No.: GSS25 Page: 1 of 13 Geismar Site Reviewed: 11/27/17 Effective: 11/27/17 Supersedes: 11/01/17 Preparer: Owner: Approver: SIH Team Leader LA Hub EHS Director RECORD OF REVISIONS Date Details of Change 03/09 Added definitions for Utility Service and Acutely Toxic Incorporated hose requirements currently covered in MP-08 and BC032.006. Eliminated requirement for annual inspection of air, water, and nitrogen hoses. Eliminated redundant design requirements referenced in BC032.006. Rearranged several sections. Added prohibition against use of Chicago-style couplings on potable water systems. 10/09 Added potable water hose and connector requirements (4.2.7). Added allowance for hoses to be coiled when pressure testing with inert gas (4.4.2) Added Attachment A Electrical Resistance Testing 01/29/10 Added Flex-Master 250 as an approved washdown hose. 03/10/12 Added definition of Higher Hazard Chemical and Lower Hazard Chemical Updated the Table of Inspection Frequencies to include Lower Hazard Chemicals 04/16/12 Updated section 4.2.8 to incorporate requirements from GSS21 (Nitrogen Assembly). 09/30/13 Revised 4.1.11 to state that Chicago couplers are limited to <110 psig in air pressure service, rather than the previously stated any pressure service. 07/25/14 Added 4.3.5 and Attachment B related to non-basf hoses. 04/04/16 Added 4.4 related to Inert Gas Purge Hoses 04/27/17 Revised 4.4.1 10/5/17 Amended scope to include permanently installed hoses. Revised 4.5 to only apply to portable / temporary transfer hoses. Added 4.6 (inspection of permanently installed hoses). 11/27/17 Replaced EHS BC References
No.: GSS25 Page: 2 of 13 Geismar Site Reviewed: 11/27/17 Effective: 11/27/17 Supersedes: 11/01/17 Preparer: Owner: Approver: SIH Team Leader LA Hub EHS Director 1. PURPOSE The purpose of this procedure is to establish a minimum standard for the types and applications of hoses, clamps, and fittings. 2. DEFINITIONS 2.1. Acutely Toxic A chemical with a LC50 <200 ppm (<2 mg/l) for 1 hour (inhalation) or LD50 of <200 mg/kg (dermal). 2.2. Dedicated Chemical Hose A hose that is committed to a specific chemical service. This hose shall not be used with incompatible chemicals. 2.3. Higher Hazard Chemical Flammable gases or liquids, or other toxic or corrosive materials with a NFPA hazard rating (H, F or I) 2 or HMIS hazard rating (H, F or P) 2. 2.4. Lower Hazard Chemical Finished products or raw materials with NFPA or HMIS hazard ratings <2. 2.5. Special Purpose Hoses A customized hose, other than what is identified in this procedure, with specifications related to the intended service and pressure. 2.6. Utility Service Hoses used for cold or hot water, potable water, plant air, nitrogen, or steam. 2.7. Worm Drive Clamp Otherwise known as a hose clamp that uses a threaded screw to tighten the clamp on the hose and fitting. 3. SCOPE This procedure applies to the following: hoses and associated clamps/fittings designed to be routinely connected and disconnected for the purposes of transferring utilities, process chemicals, finished products, or raw materials; permanently installed hoses in piping systems and/or directly connected to permanently installed plant equipment (examples include, but are not limited to,
No.: GSS25 Page: 3 of 13 vibration or weigh cell isolators, hydraulic system hoses, refrigerant system hoses, etc.). This procedure DOES NOT apply to the following: tubing or tubing systems; fire water system hoses. 4. PROCEDURE 4.1. GENERAL REQUIREMENTS: Apply Only to Portable / Temporary Transfer Hoses 4.1.1. The use of hoses for movement of chemical gases or liquids will be avoided, where practical. Permanent applications shall employ appropriately designed, permanently installed piping. 4.1.2. The maximum allowable working pressure (MAWP) of the hose assembly must consider the end fittings used and the method of attachment that could render the hose assembly MAWP less than that of the hose material. If this is the case, hose assemblies must be marked with the reduced MAWP. Utility air and water hoses purchased from the Purchasingapproved vendor come with the reduced MAWP stenciled on the hose. 4.1.3. The hose connections for Utility and other process systems must be designed to direct the discharge in a manner that minimizes the potential for employee exposure. 4.1.4. Hoses shall be fitted with the appropriate gaskets or O-rings, securely connected, and mechanically sound. 4.1.5. Hoses not in use shall be coiled and hung or returned to a recognized storage area. When storing hoses, excessive bending and/or kinking must be avoided. 4.1.6. Hoses in use should not be placed across normal walkways or aisles, where they may be potential tripping hazards. Where this is not feasible, adequate precautions must be taken to identify the potential trip hazard. 4.1.7. In all instances where hose (s) are laid across roads or areas where vehicles may pass, the hose (s) will be protected (ex. by placing planking on either side of the hose (s) to bear the weight of the vehicle or through use of another type of protective device)
