Quality Management System Manual

VESSEL CLEANING PROCEDURE

Project No.: Revision :APage : 8 of 9

Description:Issue for reviewRev. Date :16 September 2011

1.0PURPOSE

Vessel cleaning involves entry into confined that can introduce suffocation, physical entrapment, and chemical exposure hazards into the workplace. This procedure is designed to help supervisors manage the risks associated with confined space entry by establishing minimum requirements for confined space operations.

Supervisors may, at their discretion, establish more restrictive requirements based on their knowledge and assessment of the hazards associated with work conducted in confined spaces.

Any variance from this procedure shall be specified on the confined space entry permit and authorized by the Area Superintendent or equivalent level of management responsible for the facility.

2.0DEFINITIONS

2.1Approved Confined Space Entry Permit

Is a permit signed by the Area Superintendent (or equivalent level of management responsible for the facility), or designee. Approved permits are signed on the Work & Methods Approved line. In lieu of signing a permit, the Area Superintendent can give verbal authorization by issuing a unique permit control number. This number shall be entered by Person-in-Charge (PIC) requesting the work on the permit on the line labeled Work & Methods Approved. The person giving the verbal authorization shall maintain a log of the authorizations given. Copies of verbal authorization logs with copies of the entry permits verbally authorized shall be kept for one year after the date of work.

2.2Confined Spaces

Include all areas or pieces of equipment where:

2.2.1The space is large enough and designed to allow an employee to enter and perform work; and

2.2.2One or more of the following also apply:

(a)The interior atmosphere is hazardous (or has the potential to become hazardous) or the interior contains electrical or mechanical hazards capable of causing serious injury; or

(b)Entry or egress is difficult, impaired or restricted.

(c)Any airborne contaminant present at a level capable of causing immediate and often serious health consequences.

(d)Any other condition recognized as immediately dangerous to life or health.

In addition to atmospheric hazards, confined spaces often contain physical or mechanical hazards, such as unguarded machinery, exposed electrical circuits, or materials which can engulf an entrant. The risk posed by a mechanical or physical hazard is amplified inside a confined space since an injured person may not be able to self-rescue.

Examples of confined spaces are: pipelines, tunnels, tanks, vessels, and floating roof tanks (when the roof is 5 feet or more below the top of the shell), heaters, compartments, ducts, sewers, pits, cellars, or any similar-type locations.

2.3Confined Space Entry Plan

Is a written pre-work plan that complies with this procedure and specifies:

2.3.1The scope of work to be performed prior to, during, and after the confined space entry (e.g., opening, testing, ventilating, cleaning operations; inspection of the space prior to closing it).

2.3.2The PIC of the confined space entry, and the responsibilities of all departments/groups involved in the entry.

2.3.3The frequency and type of atmospheric testing required, and the area to be tested.

2.3.4The personal protective equipment required during the confined space entry.

2.3.5Safety watch procedures and personnel.

2.3.6The names of personnel qualified to use self contained breathing apparatus (SCBA) to perform confined space operations.

2.3.7Personnel that the safety watch should contact in an emergency, the means of raising an alarm, and the need for a rescue method (i.e. harness with lifeline), based on the size and configuration of the confined space, to be used in the event a worker becomes disabled while inside and must be removed.

2.3.8Lock-Out/Tag-out requirements and procedures for process, and mechanical/electrical energy isolation (Lockout and Tagout Procedures).

2.3.9Hot Work permitting requirements, if hot work is planned, or if pyrophoric (e.g., iron sulfide) material could exist inside the confined space.

2.4Hazardous Atmosphere

Is an atmosphere capable of causing injury, illness, or disablement due to the presence of flammable, toxic or otherwise injurious substances, or due to oxygen deficiency or enrichment. Refer to Table 1 in Section 8 for protective equipment requirements and access restrictions pertaining to the most common hazardous atmospheres.

2.5Person-in-Charge (PIC)

A confined space entry is designated by the appropriate Superintendent to be responsible for the safe completion of the work.

