bp oil -- toledo refinerytoledobp.com/pages/cm/work_procedures/safety/saf-120.pdf · bp oil --...

BP OIL -- TOLEDO REFINERY

PAPER COPIES ARE UNCONTROLLED. THIS COPY VALID ONLY AT THE TIME OF PRINTING.

Document Type: Practice

Refinery Wide

Reference No.: SAF 120

Effective Date: February 15, 2016

Ventilation Guideline

Revision No.: 0

Owner: Matthew T. Grimes

Authorized By: Robert Myak (signature on file)

of 21

SCOPE

This guideline applies to all BP-Husky employees, contract personnel, and visitors working in a confined space. Any time a hazardous vapor or fume is present or produced, ventilation and/or respiratory protection should be used to reduce the concentration in the environment.

HEALTH

Special PPE & Special Hazards

The use of proper ventilation helps prevent employee exposure to hazardous vapors and/or fumes.

SAFETY

Standard Refinery PPE

REFERENCE DOCUMENTS

Safe Work Procedure: • SAF 032: Confined Space Entry • SAF 044: Hot Work and Hot Work Spark Potential,

and Vehicle Entry Procedure Additional References • OSHA 29 CFR 1926.57: Ventilation • OSHA 29 CFR 1910.146: Permit-required Confined

Spaces • OSHA 29 CFR 1910.252: General Requirements • OSHA 29 CFR 1926.353: Ventilation and Protection in

Welding, Cutting, and Heating • OSHA 29 CFR 2910.1450: Occupational Exposure to

Hazardous Chemical in Laboratories • “Field Guidelines for Temporary Ventilation of Confined

Spaces”

SPECIAL MATERIALS & EQUIPMENT

Ventilation equipment, fans, local exhaust systems

QUALITY

N/A

ENVIRONMENTAL

N/A

Reference No. SAF 120 Rev. No. 0

of 21

PAPER COPIES ARE UNCONTROLLED. THIS COPY VALID ONLY AT THE TIME OF PRINTING.

OVERVIEW The purpose of this ventilation guideline is to eliminate or reduce harmful vapors and/or fumes in the work environment. Welding operations often use inert gasses that can displace oxygen. The goal of this guideline is to establish a guideline for hot work and lab operations, so that exposures to vapors and/or fumes are kept below regulatory limits. This ventilation guideline includes:

• Identifying when and how ventilation should be used. • Exchange rates for ventilation systems.

1.0 Definitions

1.1 Air Flow – The volume of air flow for a specified time period, typically expressed in terms of cubic feet per minute (CFM).

1.2 Air Velocity – The speed of air flow, typically expressed in terms of feet per minute (FPM).

1.3 Air Velocity Meter (Anemometer) – A device used to measure air velocity, typically expressed in units of feet per minute (FPM).

1.4 Full Welding Enclosure – A temporary enclosure typically constructed of a steel support structure (typically cube shaped) and draped with fire retardant fabric (e.g. fire blankets) to contain sparks/slag and/or weather protection. The enclosure has roof or ceiling, with at least 3 closed sides.

1.5 General Exhaust Ventilation – A form of mechanical ventilation that provides exhaust ventilation to a general area of contamination (e.g. ventilation supplied to a room or confined space, but not directly at the source of contaminant generation within the room or confined space).

1.6 Hazardous atmosphere - means an atmosphere that may expose employees to the risk of death, incapacitation, impairment of ability to self-rescue (that is, escape unaided from a permit space), injury, or acute illness from one or more of the following causes: 1.6.1 Flammable gas, vapor, or mist in excess of 10 percent of its lower

flammable limit (LFL).

1.6.2 Airborne combustible dust at a concentration that meets or exceeds its LFL.

1.6.3 Atmospheric oxygen concentration below 19.5 percent or above 23.5 percent.

1.6.4 Atmospheric concentration of any substance for which a dose or a permissible exposure limit is published in Subpart G, Occupational Health and Environmental Control, or in Subpart Z, Toxic and Hazardous Substances, of this Part and which could result in employee exposure in excess of its dose or permissible exposure limit.

