PUBLIC COMPANY ORLEN LIETUVA APPROVED BY Director of Quality, Labour Safety and Environmental Control January 3, 2017 Order No. TV1(1.2-1)-2 OCCUPATIONAL HEALTH AND SAFETY PROCEDURE BDS-6/1 EQUIPMENT UNSEALING AND MAINTENANCE WORKS I. GENERAL PROVISIONS Purpose and Scope of Application 1. The purpose of the Equipment Unsealing and Maintenance Works (hereinafter the Procedure) is to establish the occupational health and safety (hereinafter OHS) requirements for execution of equipment unsealing and maintenance works at Public Company ORLEN Lietuva (hereinafter the Company). 2. This Procedure shall apply to each and every employee of the Company arranging, planning and/or performing equipment unsealing and maintenance works, as well as to employees of contracting organizations (hereinafter contractor) where such works fall within the scope of respective contracts concluded with the Company. 3. The Procedure shall not apply to the unsealing and maintenance works performed at the Power Plant where the Rules for Safe Operation of Heating Facilities, as approved with Order No. 1-246 as of 13 September 2016 by the Minister of Energy of the Republic of Lithuania, apply. II. REFERENCES 4. The Procedure shall be used in conjunction with the below listed legal acts (as amended to date): 4.1. Regulations Concerning Protection of Employees from Exposure to Chemical Factors at Work, as approved with Order No. 97/406 as of 24 July 2001 by the Minister of Social Security and Labor and Minister of Health of the Republic of Lithuania; 4.2. Lithuanian Hygienic Norm HN 23:2011. Occupational Exposure Limits for Chemical Substances. General Requirements for Measurement and Impact Assessment, as approved with Order No. V-824/A1-389 as of 1 September 2011 by the Minister of Social Security and Labour of the Republic of Lithuania. III. TERMS, ABBREVIATIONS AND DEFINITIONS 5. The following are the terms used herein and definitions thereof: Personal protection equipment (or PPE) any equipment to be worn or held by an employee in order to be protected against hazards that may endanger the health and safety of the employee. For the purpose of the present Procedure: Mandatory PPE the PPE indicated in the OHS signs displayed at the entries to process unit territories, buildings or any other facilities at the Company (safety helmet with a strap, goggles, protective work clothing, safety footwear, ear and respiratory protection equipment); Special PPE the PPE selected with due respect of the performed equipment preparation works and level of hazard posed by the to be done works (safety harness, lifelines, PPE resistant to chemical substances, filtration gas mask, self-contained breathing apparatus, etc.).
Occupational risk identification card (or card) a document of established form to be used by contractor to identify risks that may arise in the course of works, and to plan measures for safe execution of works. The recommended form of the card is established by OHS Department of the Company. Contractor may use the card of any other form after agreeing upon such with OHS Department of the Company. Permit for works (or permit) a document of established form authorizing to perform equipment unsealing or maintenance works. The specimen form of the permit is established by Occupational Safety and Health Department of the Company. Work supervisor an employee of an organizational unit of the Company who has been assigned by the issuer of permit to supervise respective equipment unsealing or maintenance works. Work coordinator: an employee of an organizational unit led by Director of Maintenance of the Company who, under a decree of Deputy Director of Maintenance or Chief Mechanical Engineer, has been assigned to organize and coordinate proper execution of works during maintenance of and repairs to static and rotating mechanical equipment/facilities, structures/buildings of the respective organizational unit; an employee of Technology and Investment Department of the Company who, under a decree of Director of Investment and Technology, has been assigned to organize and coordinate proper execution of technical activities related to project implementation. When equipment unsealing and maintenance works are initiated by heads of some other organizational units of the Company, the employee of the respective organizational unit who, by means of a decree of the head of the organizational unit, has been assigned to organize and coordinate proper execution of works, must be appointed to act as a work coordinator. Work manager a manager assigned by a contractor in written form for organization of and control over equipment unsealing and maintenance works. Work executors the contractor employees who perform equipment unsealing and maintenance works. Work site a place where equipment unsealing and maintenance works are performed. Equipment any device, apparatus, piping, etc. which