Corporate Function: Ecology & Safety Procedure No.: WYN032.048 Page: 1 of 7 Preparer: Owner: Approver: EHS Hub Team Member EHS Hub Team Member EHS Hub Manager A Corporate Procedure does not exist for this subject matter. The WYN procedure is a standalone procedure and provides specific site guidance and requirements for the Wyandotte site Revision Date Revision Number 05/2001 Original Document 06/08 1 11/1/2012 2 Revision History Details of Change Revised to reflect new format and to define Wyandotte Out of Service Program requirements Revised document based on 2010 EHS Management Review and findings from recent EHS Wyandotte Audits; standard defined specific program requirements for Out of Service equipment, including identification, process to remove and return out of service equipment using MOC process. Note name change from Operation Control Tags to Operation Control Out of Service Equipment Program.
Procedure No.: WYN032.048 Page: 2 of 7 1. PURPOSE This procedure establishes the standard work practices for identifying, marking and managing Out-of-Service equipment and areas within the Wyandotte site. The procedure was developed to prevent unauthorized use or access to such equipment or areas which may cause injury to personnel or damage to equipment. The procedure was developed to address the tag out of equipment that is out of service for an extended period of time, tagged out for seasonal operations and tagged out for short periods of time for other operational reasons. 2 SCOPE 2.1 This procedure applies to all departments and units on the BASF Wyandotte site and includes Operational Tagging of Equipment, including tagging equipment Out of Service, tagging equipment for seasonal operation, and tagging equipment for other short-term operational reasons. 2.2 This procedure should not be used for: 2.2.1 Tagging equipment for safe work permits used in preparation of equipment for work by service groups or for repair work performed by operating personnel. Those procedures are described in WYN032.010, Lock, Tag and Try. 2.2.2 Tagging equipment for commissioning. 2.2.3 Tagging equipment, devices, or wiring that are left in an unfinished state during construction or demolition activities. 3. DEFINITIONS 3.1 Abandoned-in-place equipment This is any equipment that has been permanently removed from operational service but has been left in place to avoid costs of removal. This equipment is not expected to be returned to its original operational use. 3.2 Energy Isolating Device (EID) A device that physically prevents the transmission or release of energy. An EID is capable of being locked out if it has a built-in locking mechanism, or has a means of attachment to which, or through which, a locking mechanism can be affixed. 3.3 Energy Source Any source of electrical, mechanical, hydraulic, pneumatic, chemical, thermal or radiation energy, including residual or stored energy of any type.
Procedure No.: WYN032.048 Page: 3 of 7 3.4 Idled Equipment Any equipment that has been taken out of operational service for an undetermined period of time that is not currently being service or maintained by operations or onsite contractor maintenance team members. This equipment is expected to be returned to operational service at some future times which require an MOC to restore. 3.5 Out-of-Service Equipment To be used when a piece of equipment is taken out of service or abandoned in place and is not undergoing repair covered under WYN032.010, Control of Hazardous Energy. 4. PROCEDURE Out of service tags are to be used only to warn against potential hazards and to caution that special procedures must be followed. Above tags must conform to design, color, lettering, etc., as specified in MIOSHA Part 37- Accident Prevention and Tags (OSHA 1910.145). Other tags for particular purposes can also be used. However, it must be remembered that the use of tags is a temporary means of warning of a hazardous condition until positive means are established to eliminate the hazard. 4.1 Abandoned-in-place Equipment 4.1.1 The operating/owning department will ensure that the equipment that is to be abandoned-in-place has been properly shut down in accordance with this standard. The installation and removal of tags is restricted to operations personnel under the authority of the management supervision of the facility. a. Abandoned-in-place equipment will be cleaned to remove any chemical hazards that have been associated with the equipment while it is operational. b. Abandoned-in-place equipment that contains ozone-depleting substances (ODS) will have the ODS properly evacuated and removed from the site for reclamation by a certified vendor in accordance with the Wyandotte Site Refrigerant Management Plan. c. Whenever possible all active energy/utilities shall be physically disconnected and separated from affected equipment. Attempts should be made to provide approximately two foot piping separation. Appropriate line closures should be utilized such as plugs, caps, blind flanges, etc.