1.6.5 Any other atmospheric condition that is immediately dangerous to life or health.

Practice No. SAF 120 Rev. No. 0

of 21

1.7 Laboratory-type hood - means a device located in a laboratory, enclosure on five sides with a moveable sash or fixed partial enclosed on the remaining side; constructed and maintained to draw air from the laboratory and to prevent or minimize the escape of air contaminants into the laboratory; and allows chemical manipulations to be conducted in the enclosure without insertion of any portion of the employee's body other than hands and arms.

1.8 Local Exhaust Ventilation – A form of mechanical ventilation, that provides exhaust ventilation at the source of contaminant generation (e.g. directly in the welding zone, etc.). Contaminants are not allowed to escape beyond the point of generation.

1.9 Mechanical Ventilation – Ventilation provided by a mechanical force, such as a radial fan blade or other mechanical system (e.g. venturi “air horn”, etc.).

1.10 Natural Ventilation – Ventilation provided by natural wind convection or natural “up draft” (e.g. such as a heater furnace/draft stack configuration).

1.11 Powered Air- Purifying Respirator (PAPR) - Air-purifying respirator with a hood or helmet, breathing tube, canister, cartridge, filter, and a blower that passes ambient air through the purifying element. The blower can be stationary or portable. It can also be designed and equipped with a full face piece, in which case it is referred to as a full face piece powered air-purifying respirator (FFPAPR).

2.0 Responsibilities 2.1 Industrial Hygienist

2.1.1 Maintain a ventilation guideline.

2.1.2 When determined necessary, conduct or coordinate sampling of the atmosphere where work is being done.

2.1.3 Determine if added ventilation is necessary.

2.1.4 Recommend engineering controls to increase ventilation in work areas

2.1.5 Write ventilation plans for BP personnel confined space entry as requested.

2.1.6 Serve as a resource for reviewing contractor confined space ventilation plans during turnaround work.

2.1.7 Ensure that BP local exhaust hoods and booths are annually tested for functionality and flow rate.


of 21

2.2 Technical Engineering Department

2.2.1 Recommend engineering controls to increase ventilation in work areas.

2.2.2 Consider ventilation in vessel design recommendations.

2.3 Maintenance Supervisors

2.3.1 Maintain an inventory of fixed and portable exhaust systems as well as general air moving equipment.

2.3.2 Ensure ventilation equipment is properly installed per the ventilation plan.

2.3.3 Remove equipment that is not functioning properly from service.

2.3.4 Shall perform annual tests on ventilation equipment to ensure flow rates and functionality are maintained as specified in this document.

2.4 Maintenance Planner

2.4.1 Notify Industrial Hygienist to develop a written ventilation plan or document that one is not required for work in a confined space.

2.4.2 Inform the Industrial Hygienist of the chemicals involved with the process.

2.4.2 Provide vessel drawings, vessel dimensions, metallurgy, and work tasks to the Industrial Hygienist.

2.5 BP employees

2.5.1 Enforce the use of respirators when necessary.

2.5.2 Communicate additional hazards and equipment maintenance needs to your supervisor.

2.5.3 Do not proceed to work in harmful atmospheres without proper controls.

2.5.4 Follow requirements as specified in the ventilation plan.

2.6 Contractors

2.6.1 Maintain a ventilation guideline that complies with OSHA 1910.146, 1910.252, 1910.134, and 1926.353.

2.6.2 Ensure that employees use local exhaust devices correctly.


of 21

2.6.3 Ensure that local exhaust hoods and booths are annually tested for functionality and flow rate.

2.6.4 Develop a written ventilation plan or document that one is not required for work in a confined space.

2.6.5 Use proper ventilation techniques or respiratory protection when necessary.

2.6.6 Communicate additional hazards and equipment maintenance needs to your supervisor.

2.6.7 Follow requirements as specified in the ventilation plan.

2.6.8 Sampling should be conducted to determine contaminate levels as determined by the industrial hygienist.

2.7 Lab Supervisor

2.7.1 Annually ensure that lab hoods meet the capture velocity specified in this document.

3.0 Procedure 3.1 Ventilation for general welding and cutting

3.1.1 Local exhaust ventilation: Should be designed to prevent dispersion of dusts, fumes, mists, vapors, and gases into the air at concentrations that may cause harmful exposure. Exhaust systems should be designed so that dusts, fumes, mists, vapors, or gases are not drawn through the work area of employees.

