No.: BCF020.019 Page: 1 of 20 RECORD OF REVISIONS Date Rev # Details of Change 10/07 1 This standard is being revised to bring it into compliance with the template and formatting of the Corporate Safety Procedures. No major changes have been made. Changed Safety and Industrial Hygiene Manager and Site Safety and Health Expertise Team to EHS Team Leader. Added hose connections to Section 3.6 to be consistent with Section 3.7 and the corporate Line Breaking procedure. Updated the ANSI dates. There are also minor word revisions. 01/10 2 Section 4.2: Changed bullet 4. Old text: Ensure procedures for inspecting PPE are implemented. New text: Ensure procedures for inspecting, cleaning, decontaminating, and disposing of PPE are implemented. -Section 4.3: Added the following responsibility for the EHS Coordinator: Serve as the PPE Program Administrator for his or her unit/department -Section 5.1: Added text to clarify that the PPE hazard assessment must be a written document and must contain a certification statement and specific information. Added a certification statement to Attachment 1. -Section 5.3: Added the following text: While performing a work task, PPE shall be inspected periodically by the user to check for tears, punctures, discoloration, stiffness, and weakening of material during use. -Section 5.3: Added the following text: Used PPE must be cleaned, decontaminated, and/or disposed of per block, unit, shop, or laboratory procedures. -Section 5.3: Added the following text: Hardhats and gloves shall be not be placed on tables or other surfaces on which food and drinks are stored or consumed. -Section 5.6.1, Initial Training: Added additional requirements for those who wear hearing protection devices. -Section 5.6.3: Added a requirement for annual retraining for both respiratory protection and hearing protection.
No.: BCF020.019 Page: 2 of 20 RECORD OF REVISIONS Date Rev # Details of Change 01/10 2 -Section 5.6.4 (new): Added text to explain the requirements for voluntary use of PPE. -Sections 5.7.2, 5.8.2, and 5.8.3: Changed to the current version of ANSI Z87.1 instead of ANSI Z87.1-2003. -Section 5.8.1: Added a requirement for face shields and chemical splash goggles when there is potential for splashing or spraying of corrosive chemicals, skin-absorbing toxic chemicals, or known skin sensitizers into the eyes or face. -Section 5.10.2: Updated ANSI standard references and deleted the list of approved hardhats. -Section 5.10.2: Added the following text: Hard hats purchased for BASF employees or visitors must be white and have the BASF logo in black embossed on the front or side. -Section 5.12.2: Added the following text: Latex gloves shall not be selected / used. -Section 5.13.1: Added a requirement for each unit/department to perform a flash fire hazard assessment as part of their PPE hazard assessment. -Section 5.14.2: Added requirements for hearing protector evaluations and for including a copy of OSHA standard 29CFR1910.95, Occupational noise exposure in each unit/department Industrial Hygiene Notebook. -Section 6.0: Made minor revisions to the list of related documents. 09/17 3 Included a Definition for PPE Administrator - The Administrator shall be qualified by appropriate training or experience, which is commensurate with the complexity of the program elements they will oversee, to administer the PPE activities and conduct the required evaluations of program effectiveness. The PPE Administrator for the Freeport site is the Industrial Hygiene Coordinator for the Texas Hub.
No.: BCF020.019 Page: 3 of 20 1. PURPOSE 2. SCOPE To establish minimum requirements for the selection, training, use, supply, and maintenance of personal protective equipment (PPE). This procedure applies to the BASF. 3. DEFINITIONS 3.1. (PPE) Equipment worn to protect the eyes, face, head, hearing, lungs, body and extremities from injury or illness due to: Process/environmental hazards Chemical hazards Radiation or electrical hazards which may be encountered in a manner capable of causing injury or impairment in the function of any part of the body through absorption, inhalation, or physical contact Flash fires. 3.2. Immediately Dangerous to Life and Health (IDLH) 3.3 Hot 3.4. Cold Represents the maximum concentration of a chemical from which, in the event of respirator failure, one could escape within thirty (30) minutes without a respirator and without experiencing any escape-impairing or irreversible health effects. Any material with a temperature greater than 60 degrees Centigrade (140 degrees Fahrenheit). Any material with a temperature less than zero degrees Centigrade (32 degrees Fahrenheit).