No.: GSS25 Page: 4 of 13 4.1.8. Prior to disconnecting a hose, the pressure shall be bled off. Bleeds or other means of safe pressure dissipation, will be provided for hoses used in pressure service. 4.1.9. The use of damaged hoses shall be avoided. If crimps or kinks are found at the ends of the hose, they may be removed and the couplings replaced. Such repaired hoses must be re-tested in accordance with N-ID-OSA 006 before they are returned to use. 4.1.10. Hose splicing is prohibited. 4.1.11. The use of worm drive clamps is prohibited. 4.1.12. When Chicago type couplers are used in air pressure service, they must be wired or clipped and not used in services over 110 psig, unless the coupler is specifically rated for >110 psig. 4.2. UTILITY SERVICE 4.2.1. Specifications for materials of construction, pressure rating, couplings, and safety factors for hoses in Utility Service must be consistent with current BASF Technical standards for Utility Stations (11-130-15). 4.2.2. Hoses for Utility Service shall be color coded as follows: Plant air Green Service Water Green Demin Water Blue Steam - Red Nitrogen White Strahman or Flex-Master 250 Wash hoses Black 4.2.3. If Utility hoses are assembled on plant site, a hose clamp band-it tool and locking band clamps must be used. 4.2.4. Steam or water hoses used in Class 1 Div. 1 areas must: A. Not exceed 10 6 ohms resistance as measured between the end fittings; B. Not exceed a surface resistance of 10 9 ohms as measured on the outside surface if the outside diameter exceeds 3 cm; and C. Be marked to identify that they meet these requirements to prevent electrostatic charge accumulation.
No.: GSS25 Page: 5 of 13 4.2.5. Air A. Breathing air line couplings shall be incompatible with outlets for other gas systems to prevent inadvertent use of air line respirators with non-respirable gases or oxygen. B. Hoses for plant air service should not be used for nitrogen or steam. C. Chicago and Aeroquip couplings will be used on all pneumatic tools. The valved coupling will be installed on the pressurized (i.e., hose) side of the connection to shut off flow when the tool is disconnected. D. For permanent couplings to a pneumatic tool, the conventional air hose nipple with a barbed shank and threaded end for the tool may be used. E. When Chicago couplings are used in air service, safety clips shall be used at all times the hose is under pressure. 4.2.6. Service water A. Home-type garden hoses are permitted only on potable water systems. B. Chicago-style couplings shall not be used on potable water systems. 4.2.7. Potable Water A. Chicago-style couplings shall not be used on potable water systems. B. Only hose bib-type connectors shall be used on potable water systems. C. Only garden type hoses shall be connected to potable water systems. 4.2.8. Nitrogen A. Hoses designated for nitrogen service should be used only for nitrogen. B. Nitrogen hoses and connections shall be supplied with coupling incompatible with other gas systems. Fittings shall be Teflonimpregnated, permanently attached Thor couplings. C. Couplings must have a positive means of locking. D. Jumpers are not allowed at utility service for nitrogen. E. Chicago type couplings are prohibited for use in nitrogen connection on hoses or service, except at loading/unloading stations
No.: GSS25 Page: 6 of 13 when customer-furnished fixed couplings do not match site couplings. The following specific expectations must be followed: E.1. E.2. E.3. Such an arrangement may be used only upon cluster manager approval; Must be tagged with identification of the area and inspected by the cluster supervisor for control; May not be loaned to other areas of the plant and shall stay in loading/unloading areas only; E.4. E.5. The fitting arrangement shall never be hooked to the Utility manifold and never left attached to the nitrogen hose when not in use; and This fitting arrangement must be properly stored when not in use to prevent unauthorized use. 4.3. CHEMICAL SERVICE 4.3.1. Selection of Hose A. Each Owning Department will specify the hoses and fittings to be used for particular chemical service. This specification will include consideration of compatibility, pressure rating, temperature rating and wear. B. Couplings used for chemical service are required to have a positive means of locking. C. In all instances of steaming, washing or transfer of chemicals in hoses, a double block and bleed must be utilized to bleed off pressure before disconnecting. 4.3.2. Hoses used to transfer flammable liquids must: A. Not exceed 10 6 ohms resistance as measured between the end fittings; B. Not exceed a surface resistance of 10 9 ohms as measured on the outside surface if the outside diameter exceeds 3 cm; and C. Be marked to identify that they meet these requirements to prevent electrostatic charge accumulation. 4.3.2 Hose bands on chemical process hoses must be as per manufacturer s recommendation (check with supply vendor).