3.1.2 Design and operation: Ventilation equipment should be maintained and operated properly to ensure functionality.

3.1.3 Duration of operations:

o The exhaust system should be in operation continually during all operations which it is designed to serve.

o The exhaust system should continue to be in operation until the environment is no longer contaminated or respiratory protection should be used.

3.1.4 Factors determining adequate ventilation include:

o Volume and configuration of the space.

o Number and type of the operations.

o Concentration of specific toxic contaminates.

o Natural air flow and atmosphere conditions.

o Relation of workers breathing zone to the contaminate.

3.1.5 Sampling should be conducted to determine contaminate levels as determined by the industrial hygienist.


of 21

3.1.6 Fumes should be avoided by positioning the work, the head, or by ventilation that captures or directs fume away from the face.

3.1.7 When natural ventilation is not enough, mechanical ventilation or respiratory protection should be used.

3.1.8 Contaminates should not be blown to other work areas at levels that are above allowable limits.

3.1.9 Air cleaners may be used if they reduce contaminates below allowable limits.

3.1.10 When using Antimony, Arsenic, Barium, Beryllium, Cadmium, Chromium, Cobalt, Copper, Lead, Manganese, Mercury, Nickel, Ozone, Selenium, Silver, Vanadium special ventilation is needed:

o Local exhaust and when required respiratory protection. Contact the BP Industrial Hygienist to disuss/determine appropriate respiratory protection.

o All persons in the area of operation should be similarly protected.

o When in confined spaces involving fluxes, coatings, or other fluorine, zinc, and copper, compounds, local exhaust or respiratory protection should be used.

3.1.11 Arc and Gas cutting.

o Oxygen cutting using either a chemical flux or iron powder, gas-shielded arc cutting, or plasma cutting should be done using local mechanical ventilation and supplied air protection.

3.1.12 Ventilation should consist of ventilation systems or local exhaust systems and should be used when:

o A space is less than 10,000 cubic feet (284 m3) per welder.

o In a room having a ceiling height of less than 16 feet (5 m).

o In confined spaces or where cross ventilation is reduced from partitions, balconies, or other structural barriers.

NOTE: See appendix 6 for a comprehensive list and photos of ventilation equipment available at the TBU

3.1.13 Minimum rate:

o Ventilation should be at the minimum rate of 2,000 cubic feet (57 m3) per minute per welder, except where local exhaust hoods or airline respirators are used.

3.1.14 Exhaust ventilation systems.

o The air exhausted from blast-cleaning equipment should be discharged through dust collecting equipment. Dust collectors


of 21

should be set up so that the accumulated dust can be emptied and removed without contaminating other working areas.

3.1.15 Local exhaust hoods and booths.

o Local exhaust shall be annually tested for functionality and flow rate.

o Mechanical local exhaust ventilation may be by means of either of the following:

1. Freely movable hoods (dudt eaters) intended to be placed by the welder as near as practicable to the work being welded and provided with a rate of air-flow sufficient to maintain a velocity in the direction of the hood of 100 linear feet (30 m) per minute in the zone of welding when the hood is at its most remote distance from the point of welding. When brazing with cadmium bearing materials or when cutting on such materials increased rates of ventilation may be required.

2. Fixed enclosure with a top and more than two sides which surround the welding or cutting operations and with a rate of airflow sufficient to maintain a velocity away from the welder of greater or equal to 100 linear feet (30 m) per minute.

