Safe Work Procedure: Line Breaking Operations

Document Number: [SWP-NUMBER]

Revision Date: [DATE]

Next Review Date: [NEXT REVIEW DATE]

Department: [DEPARTMENT NAME]

1. Scope

This safe work procedure (SWP) outlines the necessary steps and safety precautions for safely breaking into and working on pipelines and lines carrying various substances. It includes identifying potential hazards, implementing control measures, and ensuring personnel are adequately trained and equipped to perform the task safely. This procedure applies to all personnel involved in line breaking activities. It does not cover electrical line breaking, which requires a separate specific procedure.

2. Definitions

Line Breaking The process of intentionally opening a pipeline or line that contains or has contained a substance (e.g., gas, liquid, or solid). Hazardous Substance Any substance that poses a physical or health hazard, including flammable, explosive, toxic, corrosive, or reactive materials. Isolation The process of completely separating a section of pipe or equipment from the rest of the system to prevent the release of hazardous substances. Purging The process of removing hazardous substances from a pipeline or equipment by flushing it with an inert gas or liquid. Lockout/Tagout (LOTO) A safety procedure used to ensure that dangerous machines or equipment are properly shut off and not able to be started up again prior to the completion of maintenance or servicing work.

3. Responsibilities

3.1 Supervisors

Ensure all workers are properly trained and competent to perform line breaking operations.
Conduct a thorough pre-job briefing, outlining the scope of work, potential hazards, and control measures.
Verify that all necessary permits, including hot work permits or confined space entry permits, are obtained before work begins.
Ensure that all equipment and tools are inspected and in good working order.
Monitor the work area for any changes in conditions that may affect safety.

3.2 Workers

Participate in pre-job briefings and understand the scope of work, potential hazards, and control measures.
Inspect all tools and equipment before use and report any defects to the supervisor.
Use required personal protective equipment (PPE) at all times.
Follow all established procedures and safety guidelines.
Report any unsafe conditions or near misses to the supervisor immediately.

3.3 Health and Safety Representative

Conduct regular safety audits of line breaking operations to ensure compliance with this procedure and relevant regulations.
Investigate incidents and near misses related to line breaking operations and recommend corrective actions.
Provide support and guidance to supervisors and workers on safety-related issues.

4. Potential Hazards and Risks

Hazard	Risk	Control Measures
Release of hazardous substances (gas, liquid, solid)	Exposure to toxic, flammable, corrosive, or explosive materials, leading to health effects, fire, or explosion.	1. Properly identify the contents of the line before breaking. 2. Isolate and purge the line to remove hazardous substances. 3. Use appropriate PPE, including respiratory protection. 4. Ensure adequate ventilation. 5. Monitor the atmosphere for hazardous vapors.
Fire or explosion	Ignition of flammable substances released during line breaking.	1. Eliminate ignition sources from the work area. 2. Use non-sparking tools. 3. Ensure proper grounding and bonding. 4. Monitor the atmosphere for flammable vapors. 5. Have fire suppression equipment readily available.
Asphyxiation	Oxygen displacement by inert gases or hazardous vapors in confined spaces.	1. Test the atmosphere for oxygen content before entry. 2. Provide continuous ventilation. 3. Use respiratory protection (SCBA) if necessary. 4. Implement confined space entry procedures.
Contact with energized electrical lines	Electrocution or electrical shock.	1. Identify all overhead power lines in the work area. 2. Maintain safe working clearance from power lines. 3. De-energize and ground power lines if possible. 4. Use insulated tools and equipment. 5. Designate an observer to monitor power line clearance.
Manual Handling	Musculoskeletal injuries due to lifting, carrying, or awkward postures.	1. Use mechanical aids (e.g., hoists, dollies) to move heavy objects. 2. Use proper lifting techniques. 3. Take frequent breaks. 4. Ensure adequate lighting. 5. Provide training on ergonomics.
Slips, trips, and falls	Injuries due to slippery surfaces, obstructions, or uneven terrain.	1. Maintain a clean and organized work area. 2. Use slip-resistant footwear. 3. Provide adequate lighting. 4. Mark or eliminate tripping hazards. 5. Use fall protection equipment when working at heights.
Unexpected start-up or release of energy	Injury due to uncontrolled movement of equipment or release of stored energy.	1. Implement Lockout/Tagout procedures to isolate energy sources. 2. Verify isolation before starting work. 3. Use safety interlocks and guards. 4. Bleed off any stored pressure or energy.

5. Personal Protective Equipment (PPE)

Hard Hat: Provides head protection from falling objects and impacts. Must meet ANSI Z89.1 standards.
Safety Glasses: Provides eye protection from chemical splashes, dust, and flying debris. Must meet ANSI Z87.1 standards.
Chemical-Resistant Gloves: Protects hands from contact with hazardous substances. Select gloves based on the specific chemicals being handled (e.g., nitrile, neoprene).
Flame-Resistant Clothing (FRC): Provides protection from burns in the event of a fire or explosion. Required when handling flammable substances.
Steel-Toed Boots: Protects feet from impacts and punctures. Must meet ASTM F2413 standards.
Respiratory Protection: Provides protection from inhaling hazardous vapors or gases. Use appropriate respirator (e.g., air-purifying respirator with appropriate cartridges or self-contained breathing apparatus (SCBA)) based on the specific hazards and atmospheric conditions.

