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2012 Turnaround
EHS Manual
Port Arthur 2012 TAR EHS Manual Page 2 of 77
G-P-ME-010 Annex 6.5 Issue January, 2012
(3)-5.2 EHS Manual Revision 00
Topic Page
Introduction 5
Port Arthur Responsible Care Policy 7
1. Organization, Coordination and Responsibility
1.1. EHS-Organization Chart (Planning and Execution Phase) and Role 8
Description, Interaction with site EHS Organization and Contractors
1.2. EHS Objectives, EHS Performance Indicators 11
1.3. EHS Communication, Jour Fix 11
1.4. EHS Documentation 11
1.5. Incident and Accident Analysis and Reporting 12
1.6. Personnel Tracking & Security 13
1.7. EHS Budget and Cost Management 14
1.8. Recruiting EHS Personnel 15
1.9. Evaluation and Lessons Learned 15
3. Permit Management
3.1. TAR Permit System 28
3.2. System Isolation 37
4. EHS Implementation
4.1. EHS Management Concept 42
4.2. EHS Plan 42
4.3. EHS Manual 42
4.4. Safety 43
4.5. Health 47
4.6. Environmental 52
4.7. Training 59
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Topic Page #
5. Consumable and Equipment Management
5.1. EHS Consumables 62
5.2. EHS Equipment 62
5.3. EHS Warehouse 62
6. Emergency Response
6.1. On-site/Off-site Response Units 64
6.2. Alarm and Evacuation Plan 65
6.3. Installed Safety Devices 70
7. Contractor Management
7.1. EHS Aspects for Contracting Strategy 72
7.2. Selection of Contractors 72
7.3. EHS Performance of Contractor 74
7.4. Contractors EHS Personnel 74
INTRODUCTION
This manual illustrates turnaround project organization and communication, and states the general rules
and regulations that apply during the Port Arthur BFLP – Cracker and Sabina – C4 Turnarounds. The
manual’s accepted standards and procedures for BASF- employees, contract personnel, and contractors
are the minimum requirements to perform a safe well-planned execution of all the planned activities.
The following Manual has been developed to specify safety responsibilities required by BASF of
contractors performing work associated with a Turnaround. This Manual establishes minimum
acceptable safety standards and identifies hazards that are potentially present at the BASF Port Arthur
Site. This Manual is an overview of the most important procedures followed here at BASF; for detailed
information concerning OSHA Regulations, site specifics, etc. contact a BASF EHS representative.
In order to keep the duration of the turnaround execution to a minimum, the BFLP & Sabina process
facilities will be decommissioned and recommissioned in different phases. This means that equipment
operability and planned/scheduled maintenance will be available at different times to execute the various
activities. As a result, certain areas of the process may be operational while maintenance activity is
ongoing in other areas. It is therefore of vital importance that all activities (operations and maintenance)
during the 2012 turnaround are only carried out at an appropriate time and managed through a work task
permitting process.
Duration / Timing
• Duration of the Sabina-C4 turnaround will be 55 days. Plant shutdown will begin April 9, 2012.
• Duration of the BFLP-Cracker turnaround will be 50 days (C2 out – C2 in). Plant shutdown will
begin April 18, 2012. This includes a shutdown period of 11 days, work period of 35 days, and
restart period of 4 days.
Note: Certain utilities and waste treatment functions will remain operable to satisfy refinery and/or
regulatory requirements.
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TAR Critical Path maintenance activities have been identified and will require a 24-hour work schedule.
a) C2 Splitter Re-tray
b) Flare Header Tie-ins
c) Charge Gas Compressor Repairs
All expansion project work will be stopped and placed in a hold status until Turnaround is completed.
During the Shutdown, Turner Industrial Group will execute the tie-ins and equipment modifications for the
Cracker expansion.
The Port Arthur Facility will be subdivided into two separate areas (Cracker & C-4) during the Shutdown
each area will have its own execution organization. All activities will be directed by a common scheduling
management system (RMS), which includes the decommissioning and commissioning of all process
facilities.
The Responsible Care Policy for the BASF Port Arthur Site’s BFLP/Sabina partnerships encompasses
health, safety, security and environmental protection. Our site policy supports the BASF Corporation
Responsible Care Policy Statement in its belief and implementation of the following principles:
• The health and safety of our employees, customers, suppliers and neighbors and the protection of
the environment are valued above all else.
• Accidents and incidents are preventable through continuous improvement and the personal
commitment of all employees.
• The foundation of all EHS programs at the Port Arthur Site are based on management’s
commitment and responsibility and employee’s acceptance of responsibility for their safety and the
safety of their fellow employees.
• Site Responsible Care efforts are based on a framework of goals, objectives, procedures and
measurements that meet or surpass regulatory requirements, and thereby, are based on the
philosophy of long-term sustainability.
Each site employee must realize and accept responsibility for EHS performance and continuous
improvement. Employee Responsible Care performance shall receive the same consideration as any
other work requirement when overall job performance is being evaluated.
The Port Arthur Site Leadership Team recognizes that only through the efforts, dedication, and
cooperation of each employee, supported by management, can our Responsible Care objectives be
obtained.
1.1. EHS-Organization Chart (Planning and Execution Phase) and Role Description,
Interaction with site EHS Organization and Contractors
Waste Transport
During the 2012 turnaround the following people are intended to be the primary contacts
for signing Manifest:
• Angela Hodgkinson (days) – ext 5237
• Ryan Yoes (days) – ext 5632
• Mark Screen (days) – ext 5033
• Robert Grissom (days) – ext 5207
• Chris Megas (nights) – ext 5348
Report emergencies by calling ext. 5555 or 5293 or radio by contacting the Shift
Coordinator on channel A-13 or Site Safety personnel on channel C-1.
EHS Service TAR Execution Organization
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Safety Coordinator
Environmental Specialist Environmental Specialist Environmental Specialist Environmental Specialist Safety Coordinator Safety Coordinator
Cracker / C 4 Area
Cracker / C 4 Area Cracker Area C 4 Area Cracker Area C 4 Area
Mike Van De Hoef (N)
(Contract) Chris Megas (N ?) Ryan Yoes Mark Screen Tom Davis (D) Dave Smith (D)
Tim Masters (N)
Field Safety Tech Cracker/Cold Field Safety Tech Field Safety Tech
Cracker Area NORM Monitoring C 4 Area Cracker/C4 Area
(6 - Contract) Sun Tech (3 - Contract) (3 - Contract)
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EHS Objectives, EHS Performance Indicators for BFLP Cracker / Sabina C4;
Environmental
• There will be no RQ releases and/or NOE’s, NOV’s from the turnaround.
• Compliance with requirements for flaring minimization on shutdown / restart.
Health
• No BASF / Contractor personnel exposures above the occupational exposure limits for
Benzene / Butadiene.
Safety
Safety goal is based on actual on-site hours worked for BASF, Contract, and Contractor
personnel during the duration of BFLP Cracker / Sabina C4 Turnaround.
• Zero incidents resulting in days away from work injuries
• TRIR of 0.60 or less (6 OSHA recordable injuries for 2,000,000 hours worked)
Reliability
• The expected post turnaround reliability is for continuous operation until the next
scheduled turnaround in 2018.
Quality
• C4 post turnaround startup of the plant will not have interruptions directly related to the
quality of work performed during the turnaround. Work performed during the
turnaround will not prevent reaching 100% production capacities on time.
• Cracker post turnaround startup of the plant will not have interruptions directly related
to the quality of work performed during the turnaround. Work performed shall not
prevent achieving previous ethylene production rates within 10 days of on-spec
production.
Each day the incidents reported for that day will be reviewed by BFLP TAR Leadership
and Site EHS, site communication for reported incidents will be determined by this group.