No.: BCF020.019 Page: 4 of 20 3.5. Hazardous Any material/product or source of energy that is able or likely to inflict injury upon physical contact, inhalation, or exposure. 3.6. Breaking/Opening The physical loosening or separation of all types of flanges, screwed pipe, fittings, nipples, hose connections, ell s, tee s, screwed plugs, exchanger tube plugs, valves, tubing, quick-connect or other types of connections where the loosening/separation of such may expose personnel to hot, cold, or hazardous materials. 3.7. Initial Break 4. RESPONSIBILITIES The actual separation/removal of flanges, blinds, manways, exchanger heads, pipe/tubing fittings, hose connections, piping unions, etc. to a point where it can be determined that no residual product (liquid, gas or solid) will present a hazard to personnel. This determination shall be made through a means of verification (i.e. flushing with water to neutral ph or clearing with air or nitrogen). Once the verification has been performed, the PPE may be downgraded to the most applicable level of protection. 4.1 EHS Team Leader Interpret all related OSHA PPE requirements. Update all related safety standards per OSHA requirements. Audit units for compliance and ensure consistent application of PPE across the site. 4.2 Managers Ensure PPE Hazard Assessment for unit/department is performed. Ensure PPE selection list is developed and made available to all personnel. Provide PPE for unit/department.
No.: BCF020.019 Page: 5 of 20 Ensure procedures for inspecting, cleaning, decontaminating, and disposing of PPE are implemented. Ensure personnel are trained and re-trained as per procedure requirements. Ensure documentation of training is maintained. Ensure PPE selection list is reviewed at least annually and updated when changes occur. 4.3 EHS Coordinator 4.4 Users Perform unit/department Hazard Assessment in conjunction with the Unit/department's Safety Team (UST). Develop and implement the unit/department's PPE selection list in conjunction with the UST. Ensure that the requirements in 5.6 of this procedure are met. Provide training, as needed, for personnel using PPE. Serve as the PPE Program Administrator for his or her unit/department. Inspect all PPE as per the requirements of this procedure and attached Work Instructions. Receive and understand training in the proper use and limitations of PPE before using equipment. 4.5 PPE Administrator The PPE Administrator shall be qualified by appropriate training or experience, which is commensurate with the complexity of the program elements they will oversee, to administer the PPE activities and conduct the required evaluations of program effectiveness. See Attachment 5, PPE Program Evaluation Checklist. The PPE Administrator for the Freeport site is the Industrial Hygiene Coordinator for the Texas Hub.
No.: BCF020.019 Page: 6 of 20 4.6 Daily Operations Teams (DOT s) Inspect PPE as per the requirements of this procedure and attached Work Instructions. Ensure that personnel understand/demonstrate the proper use of PPE. 4.7 Contract Companies 5. PROCEDURE Provide PPE, as per contract requirements, for their employees. Ensure that employees are trained in the selection, use and maintenance of PPE. 5.1 General Requirements Requirements for PPE use are found in the unit/department s PPE requirements list (grid). A PPE requirements list, based on a hazard assessment, must be developed by each unit/department to determine the need for and selection of PPE. The hazard assessment must be a written document that contains a statement certifying that a PPE hazard assessment has been performed. The written certification document must also include: the workplace (unit/department) where the hazard assessment was performed the name of the person certifying that the hazard assessment has been performed, the date of the hazard assessment, and a list of PPE specific for each job. The list shall be task specific for chemicals, materials and other hazardous energy sources that require the use of PPE. Note: See Attachment 4 for hazard assessment guidelines. Reference 29CFR1910 Subpart I Appendix B
No.: BCF020.019 Page: 7 of 20 The PPE Requirements List shall address the following: Chemical permeability Impact hazards Penetration Chemical exposure Temperature extremes (hot/cold) Harmful dusts Respiratory protection Light radiation (welding, etc.) Electrical hazards Pressure extremes PPE materials compatibility Product concentrations Flash fire potentials Note: Special attention should be paid to PPE requirements for work on equipment containing products that may present additional hazards as a result of decomposition by-products, i.e., concentrated sulfuric acid evolves hydrogen, which is easily ignitable, and thus may present a flash fire hazard. Include in the list PPE requirements for emergency response to flash fire potential, i.e., responding to leaks/spills/releases, where easily ignitable flammables are involved or responding to incipient type fires. The PPE Requirements List shall address routine operations (sampling/handling) as well as emergency response (spills/leaks/fires/gas releases). Note: Use Attachment 1 form and reference example. The unit/department's PPE list should be attached to this procedure in the unit/department's respective Loss Control Manual or kept in a separate notebook. The PPE Requirements List must be reviewed, signed, and dated by the unit EHS coordinator. The list must be updated at least annually or as changes in chemicals, materials, or activities/parameters occur.