Production Supervisor or Foreman, Facilities Engineering Project Engineer or Inspector, or Camp Services Supervisor or Foreman.

2.6Superintendent

Is the Production Operations Area Superintendent (or equivalent level of management responsible for the facility).

3.0RESPONSIBILITIES

3.1The PIC of the confined space entry operation shall develop a confined space entry plan. The operations Staff can assist with development of confined space entry plans upon request. The PIC shall sign the plan and review it with the Superintendent for approval.

3.2The PIC shall ensure that written copies of the approved confined space entry plan are given to affected employees, contractors, and the facility owner. The PIC shall review the confined space entry plan and permit requirements at a safety meeting with personnel involved in the confined space entry before starting the work.

3.3The Superintendent, or designee, shall be responsible for approving entry permits.

3.4The PIC will ensure that all necessary permits, Do Not Enter, and Do Not Operate tags are posted at confined space job sites for the permitted interval of work, and that expired permits are removed.

3.5The PIC shall ensure that safety watch personnel are adequately trained in the following:

3.5.1Safe entry and rescue methods

3.5.2Gas detector operation, and

3.5.3SCBA (or airline respirator) use.

For guidance on safety watch training requirements, and training documentation and verification.3.6The PIC shall ensure that personnel using respiratory protection (e.g., safety watch and those entering the confined space) have a clean face-mask seal without obstruction by facial hair, glasses, or any other obstacle that may prevent a good seal. Also, before starting work, safety watch and personnel entering the confined space shall ensure that access manways are large enough for entry while wearing required personal protective equipment.

3.7The PIC shall ensure that necessary personal protective and gas testing equipment (as defined in the confined space entry plan) is available at the job site before starting confined space entry operations.

3.8The PIC is responsible for enforcing the requirements of the approved permit, the requirements of the confined space entry plan, and must personally supervise the initial entry. The PIC may delegate site supervision to the contractor supervisor after checking the job site at the beginning of each working day, or at shift change, but must remain within radio/phone contact at all times.

3.9Operations will provide a safety watch when mutually agreed between parties.

3.10Operations will provide and calibrate MSA-361, Watchman Multigas and Orion Multigas detectors upon request.

3.11The safety watch will remain on site during the entire confined space entry operation, and will continuously observe the work (except when gas testing) and be ready to call for help and intervene if necessary.

3.12The need for additional safety watches will be determined by the PIC and documented in the confined space entry plan. The PIC is responsible for providing additional safety watches.

4.0PRECAUTIONSRisk assessment must issued before any person enters a confined space, tank or vessel, a confined space entry permit shall be available and the following checks shall be done. The atmosphere in the confined space, tank or vessel shall be checked with portable detection equipment to know the level of oxygen and presence of any toxic, flammable and explosive gases. No entry is permitted until the levels are safe.

These checks shall be done by competent persons authorized by the Company. Adequate ventilation with fresh air shall be available throughout the job. A competent person shall conduct frequent tests if flammable materials are being used.

A person shall be positioned at the entrance of the confined space whose sole responsibility shall be to communicate and get the message to the persons inside.

The person shall raise an alarm in the event of any emergency.

Personnel entering the confined space shall wear appropriate PPE including safety belt or harness with lifeline attached and suitable respiratory apparatus

Barricade system should be implemented

Blower / extra fan to be use when confine space entry will be conducted.

Drill shall be conducted before execution the job.5.0CONFINED SPACE ISOLATION AND VESSEL CLEANING PROCEDURE5.1The confined space shall be emptied, flushed or purged of flammable or toxic liquids or gases and should be opened (all man way covers removed) to ventilate toxic and flammable gases prior to entry.

5.2When a space has been opened, but not approved for entry, a "DANGER DO NOT ENTER" tag must be hung at each opening. If any openings are left uncovered and unattended, the openings must be barricaded (e.g., with tape or wire) to prevent unauthorized entry.

5.3All pipelines to and from the confined space shall be isolated and blinded. Threaded lines shall be disconnected and plugged as close to the confined space as possible. Blinds shall be installed at the closest flange to the confined space.