poses hazard to the safety and health of employees because of contained residual hazardous energy or energy supplied to such from other sources. Unit manager a superior over the employees operating a process unit (Head of Unit, Head of Section, Terminal Operations Manager, etc.). Equipment unsealing works (or works) equipment demounting / disassembling works (e.g., opening of pipeline flanges, vessel hatches, slide valves, vent valves, removal of gaskets, insertion of blinds, etc.) during which a confined space inside the equipment which contained, contains or may contain various temperatures, pressures and substances (e.g., petroleum products, water, steam. etc.) is unsealed. Maintenance works (or works) demounting / (re)assembling of unsealed equipment (e.g., demounting or (re)installing of heat exchanger tube sheets, closing of vessel hatches, inserting of slides, vent valves, etc.). Issuer of permit the head of a Company's organizational unit (Head of Operations, Deputy Head of Operations, Head of Shop, Head of Unit or any other manager), Engineer, also Shift Supervisor assigned under a decree of the head of the organizational unit. Issuer of permit shall be entitled to issue permits for the assigned to him/her facilities only. During maintenance of process units, when process units are to be shut down following a relevant order from the General Director of the Company, the head of the organizational unit may (if needed) with his/her decree assign Process Unit Operators to act as issuers of permits. Air testing person an employee of Mažeikiai Fire and Rescue Board for Protection of Facilities (hereinafter FRB) duly trained and appointed to test air samples, or an employee of the organizational unit of the Company appointed with a decree of the head of the organizational unit to perform air samples. 2 9
Process unit the entirety of indoor or outdoor crude refining installations, mechanisms, machinery, devices, apparatuses, instruments, vessels erected, installed and interconnected on supporting civil structures and foundations, isolated from or integrated with piping. IV. DUTIES AND RESPONSIBILITIES OF EMPLOYEES 6. Unit manager shall be responsible for isolation of equipment using energy isolating devices (hereinafter EID) from any actual or potential sources of dangerous energy pursuant to the Company's Occupational Health and Safety Procedure BDS-29 Equipment Isolation, and shall organize preparation of equipment for the works, as prescribed by the present Procedure. 7. Issuer of permit shall: 7.1. Issue or extend the permit as prescribed hereunder only if directly requested by the assigned work coordinator; 7.2. Make sure the equipment has been properly isolated from all types of dangerous energy sources according to EID list, and the preparatory measures related to execution of works have been implemented; 7.3. Coordinate the possibility to execute equipment unsealing works with the heads of organizational units or shift superiors operating adjacent process units which, including the persons working and/or present therein, may be exposed to the negative impact resulting from the planned unsealing works; 7.4. Consider hazardous chemical substances which were contained or could have been contained and, where such substances may release to the working atmosphere while unsealing the equipment, anticipate means to protect employees against exposure to such substances (e.g., periodical or continuous monitoring of ambient air with the works in progress, use of adequate respiratory protection equipment by work executors, etc.); 7.6. Fill out the permit form in the manner prescribed by the present Procedure; 7.7. Register the permit with the hazardous work logbook of the organizational unit (the specimen form of such log is established by Occupational Safety and Health Department); 7.8. Where alarm systems are available next to the place of equipment unsealing works, inform Dispatcher of FRB (phone No. 30 04) about potential activation of the alarm systems in the course of works, and indicate the contact person who, upon an alarm system activated, would notify FRB Dispatcher of any actual hazard posed; 7.9. Check the work manager's certification card and make sure it is still valid; 7.10. Issue (sign) the permit and allow starting the works after making sure that the signatures of all the persons indicated herein are present in the permit; 7.11. Be present on the work site during the process of expansion of flanged connections to be sure the equipment is free from any residual pressure and/or hazardous substance residue; 7.12. Make sure no hot works and any other works which may pose hazard to employees and/or unsealing works in progress are undertaken during the execution of unsealing works; 7.13. Each shift, upon completing works under the issued permit, inspect the orderliness of the work site, and sign both