No.: GSS25 Page: 7 of 13 4.3.3 All hoses put into chemical service must be pressure checked with nitrogen first. 4.3.4 Hoses used in chemical service must be emptied, cleared or cleaned after each use to the extent appropriate to the service. 4.3.5 Non-BASF Owned Hoses Non-BASF owned loading/unloading hoses, which are used to handle Higher Hazard Chemicals and that will be connected to BASF owned equipment/processes, must be tested / inspected by the owner according to the criteria in Table 1 or by a comparable procedure that is approved by BASF. Refer to Attachment B for a list of companies whose hose inspection programs have been approved by Site EHS. 4.4. INERT GAS PURGE HOSES 4.4.1. The use of any quick connect fitting for welding, cutting, or purging gases is prohibited. A. This includes, but is not limited to, the following: Acetylene, oxygen, argon, nitrogen, and other purge gas mixtures. B. Only original equipment threaded fittings will be allowed. 4.4.2. Purge hoses may not be black in color. 4.5. INSPECTION OF PORTABLE / TEMPORARY TRANSFER HOSES 4.5.1. Before each use, the user must perform a visual inspection that includes the following: A. Signs of damage to the hose (ex. Cuts, cracks, wear, kinking, brittleness or blistering) B. End fittings are intact with the contact faces showing no signs of damage or grooving. C. Clamps and gaskets are free from defects or damage; and D. The compatibility of the hose is correct for the service. 4.5.2. Each Owning Department will conduct periodic inspection and testing for all hoses, not to exceed 3 years, except as specified in Table 1. Minimum inspection requirements must include: A. Visual inspection of the hose, fittings, and clamps; B. Verification of any required markings; C. Compatibility of the hose for the assigned service;
No.: GSS25 Page: 8 of 13 D. An electrical resistance test as applicable (i.e., for flammable liquids and steam or water hose used in Class 1 Div. 1 areas). Refer to Attachment A. E. Additional leak testing with an appropriate gaseous agent at pressures not exceeding the MAWP, when fugitive emissions are a concern or the consequences of leaks are unacceptable; and F. Additional tests as indicated in Table 1. 4.5.3 Each Owning Department must have a method to verify that testing and inspection has been done. This may include written documentation, or color-coding or tagging of hoses. A. The following color-code scheme may be used to indicate when a hose was last inspected/tested: Last # in Year Color 0 or 5 Orange 1 or 6 Blue 2 or 7 Green 3 or 8 Brown 4 or 9 Yellow B. The color code bar should be approximately 6 wide and placed next to the fittings at each end of the hose. Colored tape may be used in lieu of paint. 4.5.4 Hoses that do not pass inspection or testing must be marked and removed from service until repaired, or they must be destroyed and discarded. 4.6 INSPECTION OF PERMANENTLY INSTALLED HOSES 4.6.1 Each Owning Department shall complete a risk assessment of all permanently installed hoses in their area(s) and establish the appropriate level of inspection/testing and/or replacement frequency for all hoses in this category. The Owning Department shall retain any/all documentation associated with this risk assessment. 4.6.2 Upon completion of risk assessment, options for inspection and testing may include (but are not limited to) visual inspection via the plant fixed equipment mechanical integrity program (if the hose is part of an established fixed equipment inspection in the mechanical integrity program), routine visual inspection by Operations or another entity, timebased replacement on an established frequency, pressure testing on an established frequency, etc.