Methods that will be utilized during turnaround to communicate incidents to contractors:
• Be discussed during the daily meetings held between BASF EHS and the Contractor
Safety Representatives, additional communications will be provided to Contractor
Management/Supervision. Each Contractor Company will be responsible for
communicating these findings down through their organization to ensure adequate
corrections and understanding is achieved.
• Timeout for Safety Message – BFLP and/or Contractor Leadership Group to stop work
activity and congregate the work group(s) to deliver a safety message.
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BASF Port Arthur Security Command Center contact information: Phone 409-960-5294
(in-house ext. 5294) or BASF Radio Channel C-2.
• 24/7 Security Provided
• Gates
• Patrols
• Video Surveillance
All contractor access to the BASF FINA Petrochemicals Port Arthur property including
parking area will be by authorized personnel who meet the following criteria.
• Contractor personnel must badge-in and badge-out every time they go through the
security gates and wear issued ID badges (ISTC & BFLP Contractor) in a visible
manner at all times. Exception to wearing ID badges may be permissible during actual
work activities where loose objects may cause health and safety concerns or damage
(visual & electronic reading capability) to badges may occur.
• Only the person issued the BFLP Contractor badge is allowed to use that badge. No
one is allowed to swipe another employee’s badge for accessing or exiting the site.
• Contractor suppliers will also be required to obtain vehicle passes from the Security
Command Center located at gate 99. (Vehicles and persons are subject to inspection)
This pass must be returned upon exiting the plant.
• All Contractor employees must park in designated parking lots.
• All Contractor supervision shall park in their designed areas only.
• No contractor company vehicles are allowed to park in BASF employee parking lots.
• Speed limit on BASF FINA Petrochemicals property is 14.5 mph on outer roads and
7.5 on inner plant roads.
• No cameras (includes cell phones with cameras) will be allowed on site without written
permission of BASF management. (see PA-020-0037)
• No alcoholic beverages or illegal drugs will be allowed on company property at any
time. All illegal drugs found will be confiscated, turned over to the Pt. Arthur Police
Dept. and the persons involved will be removed from the site.
NOTE: All BASF Security requirements for accessing 32nd Street parking area (across
from the TOTAL Refinery) will apply.
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The TAR EHS budget and cost management will follow the requirements of the TPEP
2012 Cost Management Plan.
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Qualification/Training
Preferred minimum of 10 years experience in related petrochemical work activities,
completion of OSHA general industry (CFR 29-1910) and/or construction (CFR 29-1926)
occupational health and safety training course(s) related to job site hazard recognition
safety inspection/audits for; Hazardous energy isolation, hot-work (metal welding-grinding-
thermal cutting), confined space entry, elevated work/fall protection, housekeeping, and
crane hoisting and rigging.
Work Requirements
• Ensure all jobs are executed in compliance with BASF EHS rules and guide-lines.
• Coaching safety behavioral and/or enforcing site Zero Tolerance Policy.
• Conduct daily safety inspections/audits to ensure all unsafe acts and conditions are
immediately addressed.
• Ensure all hazard assessments and permitting requirements are being followed.
• Inspecting and controlling housekeeping.
• Extended periods of time out in the field walking throughout assigned process area(s)
and as needed climb stairs/ladders to elevated work areas.
• Informing the Area EHS Coordinator about the results of the safety inspections/audits
and any observed deficiencies and means for correcting.
During the 2012 Turnaround Inert Entry will be required when removing or loading
catalyst, packing or desiccants that is pyrophoric in nature and could create a fire when
coming in contact with an oxygen concentration high enough to support combustion.
Compliance with Port Arthur Site procedure PA-020-0052 Inert Confined Space Entry is
mandatory.
For more information on welding in confined spaces see PA-020-0004 Confined Space
Entry Procedure and PA-020-0060 Metal Welding, Thermal Cutting, Grinding.
Catalyst/Desiccant Changes
Catalyst/Desiccant in heavy hydrocarbon services has the potential for spontaneous
combustion when exposed to air much like the Pyrophorics. The catalyst located on this
site that have this potential include: Charge Gas Dryers (S-2601), Pygas 2nd Stage
Reactors (R-5502), Gas Fractionator (T-1401) and C4 complex reactors. Site clearing
procedures, which may include inert entry in a nitrogen atmosphere, address these
concerns along with Project Safety Reviews, Job Safety Analysis and by the Management
of Change (MOC) process.
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Electrical Shock
All electrical sources should be checked in addition to welding leads, cutting torch hoses
and all other tools and materials.
All electrical equipment used inside a confined space shall be:
• Consistent with the area classification,
• In good conditions, and
• Grounded or double insulated.
• A ground fault circuit interrupter shall be used for all electrical hand tools.
Site specific Hazardous Energy Isolation Procedure PA-020- 0001 will be communicated
to contractor employees during ISTC orientation and by their employer’s safety
representatives. BASF will conduct safety audits to ensure compliance.
Elevated Work
Special care and awareness should always be practiced when working jobs on elevated
structures or platforms. Even the smallest of objects dropped from an elevated structure
has the potential of causing severe injury and death adherence to Site procedure PA-020-
0054 Falling Object Prevention must be followed. If at all possible work should be
scheduled that removes as much of this potential as possible. However when this cannot
be avoided good communication and work practices is a must in protecting people from
potential falling objects. Everyone involved in this work is responsible from the technician
writing the permit to the maintenance crews performing the work. The technician must
inform the crews working on the structure of the importance of maintaining control of their
tools and materials and the dangers they pose to crews working beneath them. Areas
should be barricaded and warning labels attached to inform and warn anyone in the area
of the ongoing elevated work.
Falling Objects
Barricade below each level where an object has the potential to fall. Ensure adequate toe
boards and additional netting (mesh, screen or wire) is in place at all times while working
from scaffolding. Use proper storage of tools and equipment to reduce the chance for
falling objects. Use proper rigging techniques for handling of material/equipment.
• Mesh will be used from handrails to platform in areas where there will be “stacked”
workers working above each other. This will prevent incident things from being
dropped where probability of someone being below is high
• Mesh will be used from handrails to platform on platforms or scaffold where there will
be materials stored or being handled a lot. The most common area this would be work
on tower platforms.
• Mesh will be used from handrails to platform on decks if materials are going to be
stored/stacked uncontained higher than the toe rail if it is within 4 feet of the edge.
• Containment shall be used to contain small object like bolts, hand tools, etc. on
elevated areas.
• Red Barricade tape should be used as needed for overhead work and lifting. Tape
should have Red tags or signs indicating overhead hazard.
• Flagging and spotting shall be used during lifts.
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Falls
Fall prevention is the first priority utilizing rigid barricade or covers for floor openings
Compliance with Site specific Fall Protection Procedure PA-020-0010 is mandatory.
Flying Objects
The proper use of PPE to protect employees from flying objects such as hardhats with
face shields and/or goggles is mandatory. The proper application of barricade tape and
physical barricades may also be used. Refer to Site specific General Site Safety Rules
Procedure PA-0200026; Section 4.6.15 for instructions for barricading hazardous areas.
Heat Stress
Compliance with Port Arthur Site procedure Heat Stress Awareness Procedure PA-020-
0061 is mandatory. The following risk factors shall be considered when there is potential
for employee exposure to high temperatures:
• Age, obesity, personal protective equipment, strenuous work levels,
dehydration/electrolytic imbalance, lack of acclimatization, alcohol,
diseases/conditions, and medications.
It is the responsibility of all contractors to develop and implement a heat stress protection
program that adequately protects contractors from heat related disorders.
All heat related disorders require evaluation by the Site Medical Responders or Site
Medical Department for BASF employees.
Heavy Rigging
Compliance with Site specific Hoisting, Rigging, and Critical Lifts Procedure PA-020-0023
is mandatory. Competent persons will conduct inspection of rigging equipment. Use tag
lines when lifting with hoist or cranes. Designated qualified crane flagman trained in
approved hand signals will be required.