counterparts of the permit in the respective section thereof; also inform, if needed, the heads of the organizational units or shift superiors operating adjacent process units about unsealing works completed; 7.14. Where the issued permit is to be extended for a new term, make sure the working conditions on the work site have not changed, and extend the permit by signing both counterparts of the permit in the permit extension section; 7.15. After completing all works under the permit or with no empty lines left for extension of the permit, close the permit by signing it and entering the date and time of closing in the section 'Permit closed' of the first counterpart of the permit; 7.16. If the issuer of permit is a head of organizational unit, he/she may assign a work supervisor to control the work and perform the duties listed in Items 7.11 7.13 and 7.15 hereof. 3 9
8. Work coordinator shall: 8.1. Before starting the works, agree with the work manager on the date, time and place for the work execution, the to-be-done works, their scopes and course of execution, make sure adequate tools, equipment, materials and/or other work means are used for the works, also discuss on the OHS equipment to be applied during the works; 8.2. Inform the issuer of permit about the need to issue / extend the permit, by indicating the work execution date and time, the contractor, the work execution place (name and technological number of unit), also the required works; 8.3. Get familiar with the requirements set in the permit and safety measures, and sign the permit (except for the cases specified in Item 30 hereof); 8.4. Coordinate the course of the works in progress; 8.5. Where the issued permit is to be extended for a new term, make sure the nature of scopes of the works on the work site have not changed, and sign the first counterpart of the permit in the permit extension section. 9. Work manager shall: 9.1. Before starting the works, get in touch with the work coordinator and agree on the date, time and place for the work execution, the to-be-done works, their scopes and course of execution, also discuss on the OHS equipment to be applied during the works; 9.2. Get familiar with the required special PPE as well as any other protective equipment indicated in the permit, and sign the permit; 9.3. In case a work manager has difficulties in communicating with the issuer of permit and/or work coordinator due to a language barrier, the work manager shall make sure an interpreter is present at the time of permit issue and during execution of unsealing works; 9.4. Evaluate the risks posed by the equipment used for the works, adverse weather conditions, also any other hazards likely to rise in the course of works, anticipate measures (equipment) for safe working, and fill in the occupational risk identification card; 9.5. Make sure the equipment, devices and tools used for the works are in proper condition and adequately selected, inspected or tested under the effective legal norms governing occupational health and safety in the Republic of Lithuania; 9.6. Assign only properly trained and duly certified work executors to perform the works; 9.7. Indoctrinate work executors by familiarizing them with the works to be done, the course of their execution, safe methods of work, required mandatory and special PPE, also any other protective equipment against their signed acknowledgment in the second counterpart of the permit and the card; 9.8. Before the start of works, enclose the hazardous area of equipment unsealing works according to the Company's Occupational Health and Safety Procedure BDS-40 Enclosures; 9.9. Provide the work site with a gas detector or analyzer where the permit requires for continuous monitoring of ambient air; 9.10. Make sure the work executors start the works only after the signatures of all the persons referred to herein have been affixed onto the permit; 9.11. Keep control over compliance by work executors with the requirements established in the permit, card and other OHS procedures of the Company, over the application of safe work methods for execution of the works, use of mandatory and special PPE and any other required protective equipment; 9.12. Refrain from expansion of flanged connections with the issuer of permit absent on the work site; 9.13. Make sure the issued permit and the card are available on the work site at all times; 9.14. Make sure that the work site is always in proper order, i.e. free from waste, irrelevant items, that required materials are kept in good order, etc.; 9.15. Each shift, upon completing works under the issued permit, organize the clear-up of the work site, notify the issuer of permit or work supervisor on works completed, and sign both counterparts of the permit in the respective section; 4 9
