Safe Work Procedure: Line Breaking

Document Number: [SWP-NUMBER] Revision Date: [DATE] Next Review Date: [NEXT REVIEW DATE] Department: [DEPARTMENT NAME]

1. Scope

[This procedure outlines the safe work practices for breaking lines (pipes, hoses, etc.) containing pressurized or potentially hazardous materials. It applies to all personnel involved in the disconnection, opening, or any activity that could result in the release of contents from a line.]

[This SWP is applicable in any work environment where lines containing hazardous substances are present, including but not limited to chemical plants, refineries, construction sites, and maintenance facilities.]

[This SWP should be used in conjunction with relevant site-specific procedures, safety data sheets (SDS), and any other applicable regulations or guidelines.]

2. Definitions

Line Breaking: The process of disconnecting or opening any pipe, hose, or other containment system that may contain pressurized or hazardous materials.

Hazardous Material: Any substance that poses a risk to health, safety, or the environment, including but not limited to chemicals, gases, and pressurized fluids.

Competent Person: An individual who is qualified because of knowledge, training, and experience to perform a specific task safely.

3. Responsibilities

3.1 Supervisors

Ensure that all workers involved in line breaking activities are properly trained and competent.
Provide necessary equipment and PPE for the safe execution of the task.
Conduct pre-job briefings to discuss potential hazards and control measures.
Ensure compliance with this SWP and all other relevant safety procedures.

3.2 Workers

Participate in required training and demonstrate competency in line breaking procedures.
Inspect PPE and equipment before use and report any defects.
Follow all steps outlined in this SWP and any additional instructions provided during pre-job briefings.
Report any hazards, near-misses, or incidents to the supervisor immediately.

3.3 Health and Safety Representative

Assist in the development and review of this SWP.
Conduct periodic audits to ensure compliance with this SWP.
Investigate incidents and recommend corrective actions to prevent recurrence.

4. Potential Hazards and Risks

Hazard	Risk	Control Measures
Exposure to hazardous materials	Skin irritation, chemical burns, respiratory problems, systemic poisoning	Use appropriate PPE (gloves, eye protection, respiratory protection), ensure adequate ventilation, follow SDS guidelines [1]
Pressurized lines	Projectiles, uncontrolled release of materials	Depressurize lines before breaking, verify zero energy state, use pressure gauges, bleed valves, and relief devices
Unexpected release of stored energy	Injury from sudden movement of equipment or materials	Lockout/tagout procedures, proper support and securing of lines, use of safety pins or blocks
Fire or explosion	Ignition of flammable materials	Eliminate ignition sources, use non-sparking tools, ensure proper grounding and bonding
Environmental contamination	Pollution of soil, water, or air	Containment measures (drip pans, absorbent materials), proper disposal of waste materials, spill control procedures

5. Personal Protective Equipment (PPE)

[Proper PPE is essential to minimize the risk of exposure to hazards during line breaking activities.]

Safety Glasses/Goggles - [To protect eyes from splashes, debris, or chemical exposure. Ensure they meet ANSI Z87.1 standards.] [1]
Chemical-Resistant Gloves - [To protect hands from contact with hazardous materials. Select gloves based on the specific chemicals involved, referring to the SDS for guidance.] [2]
Protective Clothing - [To prevent skin contact with hazardous substances. This may include coveralls, aprons, or other chemical-resistant garments.] [1]
Respiratory Protection - [To prevent inhalation of harmful vapors, gases, or dusts. Use a respirator appropriate for the specific hazard, with proper fit testing and training.] [1]
Safety Shoes - [To protect feet from impact, punctures, or chemical exposure. Ensure they meet ASTM F2413 standards.]

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

6. Equipment and Tools

[Using the correct equipment and tools is crucial for safe and efficient line breaking.]

Non-Sparking Tools - [To reduce the risk of ignition in flammable environments. Use tools made of brass, aluminum, or other non-sparking materials.]
Pressure Gauges - [To monitor pressure levels in the line before and during breaking. Ensure gauges are calibrated and in good working order.]
Bleed Valves - [To safely release residual pressure from the line. Use valves designed for the specific pressure and materials involved.]
Drip Pans/Containment Devices - [To capture any spills or leaks during line breaking. Select appropriate materials based on the chemicals involved.]
Lockout/Tagout Devices - [To isolate and de-energize the line before breaking. Use locks, tags, and other devices to prevent accidental re-energization.]

[Inspect all equipment and tools before each use for damage or defects. Replace or repair any faulty items. Use equipment according to manufacturer's instructions and relevant safety standards.]

