After review of the active permit and discussion with personnel involved in the work activity, was the permit issuance process in the site procedure followed? For example, did the Permit Issuer and the individual(s) performing the work meet at the work site and review the permit, was isolation verified to be in place per the equipment specific hazardous energy control procedure prior to the work being authorized, etc. After examination of the work area and the active permit, was the equipment specific hazardous energy control procedure adequately performed? Was proper verification of zero energy state per the equipment specific hazardous energy control procedure indicated on the permit? Were these safeguards in place prior to beginning the work? For work that is exempted from permitting, was the isolation completed per the equipment specific hazardous energy control procedure? Did the procedure adequately address all the applicable hazards (verified zero energy)? Were the procedure and all precautions in place and implemented as intended? When drawings or other documents were used to determine the isolation or preparation plan, did the documents reflect as is conditions? After examination of the active permit, was work approval authorization documented on permit? After examination of the work area and discussion with affected stakeholders, was the pre-isolation activity notification to affected stakeholders adequate (pre-shift talks, postings, etc.)? After examination of the work area and discussion with affected stakeholders, was there proper notification to affected stakeholder s prior putting equipment back into service? Permit Issuer: Person(s) performing work: Effective: 05/31/18 Approved by: EHS Manager

44 PA Annual PA Review Form Attachment D CHECK Yes No Item Details Check training records for the permit issuer and/or person(s) performing the work from the work-in-progress review. Was the required training delivered according to the EHS curriculum assignment process? Was the training documented? Were the training records retained as required? Based on a review of incidents involving the control of hazardous energy source activities, were all root causes properly identified in the incident report(s)? Do the corrective actions in the incident report address the root cause(s)? Are the corrective actions being implemented in a timely manner? Were common trends observed for the collection of incidents that were not addressed by the corrective actions for individual incidents? Were common trends used to develop site goals, targets and objectives for site management? Report/ACT Yes No Item Details Based on review of the previous annual management system review, is follow-up on non-conformances adequate? Were results of the previous review communicated to stakeholders in a timely manner? Unit/Site Reviewed Reviewer Signature Review Completion Date Effective: 05/31/18 Approved by: EHS Manager

45 PA MASTER ISOLATION PLAN (MIP) Example MASTER ISOLATION PROCEDURE Attachment E MIP # Equipment/System: Job Description(s): Iso- Approval Document Version Approval Date Isolation Verified By Verified Date Comments: List reason(s) for revisions, other. Original Rev. 1 Rev. 2 Rev. 3 Rev. 4 Rev. 5 Rev. 6 Removal Authorization (Person/Position) Remover s Name Date Closed Out Comments: MIP Acceptance Signature Date Company Permit No. MIP Release Signature Job Status Comp. Inc. Task Description Comments: Effective: 08/19/15 Approved by: EHS Manager

46 PA MASTER ISOLATION PLAN (MIP) Example Attachment E Yes N/A All Hazardous Energy sources are identified in procedure (drawing, P&ID, description) Sequence for shutdown, clearing, and start up included where it affects safety Method(s) used to isolate each Hazardous Energy source is listed Steps to release stored energy after isolation Automatically controlled or interlocked equipment verification addressed Nuclear gauge has been tagged out by RSO or designee for CSE attached or listed below (RSO or designee Signature) Hazard Energy Type Energy Magnitude ENERGY CONTROL Method used to clear and/or release energy (flushed, purged, steamed, grounded, cooled, isolated breaker, etc.) Verification Retest Frequency Verification Method (checked flush water, analyzer sniff, ph, etc.) developed/drawn by: Approved by: Date: Date: Effective: 08/19/15 Approved by: EHS Manager

47 PA Attachment F MASTER ISOLATION PLAN (MIP) Additional Form ENERGY CONTROL MIP# Hazard Energy Type Energy Magnitude Method used to clear and/or release energy (flushed, purged, steamed, grounded, cooled, isolated breaker, etc.) Verification Retest Frequency Verification Method (checked flush water, analyzer sniff, ph, etc.) Effective: 03/08/11 Approved by: EHS Manager

48 PA Attachment F MASTER ISOLATION PLAN (MIP) Additional Form MASTER ISOLATION PROCEDURE Equipment/System: Job Description: MIP Acceptance Signature Date Company Permit No. MIP Release Signature Job Status Comp. Inc. Task Description Comments: Effective: 03/08/11 Approved by: EHS Manager

49 PA Attachment G Valves Open for Clearing and Blind Flange/Plug Removal Form Date: MIP# Sheet of Blind Valve Opened NNO Bleed Flange/Plug for Clearing Opened Removed Yes No Yes No Yes No Location of Valve Open or Blind Flange/Plug Removed Restored to Normal Operating Condition by: Effective: 07/2018 Approved by: EHS Manager

50 PA Work Crew Accountability Form (WCAF) Attachment H Date: MIP Number: (If applicable) WORK CREW MEMBERS (Print full name) On Off On Off On Off (Initial to indicate status of job assignment) 22. Before any lockout device can be removed by equipment Owner/Operations, all identified Service personnel on this permit must be signed (initial) off. If not, equipment Owner/Operations must follow the requirements of PA Control of Hazardous Energy Isolation. Crew Leader or permit acceptor is accountable for: a. Reviewing all the requirements of this permit with each member of the service work group b. Obtaining names and recording workers on/off the job c. Posting permit at job site d. Returning completed permit field copy back to originator. Note: If more sheets are needed, attach additional pages to this sheet. Effective: 03/08/11 Approved by: EHS Manager

51 PA Isolation Tag - PVC Attachment I Effective: 03/08/11 Approved by: EHS Manager

52 PA Process Information Tag - PVC Attachment J Effective: 03/08/11 Approved by: EHS Manager