5.4If blinds cannot be installed to isolate the confined space, a "double block and bleed" arrangement is acceptable with approval by the Area Superintendent or equivalent level of management that is responsible for the facility. Block valves shall be locked and tagged out. Gas tests shall be performed in the confined space at the line inlet. The spool between the block valves shall be vented to the atmosphere and the vent carefully checked to ensure it is not plugged.

5.5Equipment in the confined space shall be electrically and mechanically isolated and locked & tagged out.

5.6Steam or hot oil coils inside the space shall be disconnected or locked and tagged out at the point where they enter the confined space. Electrostatic grids shall be locked and tagged out in the facility MCC room. A "DANGER DO NOT OPERATE" tag is required in both cases.

5.7All automated fire extinguishing systems in the confined space, such as CO2 systems, shall be disarmed, locked, and tagged out. A DANGER DO NOT OPERATE tag is required.

5.8If several pieces of interconnected equipment must be isolated as a unit for a confined space entry, each piece of the interconnected equipment must be depressurized, opened to the atmosphere, and made safe for entry.

5.9"DANGER DO NOT ENTER" tags shall be affixed at each opening whether or not it is barricaded by tape or wire:

5.9.1when it is not safe to enter the confined space,

5.9.2prior to issuance of an entry permit, 5.9.3at the end of a shift when the space is left open, or,

5.9.4when an unsafe condition arises and entry permits are removed.

5.10Radioactive sources, if present, shall have shutters closed and locked except during use by trained radiography personnel.5.11Open-up the manholes and discard the spools as shown in the vessel isolation plan.

5.12Spray degreaser into the vessels, set-up ventilation equipment (i.e. Air blower & Fume extractor) and defuse remaining gas in the vessel.

5.13Gastest and if result is acceptable, secure vessel entry permit and commence internal cleaning using the High Pressure Water Jet equipment.

Note : Ensure at least two (2) watchman at the manhole with spare breathing apparatus, whilst Cleaning is in progress inside the vessel.

5.14Cleaning shall continue until the vessel is satisfactory clean.

5.15Call for internal inspection (to be done by others)5.16Reinstate the vessel as and when the inspection is completed.

5.17Conduct reinstatement test.6.0REQUIRED PERMITS

6.1An entry permit is required for entry into all confined spaces. The PIC will indicate on the entry permit the required types and frequency of gas testing to be performed.

6.2No confined space shall be entered without an approved and posted entry permit.

6.3An approved hot work permit is required for hot work, i.e., welding, cutting, chipping, grinding, use of fans & lights, or any other work which could generate a source of ignition.7.0CONFINED SPACE TESTING REQUIREMENTS

7.1The safety watch (or other trained person under the direction of the safety watch) shall test the atmosphere inside the confined space using Multigas and Orion Multigas detectors. Test for the presence of combustible gas and for oxygen deficiency no less than every 15 to 30 minutes, or as prescribed on the permit, for the duration of the confined space operation (see Table 1). Gas tests shall start at the beginning of each day (or shift change), or prior to re-entering the space if it has been vacated 30 minutes or longer. Test results shall be recorded periodically (as directed by the PIC) in the appropriate space on the entry permit and initialized.

7.2The space should also be tested for hydrogen sulfide (see Table 1), and temperature, if required on the entry permit. If ambient temperatures inside the confined space are 100oF (38oC) or higher, personnel are limited to 30 minutes inside, followed by a 15 minute rest break outside. The space shall also be ventilated with a jet eductor or fan.

7.3The space should be tested for any other chemical or physical hazards identified on the permit. Monitoring for other chemical substances (e.g., benzene) is done using detector tubes or Drger CMS Analyzer by using Chips. Monitoring for naturally occurring radioactive materials (NORM) should be considered for production / test separators and other production equipment where produced sediments are concentrated.

7.4Initial gas tests should be taken just inside the opening into the confined space using an extendible wand. Tests must be taken at low spots in the space or in areas around irregular surfaces and mixers, at line inlets and areas away from openings where ventilation is restricted to assure that the most severe conditions are measured.