Housekeeping
Work areas will be kept free from debris or conditions that could contribute to slips, trips
and falls. Welding leads, extension cords and hoses shall be positioned overhead where
feasible.
The Port Arthur Site’s Hot Tap & Stopples Procedure PA-020-0014 establishes a clear set
of guidelines to be followed when performing Hot Tap and Stopple installations in piping
systems that cannot be safely cleared and isolated to make an out-of-service tie-in.
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Routine production activities (e.g. filter cleaning, hose connection or disconnection, and
process sampling) may be performed by qualified operations personnel without completion
of a safe work permit provided that current equipment-specific operating procedures are
utilized which cover the identification and control of hazards.
NOTE: For a more detailed description and requirements for initial opening of process
equipment see EHS Procedures PA-020-0005 Line Breaking
Noise
Even when process units are out of service, noise exposure is a significant problem. In
turnarounds noises sources included welding machines, light plants, compressors,
grinders, and other powered equipment. To control these sources, place engine driven
equipment as far away as possible. Ensure adequate mufflers are installed on equipment.
Provide hearing protection to all workers and require it to be worn. Hearing protection is
available to all employees and contractors. Only ANSI approved hearing protection
devices will be used.
Refer to Site specific Hearing Conservation Procedure PA-020-0011; Section 4.5. for
Noise Reduction Rating requirements for hearing protection.
Nitrogen
Nitrogen is a colorless, odorless and tasteless gas. The principle hazard associated with
nitrogen is the potential for asphyxiation. Nitrogen is used on Site to help clear the
systems of explosive and toxic materials.
Pinch Points
Communications between employees will be stressed to avoid exposure to pinch points.
Use proper gloves for the application as required.
Refractory Work
Exposure to refractory ceramic fibers (RCF) and crystalline silica may be likely in the
furnace and steam producing areas of the Site. RCF and crystalline silica are inhalation
hazards and must be controlled. General exhaust ventilation (air movers or natural draft if
sufficient) should be located to exhaust the equipment. Additional breathing protection
from ½ face breathing respirators may be needed depending on the circumstance.
Scaffolding
Scaffolds shall be furnished and erected in accordance with 29 CFR 1910.28 – Safety
Requirements for Scaffolding and 29 CFR 1926 Subpart L – Scaffolds and Port Arthur Site
specific Scaffolds Procedure PA-020- 0015. All scaffolds will be inspected by a competent
person and tagged accordingly. Scaffolds erected in excess of six feet shall have mesh,
screen or wire barricades to prevent objects from falling from the scaffold platform.
Vehicular Traffic
Compliance with site traffic regulations is mandatory. Follow posted speed limits, road
barricades and ensure vehicle entry permits are acquired before entering process areas.
2.2. Identification of High Risk Jobs and Jobs with Hazardous Potentials
C2 Splitter Re-tray
A hazard assessment and safe work concept was developed by TAR EHS Coordinator
and reviewed by Project Manager and Construction Manager for approval. The hazard
assessment reviewed and identified potential safety hazards and risk related to separate
crews performing internal and external maintenance task at different tower elevations
simultaneously. Overhead/Stacked work activities within a confined space will require a
written specific procedure to be in place that will identify, manage and communicate
hazards related to this type of confined space entry and work activity.
• Before lower level confined space entry may begin protective barriers must be in
place. These barriers must be designed to provide adequate protection of lower level
workers from the impact of dropped or falling objects from above work crews.
• If hot work activity is required protective barriers must also provide adequate protection
against welding, cutting and grinding hot work sparks and slag to lower levels of the
tower.
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• Hot Work in a confined space will follow requirements of PA-020-0004 Confined Space
Entry Procedure and PA-020-0060 Metal Welding, Thermal Cutting, Grinding.
• Dropped objects within the tower that strike/land onto a protective barrier must be
reported to BASF and actions to these types of incidents should follow the same
investigation criteria as any other reported falling object incident.
For a more detailed description and requirements to manage this work activity reference
the BFLP C2 Splitter Re-tray Hazard Assessment document.
For a more detailed description and requirements to manage this work activity reference
the Sabina C4 BD Tower Repack Hazard Assessment document.
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The OSHA exposure limit (PEL) for Hexavalent Chrome is 5 micrograms per cubic meter
of air calculated as a 8-hour time weighted average (TWA) with a Action Level of 2.5
micrograms per cubic meter of air. These respiratory protection requirements will remain in
place until employee monitoring reveals the work areas and work tasks are below the
OSHA Action Level of 2.5 micrograms per cubic meter of air.
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Use of ultra-high pressure water (where the pump pressure exceeds 20,000 psi / 1,360.5
bar) cleaning methods requires a pre-job plan.
• Water cleaning contractors used for ultra-high pressure water cleaning operations shall
have equipment designed and constructed for this application and must have
established procedures.
• All equipment associated with high pressure and ultra-high pressure water cleaning
equipment must be subject to a defined inspection and testing program.
• Operators of ultra-high pressure water cleaning equipment must complete equipment
specific training prior to the use of the equipment on a BASF site.
Water cleaning contractors shall provide equipment inspection and testing records upon
request. All high pressure water cleaning equipment must be maintained according to
design standards by qualified personnel.
When hose drops exceed ten (10) feet, the hose shall be securely tied off to a rigid
support to limit the pull due to the weight of the hose. All hoses must be protected from
damage due to vehicle traffic.
Prior to authorization of a work permit, a High Pressure Water Cleaning Checklist must be
completed by a designated company representative.
Provisions for spill containment and clean-up of hydraulic and /or lube oil spills shall be
established.
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Special attention should be given to these pieces of equipment even after the equipment
has been opened for a long period of time. The pyrophoric materials can dry out over time
and ignite long after the equipment has been opened to the atmosphere. Keeping this
material in wet conditions will help to control these potential hazards. Contact BASF
Operations personnel for additional information and safeguards related to pyrophoric
materials.
QA/QC Testing
Hydro Pressure Testing
Requirements for ensuring hazard and risk control measures are identified and followed
for this activity is addressed in the Port Arthur Site Mechanical Procedure PA-P-ME-401
Pressure Tests for Integrity after Construction or Leaks after Maintenance.
X-Raying Welding
Communications between Area Owner/Operator and Contractor performing this service
must be established and maintained throughout the x-ray inspection process. To ensure
proper communication between all affected personnel is maintained:
• All x-ray inspection work activity will require a Safework permit be issued by the Area
Owner/Operator.
• Areas of potential exposure to radiation must be physically barricaded and visual
warning signs of radiation hazard posted at all sides of the restricted area.
• All other work within the identified radiation hazard area must be stopped and
personnel evacuated from this area.
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NOTE: Additional PPE requirements are detailed in Safety and Health Procedure PA-020-
0017 Personal Protective Equipment and the Site’s PPE grids. To obtain a copy of the
Site’s PPE Grids please consult with your company’s BASF contact person.
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Contractors are required to perform a job specific safety analysis (JSA) to address
hazards that are inherent to maintenance activities such as but not limited to; PPE for task,
tool inspections, work area layout, weather, mobile equipment and power tool usage,
elevated work, etc…
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2012 Turnaround Discovery Work Team – See Turnaround Organizational chart “TAR
Support” for details.
Permitting discovery work will be handled though a manual hand written permitting permit
process. Each identified required permit (safe work, hot work, confined space entry,
etc…) will be permitted buy Operations as described in section 3.1 of this document.
Submit a list of temporary building and employee staging requirements to the Project
Manager or your site’s contact person at least 2 weeks prior to your company’s start date.
After receiving permission for bringing temporary buildings on site you must request a
Facility Sitting review and approval permit. Permit must be posted inside building in a
location that is easily visible for inspection.