3.1.16 Cadmium

o When done outdoors a minimum half mask respirator or PAPR should be used.

3.1.17 Asbestos

o Site asbestos competent person should be contacted for any work involving asbestos.

4.2 Ventilation in Confined Spaces

4.2.1 Written ventilation plan shall be required for confined spaces based on the scope of work. There may be a need for multiple ventilation plans for each confined space based on the tasks that are being performed.

4.2.2 The ventilation plan shall ensure controls are evaluated to provide adequate protection of the workers such as respiratory protection, local exhaust ventilation and continuous gas monitoring. See Appendix 6 Ventillation Flow Charts.

4.2.3 The need for a ventilation plan by task shall be determined during the risk assessment.

4.2.4 Ventilation plans shall be provided to the BP Industrial Hygiene Department for review prior to the start of the confined space entry.

4.2.5 Industrial Hygiene services, including creation of ventilation plans and sampling, are the responsibility of the company performing the work in the space.


of 21

4.2.6 Some areas may not need mechanical ventilation but the Industrial Hygienist should make that decision.

4.2.7 The written ventilation plan or documentation that one is not needed shall be document. See Appendix 1 for an example of a ventilation plan.

4.2.8 A copy of the written ventilation plan or documentation stating mechanical ventilation is not required shall be kept at the confined space with the entry permit.

4.2.9 The atmosphere within the space should be periodically tested as necessary to ensure that the continuous forced air ventilation is preventing the accumulation of a hazardous atmosphere.

4.2.10 If a hazardous atmosphere is detected during entry:

o Each employee should leave the space immediately.

o The space should be evaluated to determine how the hazardous atmosphere developed.

o Measures should be implemented to protect employees from the hazardous atmosphere before any subsequent entry takes place.

4.2.11 General ventilation air replacement.

o The minimum general ventilation rate required in a confined space is 2,000 cubic feet per minute (CFM) from a clean source, per welder. Adequate ventilation must be provided even if welders are using air-purifying respirators.

o It is recommended that a complete air change occurs every minute so that there are 60 air changes in an hour:

Ø This corresponds to a complete air change of the space volume once every minute to control potential build-up of gases, vapors or other contaminants.

Ø Certain equipment limitations (i.e. very large size) or job limitations (i.e. interference with welding inert gas, etc.) may not allow these optimal air changes.

o Air should not be blown into a confined space using plant supplied air due to the possibility of nitrogen or hydrocarbon contamination.

o Compressors and fans are acceptable means of blowing air into a space.

o In order to maintain proper pressure in confined spaces there should be an even number of manholes open so that make up air is replaced in accordance with air removal.

o It is preferred that open manholes be located at lower levels and exhaust fans be located at higher levels.


of 21

o Fans and blowers should be mounted firmly against flanges and grounded.

4.2.12 Respiratory Protection.

o All persons in the confined space should use the same respiratory protection required by the welders.

4.2.13 Oxygen for ventilation.

o Oxygen should never be used for ventilation.

4.2.14 Local ventilation.

o Local exhaust should provide an air velocity of 100 fpm at the weld site.

o 100 fpm may not be adequate when other air drafts are present.

o Usually requires the inlet to be within 12 inches of the operation.

4.2.15 Local exhaust appropriate circumstances include.

o Vessels with single man ways or single open manway

o Confined spaces with dead spots.

o Confined spaces where air-moving devices are not feasible.

o See Table 1. for local exhaust guidelines.

NOTE: Local exhaust ventilation is only effective when it captures fumes at the source.