9.16. Where the issued permit is to be extended for a new term, make sure the nature and scopes of the to-be-done works has not changed, instruct newly assigned work executors, also sign both counterparts of the permit in the permit extension section. 10. Work executors shall: 10.1. Start unsealing or maintenance works only upon getting aware of any potential hazards and risks on the work site, with all the required mandatory and special PPE indicated in the permit as well as the card, also any other protective equipment available, also after the indoctrination by the work manager (against signed acknowledgment in the second counterpart of the permit and in the card); 10.2. Execute works specified in the permit only, and comply with the requirements indicated in the permit, card and the applicable OHS procedures of the Company; 10.3. Keep the work site clean and tidy at all times, i.e. free from irrelevant items, with materials required for unsealing or maintenance works placed / warehoused in a due manner, etc. 11. Heads of organizational units operating adjacent process units shall: 11.1. Upon the potential risks which may arise during the planned unsealing works assessed, determine the possibility to perform the respective unsealing works (in respect of any possible impact on the subordinate unit); 11.2. Upon approval granted for unsealing works: 11.2.1. Inform respective shift personnel about scheduled unsealing works and their completion; 11.2.2. With unsealing works in progress at the subordinate process unit, perform no other works posing risk to employees and/or to the unsealing works in progress. 12. A head of an organizational unit shall arrange and control that unsealing and maintenance works at the organizational unit managed by him/her are performed in due compliance with the requirements established herein. 13. Any employee of the Company or contractor shall suspend the works if such are executed unsafely or their execution poses the risk of emergencies, incidents, accidents, etc. Work execution shall be resumed only after making sure that all unsafe conditions of work have been identified and their causes have been eliminated. V. OHS REQUIREMENTS BEFORE THE START OF WORKS Equipment preparations for execution of works 14. Any hazardous substances present in the equipment being unsealed and the risks posed by such shall be identified. Process diagrams, markings on pipelines, safety data sheets, etc. shall be used for this purpose. 15. The equipment to be unsealed shall be isolated with energy isolating devices (EID) from any actual or imminent sources of hazardous energy pursuant to Occupational Safety and Health Procedure BDS-29 Equipment Isolation. 16. Pressure in the equipment being unsealed shall be reduced down to atmospheric pressure. 17. Any hazardous substances present in the equipment being unsealed shall be removed from such. For this purpose, the equipment shall be drained, vented, flushed with water, steamed out, purged with inert gas, etc. Any liquid hazardous substances shall be removed by routing such to closed systems (underground drums), gas to the flare line. 18. The equipment to be unsealed shall be cooled down to the temperature below 40 C. Checking of Equipment Preparedness 19. While checking the prepared equipment, readings of pressure gauges, level meters and other measuring devices shall be checked first of all. Later, the conditions in an inside confined space of the piece of equipment shall be checked through drainage, air relief, sampling points, by slowly opening their shutoff valves. 5 9
Requirements for Unsealing of Unprepared Equipment 20. In case it is impossible to fully prepare a piece of equipment according to the requirements set forth in Items 14 to 18 hereof as well as to check the preparedness of the equipment, the following additional measures ensuring occupational health and safety shall be applied while unsealing such equipment: 20.1. Where hazardous chemical vapour or gas may release to the atmosphere while unsealing equipment, continuous air monitoring using portable explosive gas concentration analyzers shall be ensured at the site. In case the analyzer gets activated with the works in progress, work executors shall use the respiratory protecting equipment indicated in the permit; 20.2. Covers, enclosures or shields resistant to chemical substances and protecting work executors against spill-overs, also directing the releases/spills to specific collection areas shall be used; 20.3. Work executors shall wear chemical resistant clothing, panoramic closed type safety glasses, protective face shields, etc.; 20.4. Where a spill-over with etching substances (acid or alkali) is possible during unsealing works, an emergency shower and an eye flushing station shall be located within the distance of not more than 50 meters. In case no stationary emergency washing equipment is available within the above mentioned distance, other means (e.g., portable flushing equipment, a vessel with water, water hose, etc.) shall be used. Before starting works, the functioning of washing equipment (if such is in good operating condition, not closed-up and has free (nonobstructed) access to it) shall be checked. 