List requirements as number and size of:
Office space(s), Lunch / Employee staging area
Construction Material / Equipment / Tool Trailer(s)
Field Shop/Fabrication area(s)
NOTE: For a more detailed description and requirements of the Port Arthur facility,
equipment, and occupied buildings siting process see section 8. Port Arthur EHS
Procedures to access PA-020-0034 Facility and Equipment Siting.
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3. Permit Management
NOTE: See drawing for general description of each area field permitting location.
Area C-4 / Cracker Safe Work Permitting Locations
NOTE: Contact the BASF High Voltage Electrical Group for Permitting Electrical Equipment Rooms
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The Permit Issuer (Operating/Owning Department Representative) shall meet the Permit
Acceptor initially at the specific location where work will take place to review all pertinent
sections of the permit. If confined spaces, line breaking, hot work or Lockout/Tagout is
involved then an individual performing the work must meet with the Permit Issuer at the
work location.
A SWP shall be issued by the Operating/Owning Department for work such as:
• Work performed by Contractor Employee
• Service / Maintenance Work
• Work involving potential chemical exposure
• Non routine work/activities
• Maintenance or operations work performed by Operating/Owning Department not
covered by a Written Operating Procedure.
Exceptions: A SWP is not required for routine operations activities that are covered by
Written Operating Procedures. Examples of routine activities are: hose connects /
disconnects, filter change, sampling, etc.
• Permit Acceptor must understand the spoken and written language in which the
permit is written.
• The Permit Acceptor has the responsibility to inform other workers working under the
permit about the hazards of the job and the requirements of the permit.
• Permit Acceptor must not transfer the permit to other personnel or shifts, unless the
permit is revalidated from the Permit Issuer.
• If any conditions change that are listed on the permit, then the Permit Acceptor must
communicate the changes to the Permit Issuer.
• By signing the permit, the Permit Acceptor verifies workers are trained in applicable
safe work practices, to use the equipment for the job and in how to properly use the
PPE necessary for the job.
• Permit Acceptor must ensure the permit is signed and returned at the completion of
work to an authorized Permit Issuer in the unit/department where issued and
communicate any problems encountered or left in the workplace.
NOTE: For a more detailed description and requirements of the Safe Work permitting
process see Port Arthur EHS Procedures PA-020-0003 Safe Work Permits.
Safety precautions for work activities in the sites electrical equipment rooms and on the
site’s major electrical distribution equipment by:
• Ensuring clear communications about the work to be accomplished.
• Providing approval from the equipment owner.
• Identifying and communicating hazards related to the identified task.
• Providing protective measures to address the identified hazards.
• Providing specific communications on lockout/tagout of hazardous energy sources.
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All work by maintenance, contract maintenance or other BASF servicing groups working
within the plant electrical rooms or on the sites electrical distribution equipment.
This procedure does not apply to:
• Other types of permits issued in conjunction with the work being done under the Safe
Work Permit (Vehicle entry, Critical Lift, etc.) for areas outside the electrical
equipment rooms.
• HV Electrical Department personnel performing operating and maintenance tasks
within their assigned electrical discipline.
• Qualified Shift I&E Maintenance Technicians who have been trained to operate
disconnecting device in the 4.16 kV Motor Control Centers and operate circuit
breakers in the 480 volt, 4.16 kV, 13.8 kV and 34.5 kV switchgear for the purposes of
electrical isolation.
• Qualified Production Department personnel who have been trained to operate a 480
volt Motor Control Center disconnect switch for the purpose of electrical isolation.
No revalidation of an Electrical Room Safe Work permit will be allowed a new Safe Work
permit must be issued at the beginning of each shift. All of the requirements of Section 4 of
the Safety and Health Procedure PA-020-0003 (Safe Work Permits) will apply for this
procedure with the following exceptions:
Approval and Revalidation of Safe Work Permits will be done by a HV Electrician.
Any additional permits that need to be issued to complete the work (i.e., Vehicle Entry,
Critical Lift, etc.) will be obtained through Operations.
The duration of the Safe Work Permits issued by the HV Electrical Department will
coincide with the shift hours that the Electrical Department is working.
All of the Safe Work Permits, along with any additional permits/documents, that have been
issued throughout the week will be sent to the Permit Room in the Control Room for filing.
These documents will be received in the Permit Room by 8:00 am on the first scheduled
work day of the next work week.
Hotwork Permits
To establish standards for welding, cutting, brazing, grinding, or other activities which
require the use of open flames, or which may generate sparks, including electrical tools,
electronic equipment, and vehicles.
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For a more detailed description and requirements of the Port Arthur Hot Work permitting
process see EHS Procedures PA-020-0002 Hot Work Permits.
2012 TAR LEL Walker / Fire Guard Requirements (Approved PA-020-0002 procedure deviation)
LEL Escort for Vehicle Entry into the Unit(s)
Vehicle Entry is considered a Low Energy Ignition Source Hot Work.
• Plant Decommissioning/ Shutdown Phase – Plant conditions have not changed from
normal operations continue to follow PA-020-0002, Section 4.4.
o Have a properly checked/calibrated Combustible gas monitor and be trained in its
use.
o An initial atmospheric check is required where the vehicle will be operated.
o Blue Areas and plant roads outside of process areas containing flammable
materials do not require a Vehicle Entry permit.
o Red Areas require an LEL Walker to escort the vehicle in/out while continuously
monitoring atmospheric conditions.
o The vehicle escort shall maintain a distance of 30 feet ahead of the traveling
vehicle.
• Turnaround Execution Phase – When the BFLP Cracker and Sabina C4 facilities
including all ground and elevated flare systems have been cleaned/cleared the TAR
Site Leadership will evaluate the current conditions at this time to determine if the
elimination or containment of hazardous/flammable material in these process areas
still poses a credible fire/explosion risk,. If current conditions are acceptable the
change to and “LEL Rover” for atmospheric monitoring for low energy ignition source
work activity may begin under these conditions.
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o Communications from TAR Site Leadership to all affected personnel start date/time
of LEL Rovers.
o Low Energy Ignition Source is operations that produce low heat and little or no
sparks, such as electrical tools, hammering, lighting, sandblasting, vehicles, etc.
o An initial atmospheric check is required where the low energy ignition source will
be operated.
o LEL Rovers would actively walk major pipe alley and roadways within the unit(s)
and be able to travel their area of responsibility within a 10 to 15 minute timeframe.
o LEL detection of 10% or greater (meter alarm setting) will require immediate
shutdown of all low/high energy ignition source hot work in the affected area.
o Low/high energy ignition source hot work in the affected area may not restart/begin
until the cause of detection has been corrected.
• Plant Re-commissioning/Startup Phase – Revert back to normal site requirements for
vehicle entries and low energy ignition source operations.
NOTE: For a more detailed description and requirements of the Port Arthur Confined
Space Entry permitting process see EHS Procedures PA-020-0004 Confined
Space Entry.
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Excavation Permits
Excavation permits are required for any machine driven excavation equipment penetrating
any ground surface (concrete, dirt, gravel, etc.) at the Port Arthur Site. Examples of
excavation work requiring a permit are grass stripping, saw cutting, operating a machine
driven hoe or hoe ram, and a jack hammer. Hand excavations will normally be excluded
from this requirement, but must be considered on a case-by-case basis.
Excavation permits shall be in addition to, not take the place of, Safe Work Permits. For
excavations outside the Port Arthur property line, a notification to Texas ONE CALL (1-
800-545-6005) must be made 48 hours prior to digging.
NOTE: For a more detailed description and requirements of the Port Arthur Excavation
permitting process see EHS Procedures PA-020-0019 Excavation, Drilling and Pile
Driving.
Safety considerations:
• Equipment Inspections
• Proper functionality of all controls
• Ensuring the lift plan is safe and does not overload the equipment
• Ensuring the loads are secure
• Rigging is adequate and tag lines are used
• Clearances are adequate for all movements
• Weather conditions are safe. Wind Speeds over 20mph require special precautions by
operator or a suspension of work.