4.2.16 Recommendations.

o Keep duct work short.

o Smooth duct work minimizes airflow loss.


of 21

o Flexible duct work is easily collapsible so they should be straight and free of kinks.

o Instead of using many small ducts use one large duct with a plenum to distribute air on the inside of a confined space.

o Some areas may not need mechanical ventilation but the Industrial Hygienist should make that decision. Some areas include:

1. Large-open roof tanks

2. On top of floating roof tanks

3. Open top excavations.

4. Large exchanger shells.

5. Fin fan enclosures.

4.2.17 Lead.

o In confined spaces or indoors, welding or cutting operations involving metals containing lead, other than as an impurity, or metals coated with lead-bearing materials, including paint, should be done using local exhaust ventilation or airline respirators. Such operations, when done outdoors, should be done using respirators approved for this purpose. In all cases, workers in the immediate vicinity of the cutting operation should be protected by local exhaust ventilation or airline respirators.

4.2.18 Cadmium.

o In confined spaces or indoors, welding or cutting operations involving cadmium-bearing or cadmium-coated base metals should be done using local exhaust ventilation or airline respirators unless atmospheric tests shows concentrations are within acceptable limits.

4.2.19 Hexavalent Chromium.

o When ventilation measures are not adequate at removing contaminates respiratory protection should be used:

1. Cr VI exposures less than 5.0 µg/m3 require no respiratory protection.

2. Cr VI exposures of 5.0 to 50.0 µg/m3 require a half mask air purifying respirator with P-100/HEPA cartridges.

3. Also, loose fitting Powered Air Purifying Hoods (PAPR) can be used for Cr VI exposures of 5.0 to 125.0 µg/m3.

4. Cr VI exposures greater than 125.0 µg/m3 require the use of supplied air respirators.

4.2.20 Cleaning compounds.


of 21

o In the use of cleaning materials, because of their possible toxicity or flammability, appropriate precautions such as manufacturer’s instructions should be followed.

4.2.21 Degreasing.

o Degreasing and other cleaning operations involving chlorinated hydrocarbons should be located so that vapors from these operations will not be released into the surrounding atmosphere.

4.2.22 Cutting of stainless steels.

o Oxygen cutting, using either a chemical flux or iron powder or gas-shielded arc cutting of stainless steel, should be done using mechanical ventilation adequate to remove the fumes generated.

4.3 Laboratory

4.3.1 The TBU should perform initial and periodic monitoring if there is reason to believe that exposures for any regulated substance exceeds action levels.

4.3.2 Lab hoods must be checked annually to determine flow rate and functionality.

4.3.3 Flow rates shall be maintained between 80 and 100 fpm.

4.3.4 Chemical exchanges and handling should be conducted in lab hoods.


of 21

5.0 Appendices

Appendix 1: TBU Example Ventilation Plan

Ventilation plan for Stripper Reflux Drum PR 1666

*** Valid for listed work tasks only *** Work Task § Grinding on carbon steel § Wet Mag Testing Discovery Work Changing conditions requiring additional personnel, welders, or work tasks requires this ventilation plan to be re-evaluated by the site Industrial Hygienist. Entrants • BP Inspection • BP Heavy Craft • BP Process Engineer Calculations • Enclosure Height: 6 ft. • Enclosure Radius: 1.5 ft. • Enclosure Volume: 42.41 ft3

• Calculated Air Changes per hour: 2405.09 ACH Ventilation Equipment • 1 – 3HP air horn (1700 CFM @ 80psi) will be placed at the 2” vent labelled V (see attached drawing). Air horn must be

oriented to pull air from the space as an eductor (suction end in the space). • The man ways must remain open and unobstructed (see attached drawing). Monitoring All confined space work areas will require continuous gas monitoring. Inside the confined space BP employees will have a four gas monitor. This will monitor for 02, H2S, LEL, and CO. Additional Industrial Hygiene monitoring may be required. Personal Protective Equipment Requirements A minimum of half-mask respirator with NIOSH approved purple P100 HEPA filter cartridge or welding PAPR will be used during carbon arc cutting, carbon steel grinding, and stainless steel welding activities. Normal Refinery PPE as well as PPE identified by the L2RA shall be worn. No respiratory protection is required for carbon steel welding while ventilation equipment is in place. Rescue Contact C&W for any confined space rescue emergencies on 16A. See rescue plan for additional requirements.


of 21

Man hole must remain open and unobstructed.