21. In case flammable substances are likely to release in the course of unsealing works, the below extra requirements shall be complied with: 21.1. The hazard area shall be free from any sources of ignition (hot works in progress, machinery with internal combustion engines, temporary connections of el. equipment, etc.); 21.2. Only the work means (including equipment, instruments and protective equipment) intended for potentially explosive atmospheres (as specified in the manufacturer s documentation) shall be used; 21.3. Work tools shall be made from metal which does not generate sparks, or coated with nonferrous metal; 21.4. Work executors shall wear work clothes from anti-static and fire-retardant fabric. Transfer of Equipment for Maintenance 22. Before transferring equipment for maintenance to other organizational units, it shall be unsealed and prepared (washed, cleaned, steamed out, etc.) so to remove any hazardous (flammable, toxic, noxious, corrosive, etc.) substances from it. 23. Before transporting unprepared equipment to the place of its preparation for maintenance, the equipment shall be prepared so that any leaks of hazardous substances during transportation are prevented (e.g., openings shall be blinded, equipment or its separate parts shall be tightly wrapped in covers resistant to hazardous substances, etc.). 24. Compliance with the requirement in Item 22 above shall be the responsibility of the head of the organizational unit which the equipment belongs to. Compliance with the requirement in Item 23 above shall be the responsibility of the contractor in charge of equipment delivery to the place of its preparation for maintenance. VI. PERMIT FOR EQUIPMENT UNSEALING AND MAINTENANCE WORKS Procedure of Issue 25. The permit shall be executed in two counterparts: the first (top) counterpart of the permit (white) is the original, the second (duplicate, pale yellow) a copy. The permit may also be filled in electronically (in this case, both counterparts of the permit are considered original). 26. The permit shall provide for the name of the organizational unit where the works are going to be performed, the contractor, the process unit and its technological identification 6 9
number, the substance/medium that was/is present in the equipment, the required works, the preparations for work execution performed, the OHS requirements applicable to execution of works, the required special PPE. 27. Depending on the preparations made as well as on the potential risks, the permit shall also indicate any additional occupational safety and health assurance measures. 28. The permit shall be registered with the hazardous work logbook of the organizational unit; its registration number and date shall be recorded on the permit. 29. The permit shall include its expiry date and time, and shall bear the signatures of all the persons indicated herein. 30. In case of emergencies and any other contingencies (e.g., pending process unit shutdown), when the work coordinator is absent at work (after his/her working hours, on weekends, on holidays, etc.), the issuer of permit shall, based on the information received from the work coordinator, enter the contact data (name, surname and mobile phone number) of the work coordinator in the permit. 31. For performing of equipment unsealing works, the permit shall be enclosed with a copy of an isolation with EID diagram which shall indicate the permit registration number and the unsealing point/points. The diagram shall be signed by the issuer of permit. 32. The first (top) counterpart of the permit shall be kept by the issuer of permit and stored in the control room or any other established place of permit issue; the second counterpart of the permit shall be handed over to the work manager. All through the period of the works, this counterpart shall be kept on the work site. Requirements for Permit Issue 33. The permit shall be issued for each specific piece of equipment (e.g., tower, vessel, piping, etc.) separately. 34. The permit shall remain effective for the duration of one shift, however, for no longer than 12 hours. 35. The permit may be extended until the completion of the works indicated in it, however, for no longer than seven shifts from the date of issue of the permit, provided that the working conditions and nature of works remain the same. Extending of the work permit for the next following shift (e.g., extending of a permit issued for the period from 8 AM to 8 PM for the shift from 20 PM to 8 AM) shall be prohibited in case of change of responsible persons (work coordinator and /or work manager). In such cases, a new permit shall be issued and extended. 