• Has hazards in view or is always in direct communication with the spotter or signal-
man.
• The crane operator is ultimately responsible for the safe lifting of material/equipment.
This hoisting and rigging/critical lift procedure is intended to ensure proposed lifting
equipment and associated rigging accessories are technically acceptable to perform lifts
with-in predefined boom angle, weight, and wind speed limits, and to make everyone
involved in lifts aware of company and regulatory requirements that must be adhered to
when making a lift. It also documents that there are no other reasonable alternatives to
executing the work, other than by performing a critical lift. It is NOT intended to authorize a
critical lift from an operational safety perspective. Final critical lift authorization is obtained
through the safe work permit process.
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Prohibited Lifts cannot be permitted and will not be allowed. Listed are recognized
“Prohibited Lifts”.
• Any lift over personnel or occupied portions of buildings; or
• Any lift in which the load exceeds 100 % (NOTE: Crane load charts are limited to
85% of the actual crane capacity) of the load chart of a crane excluding annual
recertification of fixed location cranes; or
• Soil or ground conditions are such that the stability of the crane during a lift cannot
be guaranteed.
• Using a “friction” type crane for any lift
NOTE: For a more detailed description and requirements of the Port Arthur Critical Lift
permitting process see EHS Procedures PA-020-0023 Hoisting, Rigging, and Critical Lifts.
Hazardous Energy
All activities shall be performed, to the extent possible, under a Zero Energy State that has
been verified, at a minimum, by Operating/Owning Department personnel. The Port Arthur
facility utilizes a Master Isolation Procedure to identify and control hazardous energy.
Master Isolation Procedure (MIP) is a hazardous Energy Source control process that may
be used for control of multiple isolation points/devices. Since the Master Isolation Plan
relies primarily upon administrative means to control the release of potential hazardous
energy, additional steps for Verification of Zero Energy State are required to ensure that
protection comparable to Lockout is maintained during work covered by this procedure.
There must also be a mechanism to achieve personal acceptance of the Hazardous
Energy Isolation by each Authorized Employee (Work Crew Accountability Form - WCAF)
When Zero Energy State verification is not possible, proper PPE and/or additional
administrative/engineering controls shall be utilized to minimize exposure to hazards.
Personnel shall not perform maintenance activities involving the control of hazardous
energy sources without prior written authorization in the form of a Safe Work permit issued
by an Operating/Owning Department Permit Issuer.
NOTE: For a more detailed description and requirements for the control of hazardous
energy see EHS Procedures PA-020-0001 Control of Hazardous Energy
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Barricades
Danger areas must be identified and managed while these conditions exist. Limited or NO
access must be communicated to all affected personnel. An accepted practice in our
industry is the usage of barricade warning tape to rope off an area to ensure personnel do
not wander into a potential hazardous condition. Barricades and barricade tape will be
used whenever hazardous or possible unsafe conditions exist in a particular area of the
plant. Each barricade will be constructed to have four sides and each side will be tagged
to describe the owner and area hazard. Barricades will only be removed when the job is
complete or when the hazard no longer exists.
Wooden Barricade – Access way closed (normally used for plant roadways and process
unit travel pathways). Do not enter without permission, utilize an alternate route.
Installation of barricade tape at the Port Arthur Site requires the proper tag be placed on
each leg at the intended access point of the barricaded area. The owner (installer) is
responsible to manage their constructed barricade (ensure all legs are maintained per the
original intent) until the need for barricading an area has been eliminated, at which time
the owner (installer) is responsible for removing all posts, tape, tags, etc.
.
NOTE: If two or more service groups are utilizing one or all legs of a barricaded area each
service group is required to tag the barricade leg(s) that are being shared. The barricade
leg(s) being shared will not be taken down until all tags have been removed.
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Red Tape.
Identifies hazardous condition or
Overhead Work. Do not enter without
owner’s permission.
NOTE: Barricade Tape this is specific to a work task is acceptable, example: Radiation,
Hydroblasting, etc..
Tags
The Port Arthur Site utilizes many types of tags as an administrative process to identify
owner’s intent and communicate potential hazardous and control measures. The
placement of a Tag on a piece of equipment or barricade requires personnel to follow all
written instructions of the tag and never operate equipment, proceed past a restricted point
or remove any tag that is not directly under your control. Contact the tag’s owner if you
need assistance or clarification of what is permissible.
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4. EHS Implementation
When certain conditions are not addressed by existing BASF Corporate or Port Arthur Site
specific EHS procedures the 2012 TAR Core Team will create a 2012 Turnaround
procedure or request for a Temporary deviation to an existing procedure to ensure any
hazardous conditions will be identified, managed, and communicated effectively.
Refer to PA-020-0027 Procedure Deviation procedure for more details regarding the
requirements of requesting a procedure deviation.
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4.4. Safety
For Contractors:
• Contractor Foreman/Supervisors shall conduct two audits per shift utilizing the
appropriate TAR audit checklist.
• Contractor Safety Representatives shall conduct two audits per shift utilizing the
appropriate TAR audit checklist.
• Site Contractor Leadership Members shall conduct one audit per week the specific
subjects to be audited will be those areas identified to have been the most problematic
for the week. This will be determined by the BASF EHS Dept.
• Audit Forms will be turned in to the BASF EHS Dept. along with a summary of
deficiencies found during the day. This will be done at the Daily Contractor Safety
Meeting.
• Audit deficiencies will be reviewed at the Daily Contractor Safety Meeting. Contractor
Safety Representatives are expected to not only present the deficiencies but also
solutions to the problems.
• Those items found to be problematic will be addressed by the Contractor Safety
Representatives during toolbox safety meetings at the beginning of each shift.
• BASF EHS Dept. may schedule different types of audits/various topics deemed
necessary during the outage. ANY IDLH (Immediate Danger to Life and Health)
infractions are subject to call for a work stoppage in that area or job and immediate
corrective action will be mandatory.
Bicycles
Only BASF company approved bicycles are allowed for employee usage on company
property and/or work related activities.
Reference Port Arthur Site Procedure PA-020-0026 General Safety Rules, section 4.1.1.
for more details related to bicycle proper usage, maintenance and inspection
requirements.
Fatigue Management
Turnaround work schedules for process safety sensitive decision personnel will follow the
ANSI/API Recommended practice 755 – 2010.
This recommended practice (RP) provides guidance to all stakeholders (e.g. employees,
managers, supervisors, contractors) on understanding, recognizing and managing fatigue
in the workplace.
The hours of service limits for outages for 10-hour shifts are as follows:
• Work sets shall not exceed 14 consecutive calendar days.
• There shall be a minimum of 36 hours off after a work set. Time off beyond 36 hours
shall be addressed at the plant level.
• During outages, individuals tend to work fixed shifts. 36 hours between work sets
provides for 2 consecutive sleep opportunities, thereby allowing workers to remain on
their established circadian cycle, rather than encouraging night shift workers to revert
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to night sleep on their off days, which likely would occur with longer time between work
sets.
• Shifts are routinely scheduled for 10 hours and holdover periods should not exceed 2
hours and, where possible, occur at the end of the day shift.
The hours of service limits for outages for 12-hour shifts are as follows:
• Work sets shall not exceed 14 consecutive day or night shifts.
• There shall be a minimum of 36 hours off after a work set. Time off beyond 36 hours
shall be addressed at the company or plant level.
• During outages, individuals tend to work fixed shifts. 36 hours between work sets
provides for 2 consecutive sleep opportunities, thereby allowing workers to remain on
their established circadian cycle, rather than encouraging night shift workers to revert
to night sleep on their off days, which likely would occur with longer time between work
sets.