6. Equipment and Tools

Non-Sparking Tools: Use non-sparking tools to minimize the risk of ignition in areas where flammable vapors may be present. Ensure tools are properly maintained and inspected before use.
Gas Detector: A calibrated gas detector is required to monitor the atmosphere for hazardous gases, flammable vapors, and oxygen levels. Ensure the detector is properly calibrated and used according to the manufacturer's instructions.
Lockout/Tagout Devices: Use appropriate lockout/tagout devices (locks, tags, hasps) to isolate energy sources and prevent accidental start-up of equipment. Ensure devices meet OSHA standards and are properly applied.
Grounding and Bonding Cables: Use grounding and bonding cables to prevent static electricity buildup and reduce the risk of sparks. Ensure cables are properly connected and in good condition.
Ventilation Equipment: Use ventilation equipment (e.g., fans, blowers) to provide adequate ventilation and prevent the accumulation of hazardous vapors. Ensure equipment is properly grounded and positioned to maximize airflow.

7. Pre-Job Requirements

7.1 Training and Competency

Training and Competency: All personnel involved in line breaking operations must receive adequate training and demonstrate competency in the following areas:

Hazard identification and risk assessment
Safe work procedures for line breaking
Use of personal protective equipment (PPE)
Lockout/Tagout procedures
Emergency response procedures
Confined space entry (if applicable)
Hot work procedures (if applicable)

7.2 Pre-Job Briefing

Pre-Job Briefing: A pre-job briefing must be conducted before any line breaking work begins. The briefing should cover the following:

Scope of work and specific tasks to be performed
Potential hazards and associated risks
Control measures to be implemented
Required PPE
Emergency procedures
Communication protocols
Roles and responsibilities of each team member

7.3 Work Area Preparation

Work Area Preparation: Prior to commencing line breaking operations, the work area must be properly prepared:

Ensure adequate ventilation to prevent the accumulation of hazardous vapors.
Establish a designated work zone with appropriate barricades and signage.
Remove any potential ignition sources from the work area.
Provide adequate lighting for safe working conditions.
Ensure access to necessary equipment and materials.

8. Safe Work Procedure Steps

1. Preparation and Planning: Review the scope of work, identify potential hazards, and develop a detailed plan. Obtain necessary permits and conduct a pre-job briefing with all personnel involved.
2. Line Identification: Verify the contents of the line by reviewing process diagrams, labels, and other relevant documentation. If necessary, perform chemical analysis to confirm the contents.
3. Isolation: Isolate the section of the line to be broken by closing valves, installing blinds, or disconnecting flanges. Implement Lockout/Tagout procedures to prevent accidental opening of valves or energizing of equipment.
4. Purging: Purge the isolated section of the line with an inert gas (e.g., nitrogen) or liquid (e.g., water) to remove any remaining hazardous substances. Ensure proper ventilation during purging to prevent the accumulation of hazardous vapors.
5. Atmospheric Monitoring: Monitor the atmosphere in the work area for hazardous gases, flammable vapors, and oxygen levels. Continue monitoring throughout the line breaking process.
6. Line Breaking: Carefully loosen the flange bolts or pipe connections. Use appropriate tools and techniques to prevent sudden release of pressure or hazardous substances. Have spill control materials readily available.
7. Inspection: Inspect the inside of the line for any signs of corrosion, damage, or remaining hazardous substances. Take appropriate action to address any issues found.
8. Work Execution: Perform the necessary work on the line, following established procedures and safety guidelines. Use appropriate PPE and tools for the task.
9. Reinstatement: Once the work is complete, reinstate the line by reconnecting flanges, removing blinds, and opening valves. Ensure all connections are properly tightened and sealed.
10. Testing: Test the line for leaks and proper operation. Make any necessary adjustments or repairs.
11. Lockout/Tagout Removal: Remove Lockout/Tagout devices only after verifying that the line is safe to operate and all personnel are clear of the area.
12. Final Inspection: Conduct a final inspection of the work area to ensure it is clean and free of hazards. Remove any waste materials and equipment.

9. Precautions and Safety Measures

Never assume a line is empty. Always verify the contents and take appropriate precautions.
Ensure proper ventilation to prevent the accumulation of hazardous vapors.
Use non-sparking tools in areas where flammable vapors may be present.
Implement Lockout/Tagout procedures to prevent accidental start-up of equipment.
Have spill control materials readily available in case of a release.

10. Emergency Procedures

10.1 General Emergency Response

In the event of an emergency, follow these general procedures:

1. Immediately stop work and evacuate the area. 2. Activate the emergency alarm system. 3. Contact emergency services (e.g., fire department, ambulance). 4. Provide first aid to injured personnel. 5. Control and contain any spills or releases. 6. Follow the instructions of emergency responders.

10.2 Specific Emergency Scenarios

Release of Hazardous Substance: 1. Evacuate the area immediately. 2. Notify emergency services and provide information about the substance released. 3. If trained and equipped, attempt to contain the release using appropriate spill control materials. 4. Do not attempt to clean up the spill without proper training and PPE.
Fire or Explosion: 1. Activate the fire alarm system. 2. Evacuate the area immediately. 3. Notify emergency services. 4. If trained and equipped, attempt to extinguish the fire using appropriate fire suppression equipment. 5. Do not attempt to fight the fire if it is too large or spreading rapidly.
Contact with Energized Electrical Lines: 1. De-energize the power lines if possible. 2. Keep all personnel away from the affected area. 3. Notify emergency services. 4. Do not approach the area until it is confirmed that the power lines are de-energized.

11. Incident Reporting and Investigation

All incidents, including near misses, must be reported to the supervisor immediately. The supervisor will then notify the safety department and other relevant personnel. A written incident report must be completed within 24 hours of the incident.

A thorough investigation will be conducted to determine the root cause of the incident and identify corrective actions to prevent recurrence. The investigation team will include representatives from safety, operations, and other relevant departments. The investigation report will be reviewed by management and corrective actions will be implemented and tracked to completion.

Approved by: [NAME AND POSITION]

Date: [APPROVAL DATE]