7. Pre-Job Requirements

7.1 Training and Competency

[All personnel involved in line breaking must receive adequate training and demonstrate competency in the following areas:]

Hazard communication and SDS interpretation
Proper use of PPE and equipment
Lockout/tagout procedures
Emergency response procedures
Specific line breaking techniques for different types of lines and materials

7.2 Pre-Job Briefing

[Before commencing any line breaking activity, conduct a pre-job briefing to discuss the following:]

Scope of the work and specific steps involved
Potential hazards and risks
Control measures and safety precautions
Emergency procedures and communication protocols
Roles and responsibilities of each team member

7.3 Work Area Preparation

[Prepare the work area to minimize hazards and ensure a safe working environment:]

Ensure adequate ventilation to prevent accumulation of hazardous vapors or gases [1].
Remove any ignition sources from the area.
Provide adequate lighting for clear visibility.
Set up containment measures to capture any spills or leaks.
Barricade the area to prevent unauthorized access.

8. Safe Work Procedure Steps

Step 1: Identify and Isolate the Line

[Properly identify the line to be broken and isolate it from the system.]

Sub-step 1.1: Verify the line's contents and pressure rating using appropriate documentation (e.g., P&IDs, SDS). [1]
Sub-step 1.2: Implement lockout/tagout procedures to isolate the line from all energy sources.
Sub-step 1.3: Ensure that all upstream and downstream valves are closed and locked.

[Safety considerations for this step: Incorrect identification or isolation can lead to exposure to hazardous materials or uncontrolled release of pressure.]

Step 2: Depressurize the Line

[Safely depressurize the line to a zero-energy state.]

Sub-step 2.1: Use a pressure gauge to verify the pressure in the line.
Sub-step 2.2: Slowly open a bleed valve or relief device to release any residual pressure.
Sub-step 2.3: Monitor the pressure gauge to ensure the line is completely depressurized.

[Safety considerations for this step: Rapid depressurization can create projectiles or release hazardous materials into the atmosphere.]

Step 3: Break the Line

[Carefully break the line, taking precautions to contain any residual contents.]

Sub-step 3.1: Position a drip pan or containment device under the connection to be broken.
Sub-step 3.2: Use appropriate tools to loosen the connection (e.g., wrench, socket).
Sub-step 3.3: Slowly separate the connection, allowing any residual contents to drain into the containment device.

[Safety considerations for this step: Residual contents may be hazardous and can cause skin or eye irritation, chemical burns, or environmental contamination.]

9. Precautions and Safety Measures

Ventilation - [Ensure adequate ventilation to prevent the accumulation of hazardous vapors or gases. Use local exhaust ventilation if necessary.] [1]
Housekeeping - [Maintain a clean and orderly work area to prevent slips, trips, and falls. Clean up any spills or leaks immediately.]
Communication - [Maintain clear communication between all team members throughout the line breaking process. Use hand signals or radios if necessary.]
Emergency Preparedness - [Ensure that emergency response equipment (e.g., spill kits, fire extinguishers, first aid supplies) is readily available. Know the location of emergency exits and assembly points.]
Waste Disposal - [Dispose of all waste materials (e.g., used PPE, contaminated absorbent materials) in accordance with local, state, and federal regulations.]

10. Emergency Procedures

10.1 General Emergency Response

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

Immediately stop work and assess the situation.
Activate the emergency alarm and notify the supervisor.
Evacuate the area if necessary.
Provide first aid to any injured personnel.
Contain any spills or releases to prevent further contamination.

10.2 Specific Emergency Scenarios

Exposure to Hazardous Materials - [Immediately flush affected area with water for at least 15 minutes. Seek medical attention.]
Uncontrolled Release of Pressure - [Evacuate the area and notify the supervisor. Do not attempt to stop the release without proper training and equipment.]
Fire or Explosion - [Activate the fire alarm and evacuate the area. Use a fire extinguisher if safe to do so. Contact emergency services.]

10.3 Emergency Contact Information

[List of emergency contacts and their phone numbers]

Emergency Services: [911]
Site Security: [PHONE NUMBER]
Health and Safety Department: [PHONE NUMBER]
Supervisor: [PHONE NUMBER]

11. Incident Reporting and Investigation

[All incidents, near-misses, and hazards must be reported to the supervisor immediately.]

[The supervisor will investigate all reported incidents to determine the root cause and implement corrective actions to prevent recurrence. The investigation will involve gathering information, interviewing witnesses, and reviewing relevant procedures. A written report will be prepared and submitted to the Health and Safety Department.]

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