• Shifts are routinely scheduled for 12 hours and holdover periods should not exceed 2
hours and, where possible, occur at the end of the day shift.
Nitrogen Safety
Nitrogen is a colorless, odorless and tasteless gas. The principle hazard associated with
nitrogen is the potential for asphyxiation. Nitrogen is used on Site to help clear the
systems of explosive and toxic materials. During large turnarounds nitrogen may be bled
down to the atmosphere. This could pose serious problems to personnel walking or
working in the surrounding area if they are not aware of informed of this potential. When
blowing down large amounts of nitrogen the area Operations Technician must monitor the
affected area with calibrated meters to measure the affected area. Barricades (Red /
Black Tape) and warning signs must be posted (in the safe area) to inform personnel
passing by of the dangers within the barricaded area. Area technicians when working
around nitrogen should also use caution and proper PPE.
When plant air back-up system is activated (nitrogen introduced into header system) an
alarm located in the control room will be activated by Interlock I-7501 and alerts Utilities
Control Operator. The Control Operator will immediately announce a “Radio All-Call”
message communicating that the plant air system is now operating with nitrogen gas. This
announcement triggers work stoppage in all Analyzer House locations and initiates an
immediate review of permitted confined space entries.
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Pedestrian Traffic/Travel
Only approved means of travel is by an approved vehicle or foot.
• Walk on designated sidewalks
• Sidewalks are reserved for pedestrian traffic only.
• Yield to pedestrians
Temporary Lighting
Per OSHA 1926.405(a)(2)(ii)(G); Portable electric lighting used in wet and/or other
conductive locations, as for example, drums, tanks, and vessels, shall be operated at 12
volts or less. However, 120-volt lights may be used if protected by a ground-fault circuit
interrupter. Temporary lighting shall be provided by one of the following means:
• Intrinsically safe flashlights
• Approved low voltage (12 volt) or 120-volt lights/extension cords equipped with a
functional ground fault circuit interrupter.
• Voltage regulator devices shall be located outside of the confined space.
• Temporary lighting shall be equipped with guards to prevent contact with the bulb.
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For more specific information regarding severe weather and hurricane preparedness refer
to: Port Arthur Facility Severe Weather Plan / 2012 TAR 2011 Hurricane Plan
4.5. Health
NOTE: Employee medical clearance physicals during 2012 turnaround (March 15th
through June 15th) will be suspended. No disciplinarily actions will be taken as
stated in site procedure PA-020-0063 Mandatory Medical Surveillance for those
employees affected by this temporary suspension. Site Medical scheduling
employee medical clearance physicals either before or immediately after the
turnaround, additional medical staff resources will be required to minimize non-
compliance impact.
For absences of four (4) work days or more, please reference BC004.042 Attendance and
Absenteeism Procedure.
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The presence of Benzene or Butadiene will require the use of Respiratory Protection when
levels are within the ranges referenced below in the Respiratory Protection Selection
Guide. For more specific information on these two chemicals see the following
procedures: PA-020-0043 Butadiene Compliance and PA-020-0041 Benzene Compliance.
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Noise Exposure
ANSI approved hearing protection will be used. The minimum Noise Reduction Rating
(NRR) for any ear plug used will be no lower than 30 NRR. Provide hearing protection to
all workers and require it to be worn. Hearing protection is available to all employees and
contractors. Hearing conservation is covered in ISTC training as well. For areas at the Port
Arthur facility that will require usage of hearing protection, see Port Arthur Hearing
Protection Required Area map on next page.
Port Arthur Site Required Hearing Protection Locations
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The BASF Port Arthur Site has an active Hazcom program managed by Site Procedure
PA-020-0022. In addition the Site has developed additional BFLP and Sabina HAZCOM
Tables that provide hazard information related to on-site process chemicals in a format
that details chemical type, area and equipment specific locations, physical hazards and
target organ health hazards.
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4.6. Environmental
VOC concentration is less than 10,000 ppmv or 1 percent of the LEL. Documented
site procedures used to de-inventory equipment to a control device for safety purposes
(i.e., hot work or vessel entry procedures) that achieve at least the same level of
purging may be used in lieu of the above.
The BASF Port Arthur Facility has developed a specific site EHS procedure to ensure all
requirements for de-pressuring, emptying, and/or degassing VOC process equipment /
systems will be constantly followed to ensure compliance with TCEQ air permit
requirements. Refer to PA-031-0006 VOC Pressure Equipment Clearing, Cleaning and
Routine Maintenance for more detailed information.
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YES
[MIP generated]
YES NO
Open-Ended Lines (OEL) In VOC Service – Applicable TAR OELs will be identified
before the TAR utilizing operations planner P&ID. The OELs requirement monitoring will
be those components documented as being tagged open, not double blocked or blinded,
and adjacent to equipment/systems not yet cleared to 1% LEL. These components will be
monitored by the onsite LDAR contractor per MSS requirements.
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• Each open-ended valve or line resulting from a plant or unit turnaround shall meet the
following requirements
A. The plant or unit system(s) shall be isolated from feedstock sources using blind
flanges to prevent potential feedstock leakage into the plant or unit(s).
B. The open-ended valve or line shall be monitored once by the end of the 120 hour
period following the creation of the open ended line with an approved gas analyzer
and the results recorded. Leaks are indicated by readings of 500 ppmv.
C. If a leaking isolation valve is discovered on a flanged line, the leak must be
repaired within 24 hours or a cap, blind flange, plug, or second valve must be
installed on the line or valve. Alternatively, within 24 hours, the adjacent unit
system may be cleared to a control device so that the VOC concentration in the
adjacent system is less 1% of the LEL.
If a leaking isolation valve is discovered on a welded line the adjacent unit system shall be
cleared to a control device so that the VOC concentration within the system is less 1% of
the LEL. This clearing shall be completed within 20 days of the leak discovery.
Vacuum Truck Requirements – All vacuum trucks utilized during the TAR are to be
equipped with an MSS compliant control device/scrubber recovery system. The vendors
are required to comply with MSS Vacuum Truck requirements per their company
procedures.
NOTE: Required recordkeeping should be turned into TAR Environmental Specialist, Mark
Screen, x5033 at the end of each day shift.
The following requirements apply to vacuum and air mover tank operations to support
planned MSS at the Port Arthur site:
A. Vacuum pumps and blowers shall not be operated on trucks containing or
vacuuming liquids with VOC partial pressure greater than 0.50 psi at 95oF unless
the vacuum/blower exhaust is routed to a control device or a controlled recovery
system.
B. Equip fill line intake with a “duckbill” or equivalent attachment if the hose end
cannot be submerged in the liquid being collected.
C. A daily record containing the information identified below is required for each
vacuum truck in operation at the site each day.
1. Prior to initial use, identify any liquid in the truck. Record the liquid level and
document that the VOC partial pressure is less than 0.50 psi if the vacuum
exhaust is not routed to a control device or a controlled recovery system. After
each liquid transfer, identify the liquid transferred and document that the VOC
partial pressure is less than 0.50 psi if the vacuum exhaust is not routed to a
control device or a controlled recovery system.
2. For each liquid transfer made with the vacuum operating, record the duration of
any periods when air may have been entrained with the liquid transfer. The
reason for operating this manner and whether the “duckbill” or equivalent was
used shall be recorded. Short, incidental periods, such as those necessary to
walk from the truck to the fill line intake, do not need to be documented.
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3. If the vacuum truck exhaust is controlled with a control device other than an
engine or oxidizer, VOC exhaust concentration upon commencing each
transfer, at the end of each transfer, and at least every hour during each
transfer shall be recorded, measured using an instrument meeting the
requirements of Special Condition 35. A or B.
4. The volume in the vacuum truck at the end of the day, or the volume unloaded,
as applicable.