36. For unsealing of OSBL piping which contains, used to contain or may contain hazardous chemical substances or their mixtures, the permit shall be agreed in writing with the head of the organizational unit in the territory of which the unsealing works are to be performed. The head shall refrain from any hot works and any other works which may pose hazard to the employees involved in the unsealing works. VII. OCCUPATIONAL HEALTH AND SAFETY REQUIREMENTS DURING EXECUTION OF WORKS Equipment Unsealing 37. During unsealing of equipment (e.g., flanged connections), such shall be treated as pressurized items. 38. The flanges being unsealed shall be approached by a work executor with the wind blowing to his/her back. 39. An executor of unsealing works shall first of all loosen (by approx. three turns of the nut) the furthest from him/her bolt; only then the bolts adjacent to this bolt shall be loosened (with approx. two turns of the nut). 40. In case of failure to unseal the flanges upon loosening the bolts as per Item 40 hereof, such flanges shall be unsealed by expanding them. 41. Nuts shall not be completely turned off the bolts until flanges are unsealed in full. 42. In case some hazardous substances get released during unsealing works, or where pressure is detected inside the equipment, the unsealed point shall be immediately 7 9
resealed by tightening the bolts of flanged connections. The issuer of permit shall identify the causes of such hazards and shall authorize to resume unsealing works only upon the elimination of the causes of such hazards. 43. The blinds for process piping shall be selected, installed and removed in accordance with Process Equipment and Piping Blinding/De-blinding Manual BM-12. Collection of Released Hazardous Substances 44. In case release of hazardous substances is likely during unsealing works, certain provisions shall be made for collecting such releases and for preventing the entry of such substances to unit platforms, soil and sewers, etc. Various containers, trays, mats, screens, etc. shall be used for this purpose. VIII. EMPLOYEES ACTIONS IN CASE OF EMERGENCY 45. In case of fire, accident or any other incident during unsealing or maintenance works, the work executors shall interrupt the works immediately and report this to the Dispatcher of Production Control Department of the Company by phone 3333 (from a fixed-line or Omnitel network) or 8 433 93333 (from any other mobile communication line), also to the employees of the facility they have been working at. 46. In case of fire, accident or any other incident during unsealing or maintenance works, the permit shall become void and all its counterparts shall be transferred to the incident investigation committee. 47. In case of an accident due to released hazardous substances, data on such substances (safety data sheets, written procedures and other documents) shall be immediately provided to the medical institution where the casualties undergo medical treatment. IX. DOCUMENT CUSTODY 48. Upon unsealing works completed, the first (top) counterpart of the permit (original) shall be kept for 30 days at the organizational unit which has issued it. 49. Upon unsealing works completed, the second counterpart of the permit shall be kept at the contracting organization. 50. A hazardous work logbook shall be stored at the organizational unit for the period of its validity and for 5 more years after its completion. X. EMPLOYEE TRAINING 51. The issuer of permit, work supervisor and work coordinator shall be required to pass the test hereunder pursuant to the Company s occupational health and safety indoctrination procedure. 52. Work managers shall be tested hereunder prior to the commencement of works and later periodically, every 12 months at least. A work manager having passed the test shall be provided with a card certifying the employee's qualification. Such card shall indicate the following details: employee's full name, name of organization and period of validity of the certification. During the execution of works, a work manager shall be required to have this card on the work site. 53. Contractor employees involved in unsealing or maintenance works shall be familiarized with the requirements established herein. The responsibility for such familiarization shall be vested in the contractor's manager. XI. FINAL PROVISIONS 54. This Procedure establishes only the key and minimum occupational safety and health requirements for unsealing and maintenance works; therefore, all employees organizing or 8 9
performing unsealing and maintenance works shall, in case of need, undertake additional measures to ensure occupational safety and health. 55. Periodic review and, where appropriate, updating of this Procedure shall be the responsibility of Occupational Health and Safety Manager. Prepared by Senior Occupational Safety and Health Specialist Egidijus Luomanas 2016-12-08 9 9