Procedure No.: WYN032.048 Page: 4 of 7 4.1.2. Each respective Wyandotte s unit/department is responsible for securing and isolating the equipment to ensure that all energy sources have been isolated and that the process material sources are disconnected. a. In addition to isolating equipment from normal electrical power sources, additional precautions may be necessary to isolate the process, utility feed, emergency electrical, and/or discharge lines to properly secure the equipment. Where the energy/utility source cannot be readily disconnected it should be isolated using two methods as follows: A valve and a slip blind for piping Disconnecting power supply from motor switchgear in the motor starters and securing the power switch off with a tamperproof weather resistant seal. b. Care must be taken to ensure that residual or stored energy sources (for example: springs, elevated moveable components, rotating fire wheels, hydraulic and pneumatic systems) are reduced to their zero mechanical/energy level. 4.1.3 Each Wyandotte site operating/owning department responsible for securing and isolating the equipment will TRY the primary operational switches to verify the circuit and equipment are de-energized and in a safe position. 4.1.4 The operations/owning department responsible for securing and isolating the equipment will place standard Out-of-Service/Out-of-use (OOS) lock and tags on the equipment and the EID s used to isolate the equipment. The locks used must be different from and in addition to any standard locks used as part of each units Control of Hazardous Energy program. 4.1.5 Each unit/group is responsible to ensure a process is in place to manage the Out-of-Service Program within their respective area. 4.2 Idled Equipment 4.2.1 The Operations/owning group will ensure that the equipment that is to be idled has been properly shut down in accordance with the Wyandotte site Control of Hazardous Energy procedure and this procedure. 4.2.2 The Operations/owning group are responsible for securing and isolating the equipment and will ensure that all energy sources have been isolated and that process material sources are secured and depressurized. a. Whenever possible, equipment should be cleaned of chemicals. If this is not feasible, the hazards of the chemical or residue must remain on the vessel/equipment as part of the site hazard communication standard.
Procedure No.: WYN032.048 Page: 5 of 7 b. Idled equipment that contains ozone-depleting substances (ODS) and that is being mothballed for an extended period of time will have the ODS properly evacuated and removed from the site for storage by a certified vendor in accordance with the Wyandotte site Refrigerant Management Program. 4.2.3 The Operations Group is responsible for securing and isolating the equipment and will TRY the primary operational switches to verify the circuit and equipment are de-energized and in a safe position. 4.2.4 The Operations Group is responsible for securing and isolating the equipment and will place the unit/group agreed upon standard Out of Service locks and tags on the equipment and the EIDs used to isolated the equipment. Units will use the standard Wyandotte site Out of Service Tags in accordance with this procedure, not the regular red tags used as part of the Wyandotte Control of Hazardous Energy Procedure. In addition locks being used as part of the Out of Service Equipment program must be unique and different than the locks used as part of the Wyandotte Control of Hazardous Energy Program. 4.2.5 Returning idled equipment back into service requires the following steps: a. The initial step requires the application of the Management of Change Process to identify which equipment is being returned back into service. b. The Operations Group assigned the responsibility of preparing the equipment for service will replace each OOS lock with a lock controlled through the application of the Wyandotte site Control of Hazardous Energy process, including documentation of all process steps in combination with the Wyandotte Site Safe Work Permit and the Wyandotte Master Tag Sheet. c. Restoration of the equipment to service will then follow the work completion of the Control of Hazardous Energy process. d. Each unit/group is responsible to ensure a process is in place to manage the Out-of-Service Program within their respective area. 4.3 Out of Service Equipment Control 4.3.1 Cable tie wraps or stainless steel car seals (outside) shall be used to secure Abandoned-in-place Equipment or Idled Equipment in OOS status will be marked with appropriate identification. Files will be maintained as records preferably in Documentum.
Procedure No.: WYN032.048 Page: 6 of 7 4.4 Out of Service Tags 4.4.1 Out of Service tags are to be dated and signed in the designated places prior to installation. A statement as to why equipment is not to be operated is to be noted on danger or out of service tags. The Out of Service tag must only be removed by the person/department responsible for placing the tag. 4.4.2 Special instructions covering operation of equipment is to be noted on reverse side of the "Caution" tag. These instructions may relate to allied equipment as well as item tagged. Due to space limitations, notation on card may simply refer to special instructions obtainable from supervision. 4.4.3 Tags are to be removed as soon as the special conditions relating to their use no longer apply. As part of the process, once the tags are removed a Management of Change shall be initiated. 4.5 Program Review Each unit needs to develop a process to ensure that Out-of-Service tags are being either attached or removed from equipment that meets the definition of abandoned or Out-of-Service equipment. 5. TRAINING 5.1 Personnel who are assigned responsibility for placing equipment into or out of OOS status must have an understanding of the requirements of this procedure prior to starting any tasks associated with OOS equipment. 5.2 Training will be conducted and documented in accordance with each unit/group EHS training program. 5.3 Contractors whose work activities may involve or be affected by an Out-of-Service piece of equipment/process will be informed of this procedure on a case-by-case basis. If applicable, each contractor is responsible to train their employees in the application of this procedure to their assigned work. 6. RESPONSIBILITIES 6.1 Hub EHS Hub EHS personnel are responsible for the initiation, issuance, and interpretation for this procedure. 6.2 Site Units/Groups Each unit/group on the Wyandotte site is responsible for the administration and implementation of this procedure.
Procedure No.: WYN032.048 Page: 7 of 7 6. ATTACHMENTS Appendix A Wyandotte Out-of-Service Tag 7. RELATED DOCUMENTS Description of Procedure Corporate No. Wyandotte No. Lock, Tag, Try of Controlled Hazardous Energy Sources BC032.014* WYN032.001 Wyandotte Safe Work Permit WYN032.054A Wyandotte Out-of-Service tag WYN032.048A