D. The permit holder shall determine the vacuum truck emissions each month using
the daily vacuum truck records and the calculation methods utilized in the permit
application. If records of the volume of liquid transferred for each pick-up are not
maintained, the emissions shall be determined using the physical properties of the
liquid vacuumed with the greatest potential emissions. Rolling 12 month vacuum
truck emissions shall also be determined on a monthly basis.
E. If the VOC partial pressure of all the liquids vacuumed into the truck is less than
0.10 psi, this shall be recorded when the truck is unloaded or leaves the plant site
and the emissions may be estimated as the maximum potential to emit for a truck
in that service as documented in the permit application. The recordkeeping
requirements in Special Condition 37.A through 37.D do not apply.
Frac Tanks
This permit authorizes emissions from the following temporary facilities used to support
planned MSS activities at permanent site facilities: frac tanks, containers, vacuum trucks
and portable devices identified in Special Condition 41. Emissions from temporary
facilities are authorized provided the temporary facility:
A. does not remain on the plant site for more than 12 consecutive months;
B. is used solely to support planned MSS activities at the permanent site facilities; and
C. does not operate as a replacement for an existing authorized facility.
The following requirements apply to frac, or temporary, tanks and vessels used in support
of MSS activities.
A. The exterior surfaces of these tanks/vessels that are exposed to the sun shall be white
or aluminum effective May 1, 2013. This requirement does not apply to tanks/vessels
that only vent to atmosphere when being filled.
B. These tanks/vessels must be covered and equipped with fill pipes that discharge within
6 inches of the tank/vessel bottom.
C. These requirements do not apply to vessels storing less than 100 gallons of liquid that
are closed such that the vessel does not vent to atmosphere.
D. The permit holder shall maintain an emissions record which includes calculated
emissions of VOC from all frac tanks during the previous calendar month and the past
consecutive 12-month period. The record shall include tank identification number,
dates put into and removed from service, control method used, tank capacity and
volume of liquid stored in gallons, name of the material stored, VOC molecular weight,
and VOC partial pressure at the estimated monthly average material temperature in
psia. Filling emissions for tanks shall be calculated using the TCEQ publication titled
“Technical Guidance Package for Chemical Sources - Loading Operations” and
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standing emissions determined using: the TCEQ publication titled “Technical Guidance
Package for Chemical Sources - Storage Tanks.”
E. If the tank/vessel is used to store liquid with VOC partial pressure less than 0.10 psi at
95oF, records may be limited to the days the tank is in service and the liquid stored.
Emissions may be estimated based upon the potential to emit as identified in the
permit applications.
Requirements for the use of Carbon Canisters, Plant Flare Systems – The Port Arthur
Site LDAR contractor will be responsible for the following TAR Carbon Canister
requirements.
NOTE: Required recordkeeping should be turned into TAR Environmental Specialist, Mark
Screen, x5033 at the end of each day shift.
Control devices required by this permit for emissions from planned MSS activities are
limited to those types identified in this condition. Control devices shall be operated with no
visible emissions except periods not to exceed a total of five minutes during any two
consecutive hours. Each device used must meet all the requirements identified for that
type of control device.
four hours. Sufficient new activated carbon canisters shall be maintained at the site to
replace spent carbon canisters such that replacements can be done in the above
specified time frame.
5. Records of CAS monitoring shall include the following:
a. Sample time and date.
b. Monitoring results (ppmv)
c. Canister replacement log
6. Single canister systems are allowed if the time the carbon canister is in service is
limited to no more than 30% of the minimum potential saturation time. The permit
holder shall maintain records for these systems, including the calculations performed
to determine the saturation time. The time limit on carbon canister service shall be
recorded and the expiration date attached to the carbon can.
In summary, the plan will need to be consulted for any additional oil and fuel storage or
equipment that contains 55 gallons or greater. Contractors should provide their own
containment which will hold the amount of the tank plus the appropriate freeboard for
rainfall. Inspections are required before containment is released to grade. However, if
containments are handled via vacuum trucks, NO inspections are required.
For more detailed information regarding 2012 TAR SPCC requirements reference the
BASF Port Arthur Spill Prevention Control and Countermeasures Plan .
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This plan requires updating for any new lay down areas planned for the TAR. Some
inspections may be necessary.
For more detailed information regarding 2012 TAR SWP3 requirements reference the
BASF Port Arthur Stormwater Pollution Prevention Plan
Waste Management
Accumulation, monitoring/sampling, transporting and disposal of hazardous aqueous /
solid waste, non-hazardous, universal, general non-recyclable waste, empty containers,
salvaged equipment and recyclable material generated throughout the site (BFLP Cracker
& Sabina C4) during 2012 turnaround will be managed per site procedures;
• PA-TAR-0003 Management and Handling of TAR Incidental Waste
• PA-033-0002 Source Reduction and Waste Minimization Plan
• PA-033-0003 Site Recycling Program
• PA-033-0005 Waste Management Plan
• PA-033-0006 Hazardous Waste Training Plan
• PA-033-0008 Management of Empty Containers
• PA-033-0010 PA Salvaged Equipment and Materials
• PA-033-0011 Universal Waste
4.7. Training
The training objective is to ensure that key personnel have knowledge to lead and follow-
up all EHS activities required for a successful Turnaround.
• Inform all involved TAR Stakeholders of the safety rules for the 2012 Turnaround
• Establish a good working knowledge base for TAR Area Management Team(s) to
facilitate resolution of EHS issues during the TAR.
Section 7 Permits
Safe Work
Hot Work
Confined Space
Vehicle Entry
Excavation
Section 8 Lock/Tag/Try
Use of Locks and Tags Required
No Plant/Instrument Air to be used as Breathing Air or in Confined Spaces
to Power Air Tools
Section 9 Tools and Equipment
Only Qualified People to Use Specialized Tools
Employee Responsibility
Utility Hoses and Proper Use
Ladder Safety
Section 10 LEL Monitoring Equipment Usage
Closing
Each Employee is Responsible for Safety
Violation of Safety Rules is Grounds for Dismissal/Removal
Test for competency of all 10 site specific sections
….
6. Emergency Response
This plan details response actions for protecting the health and safety of BASF employees,
contractors and community members, as well as safeguarding the environment and property. Port
Arthur Site designates all of the process and mechanical equipment, as well as the buildings and
property associated with the BASF FINA Cracker and the BASF FINA Sabina units. The Plan
addresses the following emergencies:
• Chemical spills or other releases to the environment
• Toxic/flammable vapor or gas releases
• Fires and explosions
• Medical Emergencies
• Emergencies at TOTAL Refinery that may affect the Port Arthur Site
Reporting Emergencies
• Call Control Room @ ext. 5555
• Call Security @ ext. 5294
• Contact Shift Coordinator on Radio channel A-13
• Contact Site Safety on radio Channel C-1
When reporting an emergency, remain calm and speak clearly / slowly and communicate the
following information:
• Where the emergency is occurring
• The nature of the emergency i.e. fire, gas release, medical, etc.
• The name and company of the person reporting the emergency.
For detailed Emergency Response resources and their capabilities refer to the Port Arthur Site’s
Emergency Response Plan.
The Port Arthur Site Emergency Response Plan satisfies the requirements of the following
Federal Regulations with regard to the development of emergency response plans:
• 29 CFR 1910.38 – Emergency Action Plans
• 29 CFR 1910.119 – Process Safety Management
• 29 CFR 1910.120 – Hazardous Waste Operations. and Emergency Response.
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Emergency Responders
BASF FINA & SABINA will operate and maintain an around the clock on shift Emergency
Response Team (ERT). This ERT will be trained as an Advanced Industrial Exterior
Structural Fire Brigade and as a site specific Hazardous Material Technician Team to
address fires, and the release of flammable materials and or site specific hazardous
chemicals. ERT volunteers will also be trained in High Angle - Confined Space Rescue
and as a Medical First Responder.