No.: BCF020.019 Page: 8 of 20 Updates/revisions must be reviewed, signed, and documented by the unit EHS coordinator and dated. The required minimum annual revision must be documented on the review sheet Attachment 2. The PPE Requirements List and annual review sheet shall be readily available to all personnel. Attachment 3 shows the PPE requirements for Levels A through Level D protection. If one of these levels is designated, (i.e. Level A) for a task, then all of the equipment listed under the level is required unless explicitly stated. 5.2 Provisions for PPE 5.3 Use PPE designated for use by BASF employees will be provided by their respective units/departments. Contract employers are responsible for supplying necessary PPE for their employees as per their contract with the. PPE for temporary visitors will be provided by BASF. PPE for vendors and temporary contracted employees will be provided as per the requirements of their contract with BASF. BASF Security will maintain approved hard hats and safety glasses for use as needed. BASF currently has an alliance vendor that distributes and sells PPE that meets all government-required standards. For costeffectiveness, every effort should be made to purchase PPE from the alliance vendor. All PPE shall be maintained and worn per manufacturer s recommendations. While performing a work task, PPE shall be inspected periodically by the user to check for tears, punctures, discoloration, stiffness, and weakening of material during use. Damaged or defective PPE shall not be used. All PPE selected for use must fit properly. Used PPE must be cleaned, decontaminated, and/or disposed of per block, unit, shop, or laboratory procedures.
No.: BCF020.019 Page: 9 of 20 Hardhats and gloves shall not be placed on tables or other surfaces on which food and drinks are stored or consumed. 5.4 Inspection All PPE must be inspected before and after use or discarded. Deficient equipment must be replaced or red-tagged and removed from service until repaired/replaced. PPE must be inspected/repaired as per manufacturer s recommendations/specifications. Note: See BCF020.019a WI, Acid hoods/suits/boots/gloves for specific inspection requirements for this equipment. 5.5 Storage Cabinets or other protective measures will be used to store protective clothing. Coats, pants, and Level "A" suits must be hung on a rack, hanger, or in storage cases designed for that purpose. Boots and gloves must be stored so they can stay dry and clean. 5.6 Training 5.6.1 Initial Training Employees shall receive training prior to being assigned work involving the use of PPE. Training must be documented and the records maintained. Training must include instructions on the following: When PPE is necessary. What PPE is necessary? How to properly don, doff, adjust, wear, and inspect PPE. Limitations of the PPE. Proper care, maintenance, useful life, decontamination and disposal, where applicable, of the PPE.
No.: BCF020.019 Page: 10 of 20 In addition to the above training requirements, employees who are required to wear hearing protection devices shall receive training that includes the following: The effects of noise on hearing. The purpose of hearing protection devices. The advantages, disadvantages and attenuation of various types of hearing protection devices. The purpose of audiometric testing and the test procedures. 5.6.2 Demonstration of Understanding A. General Requirements Each affected employee must demonstrate an understanding of the required training before being allowed to perform work requiring the use of PPE. The demonstration may include showing competency or a written evaluation. B. Written Certification 5.6.3 Retraining The employer will verify that each affected employee has received and understood the required training through a written certification that contains the following: Name of employee trained. Date(s) of training. Subject of the training. Name of trainer. Respiratory protection and hearing protection require annual retraining, at a minimum. In addition, retraining (via Mockingbird Online and/or safety meetings) is required when: Changes in work place conditions or types of PPE to be used render previous training obsolete, or It is evident that the employee has not retained the understanding or skill required to use the PPE properly.
No.: BCF020.019 Page: 11 of 20 5.6.3 Retraining When there is reason to believe that any affected employee who has been trained does not have the understanding and skill required to be able to recognize hazards and the requirements for PPE usage to minimize these hazards. Compliance driven changes will be communicated to the unit by the EHS Team Leader. 5.6.4 Voluntary Use of PPE If personnel choose to use PPE for a task that does not require its use, the user must be fully trained on the proper use and limitations of the PPE that is used. For voluntary use of respiratory protection, refer to Section 5.5.3 of BCF020.013, Respiratory Protection. 5.7 Eye and Face Protection 5.7.1 General Requirements Each employee shall use appropriate eye and face protection when a potential for exposure to eye and face hazards exists from flying particles, wind-blown objects, molten materials, liquid chemicals, acids or caustic liquids, chemical gases or vapors, potentially injurious light radiation, or electrical hazards. 5.7.2 Safety Glasses Safety glasses must be marked as meeting the specifications of the current version of ANSI Z87.1 (usually on the inside of a paddle). Safety glasses with side shields (and approved hard hats) are the minimum required eye (and head) protection inside the fenced plant site. This protective equipment must be worn inside the gate except when reporting to or leaving work by an
No.: BCF020.019 Page: 12 of 20 approved route, or in offices, control rooms, restrooms, conference rooms, and eating areas. Note: When walking or riding in vehicles from one block to another via company roadways, safety glasses (and hard hats) must be in your possession. 5.8 Goggles/Face Shields/Protective Hoods 5.8.1 Selection Appropriate protection for splash, heat or other special hazards for eyes and face must be worn as per the unit/department's Hazard Assessment and the requirements in the unit/department's PPE List. Splash goggles with dark tinted lenses are not to be worn at night or in dark locations. When wearing chemical splash goggles over the eyes, the band must be around the head and not attached to or over the back of the hard hat. Chemical splash goggles and a face shield (or equivalent) shall be worn when there is a potential for splashing or spraying of corrosive chemicals, skinabsorbing toxic chemicals, or known skin sensitizers into the eyes or face 5.8.2 Specifications Goggles, face shields and protective hoods must be marked as meeting the current version of ANSI Z87.1. Goggles, face shields or protective hoods which are not marked as meeting the current version of ANSI Z87.1 standards shall be used only in conjunction with safety glasses that are marked as meeting the current version of ANSI Z87.1 standards.
