Non-System Lockout/Tagout BASF Requirements

1. Non-System Lockout/TagoutBASF Requirements References: GSS01 – Non-System Lockout/Tagout & Line Breaking

2. Lockout/Tagout at Geismar • Applies to all activities that require isolation of hazardous energy sources in order to prevent unexpected or unintentional energizing, start-up, or release of stored energy that could cause injury or equipment damage. • Does not apply to: • Hot Taps done according to MP-56 • Work on cord and plug connected equipment • Plug must be under the exclusive control of the using individual • Plug must be tagged with a “Do Not Operate” tag or in line-of-sight and arm’s reach

3. Covered Activities • The following activities, as identified on the Safe Work Permit, require lockout/tag out: • Line breaking • Non-system Tag Out • System Tag Out • Interdepartmental Tag Out • GAMA Tag Out • Confined Space • Electrical Tag • Instrument Tag • If the Safe Work Permit identifies one of these activities then compliance with the Geismar Site lockout/tag out requirements must be followed.

4. General Steps • Operations preps and isolates the equipment, including hanging of Red Tags and red locks where required according to equipment-specific procedures. • All electrical energy sources must be locked. • Red Tags are hung on valves and other isolation points. • Operations verifies that the equipment is de-energized, de-pressured, clean, and Tried. • The Tag Out Sheet is then signed by the respective Operator signifying that the equipment is ready for maintenance. • No additional work can be done on the equipment by Operations unless the Tag Out Sheet is revoked.

5. One Plus Isolation • One Plus Isolation is required in the following situations: • All ¼ turn valves that are tagged “closed,” regardless of handle type. • Chain actuated valves • Electrical energy sources (ex. Breakers) that cannot be locked. • One Plus Isolation includes: • Removal of the valve handle • A chain or cable • A valve cover or locking arm • Tie wraps • Valve gap • Slide lock on the valve handle • Chains secured together at a height of 7 feet or more; or secured out of the way

6. Lockout/Tagout and Line Breaking Electrical Verification • A Qualified Electrician is required to verify that electrical components (ex. breakers, electrical lines, electrically traced lines, etc.) are de-energized anytime the work involves exposure to electrical components. • The electrician must verify de-energization of the electrical components where the work is to be performed. • The electrician must initial the Tag Out Sheet. • During installation of electrical tracing, the circuit breaker must be locked by the installing contractor until the tracing is turned over to the Owning Department.

7. General Steps • The contractor work crew is issued a Safe Work Permit and Tag Out Sheet • All previously identified activities require a field review (4 Eyes) with Operations before the permit can be issued. • This means that an operations rep (typically an operator) meets with the Work Crew rep at the specific job location to discuss the job scope, hazards, equipment status, location of safety showers, etc. • The Work Crew Representative (or designee) walks the Red Tags associated with the job and hangs the Work Crew Yellow Tag on the identified location(s), listed on the Tag Out Sheet. • Contractor locks are also required on electrical energy sources. Locks must be yellow and the keys must be controlled by an assigned work crew member.

8. General Steps Cont’d • The Work Crew Representative (or designee) covers the Safe Work Permit with the crew. • Each Work Crew member signs on the back of the permit (i.e., Work Crew Accountability) section: • Each individual must sign their own name onthe permit • This is required by OSHA since BASF does not require individual locks • The Work Crew completes the job and each crew member signs off the back of the permit. • The Work Crew Rep removes any associated Work Crew Tags and locks. • The permit and Tag Out Sheet is returned to Operations • The Closeout section must be properly completed, including all crew members signed off the back of the permit.

9. Permit Closeout for Unfinished Work • If the work is not completed, but the Work Crew is finished for the shift, then the following applies: • The unsigned Tag Out Sheet must be returned to Operations • The Work Crew Tag(s) / lock(s) must be left in place or removed as directed by Operations. • Electrical disconnects: Tag / Lock • Valve: Tag • If Maintenance Tag(s) / lock(s) are removed then re-verification of isolation (lockout and “try”) must be performed when the Work Crew returns.

10. Equipment Testing • Testing of equipment by Operations is sometimes required during the course of work. Such activities require the following: • All Work Crew locks and tags to be removed. • The “Release for Testing” section of the Tag Out Sheet to be signed and the Tag Out Sheet to be returned to Operations. • Each Work Crew member to sign off the back of the Safe Work Permit. • If additional maintenance work must be done after the testing then all lockout/tag out steps must be followed.

11. Work Crew Locks/Tags Left in the Field • If a Work Crew lock or tag is not removed after the work is completed then the following steps must be taken: • During normal work hours, the responsible Work Crew Rep shall be contacted to remove the lock or tag. • During off-hours, the Owning Department supervisor shall first attempt to call out the responsible Work Crew Representative. • If unsuccessful then the on-call maintenance representative will be called to remove the lock/tag, after determining that all associated Work Crew members are off the job.

12. Line Breaking and Lockout/Tagout • Written job plans are now required for work on process equipment, which involves energy isolation or line breaking. • The details of the job plan will be determined by the job planner or Maintenance Coordinator based upon the complexity of the work activity. • Whenever equipment is to be isolated for Servicing/Maintenance, a drawing showing the location of each isolation device must be generated. • A hand drawing, ISO drawing or P&ID may be used. • This drawing should be used in conjunction with the Tag Out Sheet to ensure all isolation points are identified for Hazardous Energy Sources.

13. Do not tamper with or attempt to operate any equipment with the following tag(s) attached…

14. Red Tags Applied by Operations

15. Electrician Tags

16. Instrument Technician Tags

17. Operations Tags (When Operations Performs Covered Work)

18. Tag Placed by Maintenance Crew

19. This tag is to be used for isolating equipment that will be abandoned in place or for other activities that do not involve Servicing/Maintenance or Equipment Preparation. Blue Danger Tag

20. Line Breaking • Any relaxing of Line Breaking precautions (ex. Downgrading of PPE) must be approved by the Permit Issuer and documented on the Safe Work Permit. • If a system or piece of equipment is closed and then subsequently reopened, after it has undergone a Line Break but not put back into service, the subsequent reopening is considered a new Line Break and must adhere to all the requirements of the initial Line Break.

21. Line Breaking • Precautions to be taken: • Restrict access using barricades and barrier tape when work is elevated or over grated platforms. • Use splash or drain pans, as needed, to protect personnel and equipment below. • Ensure that each work crew member is fully informed of any potential hazards, special safety precautions and the location of nearest safety shower/eye wash stations. • Coordinate/communicate with adjacent work groups to ensure everyone is aware of the line breaking activities. • Use defensive positioning in order to avoid a spray or release when attempting each line break. • Break flanges on the opposite side of the piping from the employee. • Continue to use required PPE until the equipment can be verified free of hazardous contaminants and Operations approves, in writing, the downgrading of any PPE. • Specified PPE must be worn by all personnel in immediate vicinity of the line break • These have been added to the back of the permit for your review

22. Maintenance On/Near Railroad • Site Safety procedure #18 (GSS18) covers maintenance work on/near the railroad tracks. • Such work requires a derail and blue flag, which must be locked and red tagged by the Owning Department • The Work Crew must hang a Maintenance Tag on the derail, same as work performed in the units.

23. This completes the overview of BASF Geismar’s Lockout/Tagout requirements.