Safe Work Procedure: Line Break Procedure

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 to be followed when performing a line break. A line break involves opening or disconnecting a pressurized line or system containing hazardous materials (liquids, gases, or solids). This procedure applies to all personnel involved in line breaking activities.]

[This procedure applies to all areas where pressurized lines containing hazardous materials are present, including but not limited to processing units, storage facilities, and utility systems.]

[This SWP should be used in conjunction with relevant site-specific procedures, permits, and safety data sheets (SDS) for the specific hazardous materials involved.]

2. Definitions

Line Break: The process of opening or disconnecting a pressurized line or system that contains or has contained hazardous materials.

Hazardous Material: Any substance or material that poses a risk to health, safety, or the environment.

Competent Person: An individual who has the necessary training, knowledge, and experience to safely perform a line break.

3. Responsibilities

3.1 Supervisors

[Ensure that all workers involved in line breaking activities are properly trained and competent.]
[Provide all necessary equipment and personal protective equipment (PPE).]
[Ensure that a pre-job briefing is conducted before any line breaking activity begins.]

3.2 Workers

[Follow all instructions and procedures outlined in this SWP.]
[Use all required PPE.]
[Report any hazards or unsafe conditions to the supervisor.]

3.3 Health and Safety Representative

[Assist in the development and review of this SWP.]
[Monitor compliance with this SWP.]
[Investigate incidents and near misses related to line breaking activities.]

4. Potential Hazards and Risks

Hazard	Risk	Control Measures
Exposure to hazardous materials	Skin irritation, chemical burns, respiratory problems, poisoning	Identify the hazardous material, use appropriate PPE, ensure adequate ventilation, follow SDS guidelines [1]
Pressurized lines	Injury from sudden release of pressure, equipment damage	Depressurize and isolate the line before breaking, verify zero energy state, use appropriate tools and techniques
Fire or explosion	Burns, injury, equipment damage	Eliminate ignition sources, use non-sparking tools, ensure proper grounding and bonding
Slips, trips, and falls	Injury	Maintain a clean and organized work area, use appropriate footwear

5. Personal Protective Equipment (PPE)

[Proper PPE must be worn at all times during line breaking activities to protect against potential hazards.]

[Chemical-resistant gloves - To protect hands from contact with hazardous materials.]
[Safety glasses with side shields or goggles - To protect eyes from splashes or projectiles.]
[Face shield - For additional face protection when handling highly hazardous materials.]
[Chemical-resistant suit or apron - To protect clothing and skin from contamination.]
[Steel-toe boots - To protect feet from impact and punctures.]

[Inspect PPE before each use for damage or defects. Replace damaged PPE immediately. Clean and store PPE properly after use.]

6. Equipment and Tools

[Use the correct equipment and tools for the specific line breaking task to ensure safety and efficiency.]

[Wrenches - Use appropriate size and type for the fittings.]
[Non-sparking tools - To prevent ignition in flammable environments.]
[Grounding and bonding equipment - To prevent static electricity buildup.]
[Drip pans or containers - To collect any spills or leaks.]
[Absorbent materials - To clean up spills.]

[Inspect equipment and tools before each use for damage or defects. Replace damaged equipment immediately. Use equipment and tools only for their intended purpose.]

7. Pre-Job Requirements

7.1 Training and Competency

[Workers must be trained and competent in line breaking procedures, hazard identification, and the use of PPE and equipment. Training should include site-specific requirements and the properties of the hazardous materials involved.]

7.2 Pre-Job Briefing

[Conduct a pre-job briefing with all personnel involved to discuss the scope of work, potential hazards, control measures, and emergency procedures. Review the SDS for the hazardous materials involved.]

7.3 Work Area Preparation

[Ensure the work area is clear of obstructions and properly ventilated. Barricade the area to prevent unauthorized access. Post warning signs to alert others of the line breaking activity.]

8. Safe Work Procedure Steps

Step 1: Preparation and Isolation

[Identify the line to be broken and the hazardous material it contains. Review the SDS for the material. Ensure that the line is properly isolated and depressurized. Lockout/tagout procedures must be followed to prevent accidental re-pressurization.]

[Verify that the line is depressurized using a pressure gauge.]
[Install grounding and bonding equipment if flammable materials are present.]
[Ensure adequate ventilation in the work area.]

[Safety considerations: Failure to properly isolate and depressurize the line can result in serious injury or equipment damage.]

Step 2: Opening the Line

[Carefully loosen the fittings on the line, starting with the upstream side. Use appropriate tools to prevent damage to the fittings. Be prepared for potential leaks or spills.]

[Loosen fittings slowly to allow any residual pressure to escape.]
[Use drip pans or containers to collect any leaks or spills.]
[Have absorbent materials readily available to clean up spills.]

[Safety considerations: Hazardous materials may be released during this step. Wear appropriate PPE and avoid direct contact with the material.]

Step 3: Line Cleaning and Purging

[After the line is opened, clean and purge it to remove any remaining hazardous material. Use appropriate cleaning agents and disposal methods.]

[Flush the line with a suitable cleaning agent.]
[Purge the line with an inert gas, such as nitrogen, to remove any remaining vapors.]
[Dispose of cleaning agents and purged materials in accordance with environmental regulations.]

[Safety considerations: Ensure that cleaning agents are compatible with the line material and the hazardous material that was present. Dispose of waste properly to prevent environmental contamination.]

9. Precautions and Safety Measures

[Never assume a line is empty or depressurized. Always verify using appropriate methods.]
[Always wear appropriate PPE when performing line breaking activities.]
[Ensure adequate ventilation to prevent exposure to hazardous vapors.]
[Use non-sparking tools in flammable environments.]
[Follow lockout/tagout procedures to prevent accidental re-pressurization.]

10. Emergency Procedures

10.1 General Emergency Response

[In the event of an emergency, immediately stop work and evacuate the area. Activate the emergency alarm and notify the supervisor and emergency response team.]

10.2 Specific Emergency Scenarios

[Exposure to hazardous material - Immediately flush the affected area with water for at least 15 minutes and seek medical attention.]
[Fire or explosion - Activate the fire alarm and use appropriate fire extinguishers to extinguish the fire. Evacuate the area.]
[Spill or leak - Contain the spill and clean it up using absorbent materials. Dispose of the waste properly.]

10.3 Emergency Contact Information

[List of emergency contacts and their phone numbers]

11. Incident Reporting and Investigation

[All incidents, near-misses, and hazards must be reported to the supervisor immediately. An investigation will be conducted to determine the root cause of the incident and prevent future occurrences.]

[The investigation procedure will include gathering information, interviewing witnesses, and analyzing the sequence of events. Corrective actions will be implemented to address the identified hazards.]

Approved by: [NAME AND POSITION] Date: [APPROVAL DATE]