No.: BCF020.019 Page: 13 of 20 5.8.3 Welding Protection A. Selection Personnel engaged in welding-type operations where light radiation may cause injury to the eyes must use equipment with lenses that have a shade number appropriate for the work being performed. Refer to the table in 29CFR1910.133 (a)(5). Welder s helpers shall also be provided with and required to use appropriate equipment for protection against potential injury to the eyes and face. Note: Workers or other persons adjacent to the welding area shall be protected from the rays by noncombustible or flameproof screens/shields. B. Specifications 5.9 Respiratory Protection For face protection, a welding hood will be provided to shield the face from injurious light radiation and impact. Welding hoods, which do are not marked as meeting the current version of ANSI Z87.1 shall be used only in conjunction with safety glasses or goggles that are marked as meeting the current version of ANSI Z87.1 standards for impact protection. The site requirements for respiratory protection are included in BCF020.013, Respiratory Protection. 5.10 Head Protection 5.10.1 General Requirements Hard hats (and approved safety glasses) are the minimum required head protection inside of the fenced plant site. This protective equipment must be worn inside the gate except when
No.: BCF020.019 Page: 14 of 20 reporting to and leaving work by an approved route; or in offices, control rooms, restrooms, conference rooms, and eating areas. Note: When walking or riding in vehicles from one block to another via Company roadways, hard hats (and safety glasses) must be in your possession. Hard hats shall not be altered by drilling holes, cutting, painting, or other methods, which may compromise the integrity of the unit. Hard hats, which become damaged or have defective parts, must be replaced immediately. 5.10.2 Selection All hard hats currently in use must be marked as meeting ANSI Z89.1-1997 Class G and Class E requirements. All hard hats shall be worn per the manufacturer s instructions as far as the orientation of the bill. Hard hats purchased after the effective date of this standard must be marked as meeting ANSI Z89.1-2003 Class G and Class E requirements. Hard hats constructed of aluminum alloy shall not be issued. Hard hats purchased for BASF employees or visitors must be white and have the BASF logo in black embossed on the front or side Note: Hardhats shall be purchased, stocked and distributed by the individual units.
No.: BCF020.019 Page: 15 of 20 5.11 Foot Protection 5.11.1 General Requirements Steel-toed safety shoes are required to be worn by all personnel (BASF/Contractor/Service) while in production, manufacturing, construction, maintenance shops, I/E shops, and laboratory work areas. Safety shoes are not required when reporting to or leaving work by an approved route or in offices, control rooms, restrooms, and eating areas. Visitors such as delivery drivers, vendors and guests are exempt from safety shoe requirements. Safety shoes must be made of leather, simulated leather, or other non-permeable materials. Safety shoes made of the above materials cannot have perforations, which will compromise their permeability resistance. Used safety shoes will be taken to BASF Receiving for proper disposal. When dropping off used shoes, BASF employees will sign the log sheet indicating that shoes have been left. 5.11.2 Specifications 5.12 Hand Protection All protective footwear must be marked as meeting the specifications of the current version of ANSI Z41. 5.12.1 General Requirements Appropriate hand protection is to be worn for the specific hazard(s), which may be present or encountered while performing tasks.