No.: GSS25 Page: 9 of 13 4.6.3 The inspection/testing requirements shown in Table 1 of this document are not required for permanently installed hoses, but may be used as general guidance. 4.6.4 Inspection records for hoses in this category shall reside with the Pressure Equipment Group if the hose is inspected as part of an established fixed equipment mechanical integrity inspection, or with the Owning Department if inspection/testing/replacement of the hose is managed entirely within said department. 5. RELATED DOCUMENTS BASF Technical Standards for utility Stations (11-130-15) N-ID-OSA 006 Asset Integrity GSS21 (Nitrogen Assembly)
No.: GSS25 Page: 10 of 13 Geismar Site Reviewed: 11/27/17 Effective: 11/27/17 Supersedes: 11/01/17 Preparer: Owner: Approver: SIH Team Leader LA Hub EHS Director Table 1 Service Inspection/Testing Requirements Frequency Steam Or Hot Condensate Pressurized Gas >15 psig operating pressure; and >1 nominal diameter Gases or liquids acutely toxic by inhalation or skin absorption Higher Hazard Chemicals Lower Hazard Chemicals EPCRA hazardous material w/out secondary containment or transferred between vessels on navigable waters Visual inspection; and Hydrostatic test at 1.5 times the MAWP with water or appropriate fluid*, or with an inert gas (ex. Air or nitrogen) under water, to indicate leaks. Tests must be done at ambient temperature. Hoses must be straightened, laid out horizontally and subsequently filled with the test agent. When testing with inert gas under water, the hose may be coiled so that it can be placed in a holding container (ex. Tub). The test pressure must be held for at least 5 minutes and the hose checked for any signs of blistering or leakage. *Pneumatic testing at 110% of MAWP is acceptable for units which may have hazards associated with water reactivity and hydrostatic testing. Visual inspection; and Hydrostatic test at 1.5 times the MAWP using water or appropriate fluid Visual inspection; and Hydrostatic test at 1.5 times the MAWP using water or appropriate fluid Visual inspection; and Leak test using an appropriate fluid at pressures not exceeding the MAWP. At least every 2 years At least every 2 years At least every year At least every 2 years Visual inspection At least every 3 years Visual inspection; and Hydrostatic test at 1.5 times the MAWP using water or appropriate fluid At least every year
No.: GSS25 Page: 11 of 13 Attachment A Electrostatic Resistance Testing 1.0 Set-up for testing: 1.1 Clean the hose fittings and hose covering. 1.2 Ensure that the hose is electrically insulated from external grounding means. This may be accomplished by placing the hose on a non-conductive, clean and dry surface and performing a test to ensure that the hose is not short circuiting through this surface. See Figure 1 in Attachment A for an example. 2.0 Check the ohm meter for proper operation per the manufacturer s instructions. 3.0 Test the hose resistance (continuity): 3.1 End Fittings: A. Place the positive test lead on the fitting at one end of the hose and the negative test lead on the fitting at the opposite end. If the meter does not respond, then ensure that the test leads are in good contact with the fittings and retry. B. If the resistance reading is not acceptable then remove the hose from service. 3.2 Surface A. Place the positive test lead on the stainless braided covering of the hose at one end of the hose and the negative test lead on the stainless braided covering at the opposite end. If the meter does not respond then ensure that the test leads are in good contact with the covering and retry. B. If the resistance reading is not acceptable then remove the hose from service.
No.: GSS25 Page: 12 of 13 Geismar Site Reviewed: 11/27/17 Effective: 11/27/17 Supersedes: 11/01/17 Preparer: Owner: Approver: SIH Team Leader LA Hub EHS Director HOSE CONTINUITY TESTING DIAGRAM Hose Fittings Hose Figure (1) Hose laid out on clean, dry horizontal surface without touching itself. Check that hose is not short circuited through the surface by firmly touching the surface with the tester body lead and touching the hose connections and braid with the tester wire lead. The tester LED will not be lit and there will be no audible tone if the hose is insulated correctly from the horizontal surface to allow for proper continuity testing to proceed. Use the tester on each fitting and the hose jacketing.
No.: GSS25 Page: 13 of 13 ATTACHMENT B Non-BASF Companies with Approved Hose Inspection Programs Vendor Chemical Class Inspection Frequency Test Criteria Comments Schneider Higher Hazard Annual 1.5 X MAWP with water Detailed written procedure Nalco Higher Hazard Annual 1.5 X MAWP with water Lamberts Higher Hazard TBD 1.5 X MAWP with water Testing done by Rubber House Service Transport Higher Hazard Quarterly 1.5 X MAWP with water Done by 3rd party (Polar); written procedure provided by Polar Trimac Higher Hazard 6-months 1.5 X MAWP with water Have detailed written procedure CTL Higher Hazard Annual Use water 2'' hose at 250 /the wp psi is 200; 3'' hose at 175 / the wp psi 150 Refer to B:\GLOBAL\2063-BASUS\GEISMAR\EHS\LA Hub\SIH\Vendor Hoses for copies of each company s hose procedure.