7.5The safety watch must remain outside the confined space unless entry is required for gas testing. If the safety watch must enter a confined space for gas testing, he must designate an assistant to stay outside. Until the atmosphere inside the confined space proves to be safe, the gas tester shall wear a disposable tyvek, airline respirator or SCBA. A "DANGER DO NOT ENTER" tag shall be posted at the entrance of the confined space until tests verify the atmosphere is safe and the entry permit is approved. Entry into the space shall be controlled according to the test results shown in Table 1.

7.6Atmospheric tests shall be performed in the following order: oxygen deficiency, flammability, and (if necessary) toxicity. It is also important to ensure that sampling is representative of the total atmosphere in the space (e.g., sample at multiple depths in a deep space). If air testing indicates a hazardous situation, contact the area operations representative before proceeding.8.0Materials8.1Nitrogen for purging & reinstatement testing.

8.2New studbolts and gasket required for the affected joints identified in the Vessel Isolation Plan.

8.3Fresh Water

8.4Degreaser

9.0Equipment to be used :9.1High pressure water jet complete with hoses and nozzles.1 unit

9.2Breathing apparatus complete with oxygen bottle and one (1)2 set

Set spare bottles.

9.3Air Blower 6 dia. Discharge out flow.1 unit9.4Fume extractor 6 dia to 8 dia.1 unit

9.5Hand Held lighting, explosion proof, AC.2 EA

9.6Torch light (Exd type)1 EA

ATTACHMENTTable 1: Level of Entry Specifications for Selected Air Contaminants

Level of Entry Safe to EnterRespiratory Protection RequiredNo Entry

AllowedComments

Contaminant Mechanical filterSCBA or Airline

Oxygen19.5 to 23.5%not allowed16.5 to 19.5%< 16.5% or >

23.5%

LEL *10%not allowed< 10% 10%

H2S 10 ppmnot allowed11 to 99 ppm 100 ppm

Benzene 1 ppm> 1 to 10 ppm11 to 499 ppm 500 ppmskin protection required to prevent contact

Toluene 50 ppm51 to 250 ppm251 to 499 ppm 500 ppmskin protection required to prevent contact

use chemical goggles or full facepiece for eye protection.

Xylene 100 ppm101 to 300 ppm301 to 999 ppm 1000 ppmskin protection required to prevent contact

use chemical goggles or full facepiece for eye protection.

Hydrocarbons 300 ppm301 to 50 ppm> 500 ppm 10% LEL *2skin protection required to prevent contact

Carbon Monoxide 25 ppmnot allowed35 to 1499 ppm 1500 ppm

Sulfur Dioxide 2 ppm> 2 to 20 ppm21 to 99 ppm 100 ppmskin protection required to prevent contact

use chemical goggles or full facepiece for eye protection.

Methanol 200 ppm200 to 250 ppm251 to 5999 ppm 6000 ppmMethanol is toxic. If ingested or inhaled it can cause a wide

range of harmful effects, from sickness, heart and liver

damage to reproductive harm, blindness or death

Ammonia 25 ppmnot allowed26 to 299 ppm 300 ppmskin protection required to prevent contact

use chemical goggles or full facepiece for eye protection.

Chlorine 0 ppmnot allowed> 0 to 9 ppm 10 ppmskin protection required to prevent contact

use chemical goggles or full facepiece for eye protection.

*1 NOTE: Hot work is not allowed inside a confined space unless there is no LEL (0% reading) in the space

*2 NOTE: The upper limit for hydrocarbons (no entry allowed) is controlled by the LEL reading. No entry allowed if LEL is 10%.

DESCRIPTION:

Safe to Enter: Entry into confined space without respiratory protection is allowed for a maximum of 8 total hours exposure per day.

Respiratory Protection Required: No entry is allowed into the confined space without the proper level of respiratory protection.

No Entry Allowed: No entry is allowed into the confined space regardless of the degree of personal protection.

Comments Section: Skin and eye protection is required as indicated. Refer to MSDS for more specific information.EJ Joint Venture Sdn Bhd