No.: BCF020.019 Page: 16 of 20 5.12.2 Selection The type of hand protection required shall be determined as per the unit/department hazard assessment and as specified in unit/department's PPE List. BASF and contractor employees must have gloves in their possession at all times when inside all plant areas. The hazard assessment shall determine the type of hand protection to be worn and the specific hazard it is protecting against; i.e., skin absorption of harmful substances, cuts or lacerations, abrasions, punctures, chemical burns, thermal burns, harmful temperature extremes, and electrical hazards. Selection of appropriate hand protection shall be based upon materials of construction, contaminant penetration, physical durability, dexterity requirements, and reusable versus disposable concerns. Latex gloves shall not be selected/used. 5.12.3 Electrical Hazards Hand protection (gloves and sleeves) specified for protection against electrical hazards must be provided, inspected, and tested (including documentation) in accordance with Tables 1-2, 1-3, 1-4, 1-5, and 1-6 of 29CFR1910.137. Note: See BCF020.019b WI, Switchgear Room Safety Equipment, for inventory/inspection requirements/instructions.
No.: BCF020.019 Page: 17 of 20 5.13 Protective Clothing 5.13.1 Selection 5.13.2 Use 5.14 Hearing Protection Protective clothing selection and use shall be determined as per the unit/department PPE hazard assessment and as specified in unit/department's PPE List. The unit/department PPE hazard assessment shall include an evaluation of the need for flame-resistant garments for the protection against flash fires. The BASF Flash Fire FRC Assessment Tool is recommended, and can be obtained by contacting a member of the BASF OS/IH Center of Expertise. Other hazard assessment tools and methods may be used as long as they consider task hazards, previous incidents, and area hazards. Protective clothing shall be worn so that it provides the protection for which it is intended. Buttons and closures shall be used, and clothing shall not be cut or otherwise modified. 5.14.1 General Requirements The BASF Freeport site shall maintain a workplace noisemonitoring program to identify all employees that may have exposures requiring the use of hearing protection. Whenever feasible, time-weighted average (TWA) noise levels will be reduced below 90 dba by utilizing engineering and/or work practice controls. Approved hearing protection must be worn in areas designated. "Hearing Protection Required" signs shall identify these areas.
No.: BCF020.019 Page: 18 of 20 5.14.2 Hearing Protectors 5.15 Fall Protection Equipment Hearing protectors are required for employees who may be exposed to an 8 hour TWA noise level of 85 dba or higher. Employees shall be given the opportunity to select hearing protection from a variety of hearing protectors. The Texas EHS Hub shall evaluate hearing protectors per 29CFR1910.95 taking into account that some employees are exposed up to 12 hours per shift. A copy of OSHA standard 29CFR1910.95, Occupational noise exposure shall be made available to all personnel. A copy of this standard shall be included in each unit/department Industrial Hygiene Notebook. The site requirements for fall protection are included in BCF020.003 Fall Protection. 5.16 Emergency Response Equipment (Bunker Gear) Units that specify the use of bunker gear for work where there is a risk of a flash fire are to ensure that the equipment is marked to meet the requirements of NFPA 1971 Protective Clothing for structural fire fighting. Units with bunker gear are to develop and implement an inspection program to ensure that the equipment is maintained in a ready state at all times. The manufacturers recommendations for the following should be included: Storage Care Decontamination procedures Inspection frequency
No.: BCF020.019 Page: 19 of 20 6. RELATED DOCUMENTS All information needed to comply is included above. Additional information on the topic may be found in the following documents: ANSI Z41 ANSI Z87.1 ANSI Z89.1 Foot Protection Eye and Face Protection Head Protection ASTM D-120-87 Specifications for Rubber Insulating Gloves ASTM D-178-193 Specifications for Rubber Matting ASTM D-178-88 Specifications for Rubber Matting ASTM F-496-936 Specifications for in-service care of insulating gloves and sleeves OSHA 29CFR1910.95 Noise OSHA 29CFR1910.120 Hazardous Waste & Emergency Response Operations OSHA 29CFR1910.132-138 OSHA 29CFR1910.335 Electrical OSHA 29CFR1910.502 Fall Protection BCF020.003 BCF020.013 BC032.002 BC032.007 NFPA 1971 NFPA 2113 Elevated Work / Fall Protection Respiratory Protection Contractor Selection, Oversight and Safety Protective Clothing for Structural Fire Fighting for the Selection, Care, Use, and Maintenance of Flame-Resistant Garments for Protection of Industrial Personnel Against Flash Fire BCF020.019 Attachment #1 PPE List Example and Blank Form BCF020.019 Attachment #2 Review and Certification Record BCF020.019 Attachment #3 Guidelines for Level of Protection BCF020.019 Attachment #4 Guidelines for Hazard Assessment BCF020.019 Attachment #5 PPE Program Evaluation Checklist
No.: BCF020.019 Page: 20 of 20 BCF020.019a Work Instructions - Acid Hoods/Suits/Boots/Gloves BCF020.019b Work Instructions - Electrical Switchgear Room Safety Equipment