Air horn must be connected to the 2” vent (V) as an eductor.


of 21

Appendix 2: Respiratory Protection requirements

Grinding Oxy/Acetylene Torch Cutting

StickTig or Heli-‐

ArcMIG Arc Gouging

CarbonNo

Respiratory Protection

No Respiratory Protection





GalvanizedNo

Respiratory Protection






StainlessHalf Mask or PAPR

Half Mask or PAPR

Half Mask or PAPR

Half Mask or PAPR

Half Mask or PAPR

Half Mask or PAPR

AlloysHalf Mask or PAPR

Half Mask or PAPR

Half Mask or PAPR

Half Mask or PAPR

Half Mask or PAPR

Half Mask or PAPR

Open Space without Local Ventilation

Grinding Oxy/Acetylene Torch Cutting

StickTIG or Heli-‐

ArcMIG Arc Gouging FCAW Pac/W

CarbonHalf Mask or PAPR

Half Mask or PAPR

Half Mask or PAPR

Half Mask or PAPR

Half Mask or PAPR

SA or PAPR Half Mask or

PAPR Half Mask or PAPR

GalvanizedHalf Mask or PAPR

PAPRHalf Mask or

PAPR PAPR PAPR SA PAPR PAPR

StainlessHalf Mask or PAPR

PAPRHalf Mask or


AlloysHalf Mask or PAPR

PAPRHalf Mask or


Confined Space with Ventilation

Note: *PAPR – Powered air-purifying respirator

*SA - Supplied air


of 21

Appendix 3: Ventilation Equipment List

Quantity Unit Model number Flow Rate

5 3" air horns short1 TX3AMS 1076 CFM

3 3" air horns2 TX3AM 1308 CFM

4 6" air horns3 TX6AM 3020 CFM

1 3" air horn4 MP-6AM 3347 CFM

3Coppus Jectair 3" air

horns5 3-HP 1700 CFM

1 Coppus fan (20")6 TX- JF 20 up to 10,420

2 12" ducts7

3 8" ducts8

1stationary unit with two collectors and one vent

duct9

1 Lincoln x-tractor 1GC10 K652-1 55-115 CFM

5 Lincoln Portable units11 LFA 4.1 MOB CPL 735 CFM

2 Dust Hogs12 FPH2-3 1200 CFM

1Lincoln Statiflex® 200-M

Dual Arm Base Unit13 K654-2

Single arm operation = 700 CFM,

Double arm operation =550 CFM

1 Lincoln Portable unit14 LFA 4.1 MOB CPL 735 CFM

Ventilation Equipment

Instrument shop

Heavy Craft Shop

Machine Shop

NOT IN USE

NOTE: Superscripts are to be used to reference pictures in Appendix 4.


of 21

Appendix 4: Ventilation Equipment

1 2 3 4 5

6 7

8 8 9

10

10 11/14

11

11 12

13


of 21

Appendix 5: Ventilation Techniques


of 21

Appendix 6: Ventilation Flow Charts


of 21


of 21

Is asbestos involved?

Is welding, torch cutting, or

brazing being performed?

Is work being done on stainless steel or

alloys?

Contact site asbestos

competent person for any work with

asbestos.

Mechanical ventilation is not

required.

Start

Flow Chart for Open Atmosphere Ventilation

YES

YES

No

No

Local exhaust ventilation is required.

Mechanical ventilation is not

required.

No

YES

Note: See appendix 2 for respiratory protection in open spaces without local exhaust ventilation.


of 21

Revision History The following information documents at least the last 3 changes to this document, with all the changes listed for the last 6 months.

Date Revised By Changes

February 15, 2016

Matthew T. Grimes

Implementation of this document. Initial Revision. MOC # M2016445-001

THIS IS THE LAST PAGE

bp oil -- toledo refinerytoledobp.com/pages/cm/work_procedures/safety/saf-120.pdf · bp oil --...

Documents