Fire Brigade
All Fire Brigade members receive quarterly training and are mandated to attend Annual
Live Fire training at the Beaumont (previous Lamar University) Fire Training Grounds or
other comparable live fire training facilities.
Hazmat
Site personnel required to respond to hazardous materials releases are trained to the
“Technician Level” as designated by 29 CFR 1910.120 (HAZWOPER) Standard and to
meet BASF “ER Advisory Alert 1”. Mandated annual refresher training is conducted by a
BASF certified vendor to meet the ER Alert 1 competencies.
NOTE: For a more detailed description and requirements of the Port Arthur Detailed
Emergency Response Hazmat Procedure see Appendix E of the Site’s Emergency
Response Plan.
Written Rescue Pre-plans for Confined Space Entries are in place and required to be
reviewed before each initial CSE begins. A copy of Rescue Pre-plan will be provided to
contractors as part of a CSE safe work permit.
Medical Response
The Site 1st Responder Medical Response Team is comprised of volunteer personnel who
are trained to a 1st Responder level. Personnel receive an initial 40 hours Basic class,
which is supplemented by quarterly training classes to help maintain skills and proficiency.
1st Responder personnel are on each shift such that qualified emergency medical care is
available on a 24-hour basis. The on shift response of Medical 1st Responder personnel
will be in such a manner as to render initial First Aid services for minor and severe injuries.
The on site medical equipment used for all medical responses will be kept in the Rescue
Vehicle. The Rescue Vehicle may be used for a medical response call.. Also a shift
medical jump bag and Life Pak 500 AED will supplement this equipment. In Addition to the
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In addition to Site 1st Responder Medical Response Team a contracted medical response
unit (Accadian Ambulance Service) will be on-site to provide assitance for immediate
medical care. BASF Site 1st Responder Medical Response Team will be intial primary
responder in the event of a medical response call. Accadian Ambulance Service will
respond when requested by BASF. Accadian Medical Technicans may assist with non
response occuaptional medical needs (minor cuts, scraps, flushing/washing, band-aid
application, over-counter treatment, etc..) for BASF and contractor personnel.
NOTE: For a more detailed description and requirements of the Port Arthur Detailed
Medical Response Procedure see Port Arthur 2012 BFLP & Sabina Turnaround Additional
On-Site Medical Response Support and Appendix D of the Site’s Emergency Response
Plan and PA-021MD-0002 Medical 1st Responder Quality Assurance/Quality
Improvement Program
Mutual Aid
PA-021-0006
Mutual aid agreement between BASF FINA Petrochemicals LP / Sabina Petrochemicals
LLC Facility (BASF-PA) and the Sabine Neches Chief’s Association. The procedure details
what assistance will be offered and what assistance will be expected in the event of an
emergency. This agreement will be implemented during any mutual aid emergency which
requires a response of additional personnel and or equipment at the request of SNCA.
PA-021-0009
Mutual aid response agreement between BASF Port Arthur (BASF – PA) and TOTAL
Refinery as to what assistance will be offered in the event of an emergency. This
agreement will be implemented during any minor emergency which requires a quick
response of additional personnel and or equipment, but does not necessitate a call to the
Sabine Neches Chiefs Association.
All personnel on the site must go to a designated shelter or evacuate to an assembly area,
according to the Unit Emergency Plan.
If operating a motor vehicle in an area where an emergency signal is sounding, stop the
vehicle, shut off the engine, leaving keys in ignition and proceed to an assembly area on
foot. Be prepared to evacuate the area if necessary.
When evacuating an area, move crosswind or upwind from the affected area. Do not drive
into an area downwind of a gas release. Follow all instructions given by BASF personnel.
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Emergency Alarms
U – Unit Emergency = 1 Blast
S – Seek Shelter = 2 Blasts
E – Evacuate Site = 3 Blasts
Assembly Areas
There are four assembly points at the Port Arthur site all are equipped with an electronic
reader to scan BASF Employee/Contractor badges for Accountability/Head Count.
• Assembly Area – A: Gate 99, West side of Security Command Center
• Assembly Area – B: South/West end of the site (near Fire Water Pumps)
• Assembly Area – C: South Gate to Hwy 87 exit (near Fire House)
• Assembly Area – F: Northeast corner of C4 complex, where 907 Rack enters TOTAL
• Personnel evacuating the site will meet at the designated Muster Points and notify
Security of their destination:
o Gate 103 (West side of Trailer/Do Not Stay inside Trailers)
o AA Storage (Old Wal-Mart Via Hwy 87)
o 32nd St. (Walk inside fenced area or side of Hwy 366)
o Hwy 87 Crossover (By Fruit Stand)
o TOTAL (To 17th St. Via Assembly Area “F” Gate)
• Upon reaching the Muster Point, personnel are to seek out a Building Warden (or
PAD) and organize for a head count and remain until the ‘All Clear’
Communications:
• Operations will provide further information via site radios Channel
For detailed description of the site’s alarm systems and required actions for Emergency
Response and non-response personnel see Port Arthur Site’s Emergency Response Plan.
BFLP Cracker
Fixed systems – Safety Systems Manual describes in detail the operational functions of
these systems:
Fire and Gas Panel
Combustible Gas Detectors (Including Benzene)
H2S Detectors and NH3 Detectors
O2 Detectors and CO Detectors
Fire Water Systems
Fire-water Supply and Distribution
Monitors and Hydrants
Deluge Systems
Portable Fire Fighting Equipment
Extinguishers
Other Equipment
Fire Suppression Systems
FM-200 System
O2 System
Steam Curtain
Building HVAC Systems
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Sabina C4
Fixed systems
Fire Water Systems
Fire-water Supply and Distribution
Monitors and Hydrants
Deluge Systems
Portable Fire Fighting Equipment
Extinguishers
Other Equipment
Fire Suppression Systems
FM-200 System
O2 System
Building HVAC Systems
Safety Showers/Eyewash Stations
Emergency Shut Down System (ESD)
Quick Isolation and Shutdown System (QISS)
Employee Evacuation System
Chemical Mixing Matrix
Uninterruptible Power Supply (UPS
7. Contractor Management
Special Consideration Requirements for BFLP/Sabina TAR Contractor / Agency EHS and Procurement Table.
Contractor / Agency PICS Registration EHS Annual Review / Approval Procurement Requirements
Special Considerations
No licensed base of NO – PICS is currently not set NO - An acceptance of risk must be obtained Yes –All commercial requirements,
operations within the up to analyze and/or manage from SLT. including insurance, must be met by
geographical boundaries EHS PQF data generated contractor and approved by Procurement
or governing laws of the outside the United States and While on site all contractor personnel must be before contractor is allowed to perform
United States and Canada. accompanied by a BASF Representative at all services on site. Contact your site
Canada. times. purchasing rep. to obtain approval.
Small specialty services 1st Option – Assistance to help NOTE: PICS application, PQF review / Yes –All commercial requirements,
with limited resources contractor enroll and submit all verification process could take up to 4 weeks. including insurance, must be met by
and limited intended use required PICS information contractor and approved by Procurement
(one to two times a year) should strongly be considered. before contractor is allowed to perform
of on-site service. services on site. Contact your site
purchasing rep. to obtain approval.
2nd Option – If contractor N/A N/A
company chooses not to
register with PICS consider
other alternatives such as
finding a different service
provider.
3rd Option - If option #2 is not YES – The submitted PQF will be reviewed in- YES – All commercial requirements,
viable, contractor to submit house by EHS, same qualifying criteria as including insurance, must be met by
completed PQF form directly used in PICS approval must be followed. contractor and approved by Procurement
back to Port Arthur After verification and acceptance of EHS before contractor is allowed to perform
Procurement Rep. minimum criteria, submit approval request to services on site. Contact your site
Perry Guentzel or John Davis. purchasing rep. to obtain approval.
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