WESTLAKE CHEMICAL CORPORATION

DOCUMENT #: 4301-06-315A
LAKE CHARLES
SAFETY & HEALTH
REVISION DATE: 2/13/2018

DOCUMENT NAME: SAFE PROCESS PIPING, EQUIPMENT

& VESSEL OPENING PROCEDURE PAGE: 1 of 14

1.0 Purpose
To minimize the consequences that may result from the potential unexpected release of
hazardous chemicals while opening process piping, equipment and vessels at Lake
Charles Facilities.
2.1 Scope
2.2 The scope of this procedure applies to anyone performing activities that involve
opening of pipe flanges, un-coupling of threaded pipe fittings or instrumentation
(that is mounted with no isolation valves), physically cutting into process piping or
equipment, the opening of process related equipment and removing process
relatedequipment from service for repairs that have contained or had the potential
to contain hazardous materials as defined in 3.7.
2.3 Site PPE matrices shall meet at a minimum the requirements of the PPE matrix in
Minimum PPE Requirements for Line Breaking & Equipment Opening. If a line
opening will involve a hazardous material not found in Minimum PPE
Requirementsfor Line Breaking & Equipment Opening then the Safety Data Sheet
shall be reviewed. If more information is needed, the EHSS Department shall be
contacted in order to provide information on the proper PPE.
2.4 There are numerous activities that are performed each day as part of normal
operations by the equipment owner/operator that present potential hazards that
willnot fall under the scope of this procedure but will require that an associated
risk assessment be completed and documented as part of a standard operating
procedure or written Job Safety Analysis. Some of those normal daily operational
activities include but may not be limited to:
2.4.1 Flushing / Draining Process Equipment
2.4.2 Opening Vents and Bleeders
2.4.3 Routine Maintenance on Instrumentation & Process Analyzers
2.4.4 Routine Sampling Activities
2.4.5 Routine Maintenance on steam traps open to atmosphere by
complex maintenance steam trap crew.
Additional activities may be added upon a Safety Department review.
2.5 Personnel performing these activities shall, at a minimum wear the personal
protective equipment required by the specific standard operating procedure or
written Job Safety Analysis and meet the minimum protection requirements for
thepotential risks and hazards identified as part of the associated risk
assessment.
2.6 If Operation personnel will be completing a line opening as defined in the scope
2.1 and definition 3.15 all requirements detailed in sections 4.1, 4.2.1, 4.3 and 4.4
shallbe followed. A permit will not be required when operation personnel perform
a line opening, but, all operations personnel will be required to Minimum PPE
Requirements for Line Breaking & Equipment Opening.
 WESTLAKE CHEMICAL CORPORATION
DOCUMENT #: 4301-06-315A
LAKE CHARLES
SAFETY & HEALTH
REVISION DATE: 2/13/2018

DOCUMENT NAME: SAFE PROCESS PIPING, EQUIPMENT

& VESSEL OPENING PROCEDURE PAGE: 2 of 14

3.0 Definitions
3.1 Affected Line Opening Personnel – The fewest number of personnel required
toperform the line openings. All non-essential personnel (those who are not
physically performing the line opening) shall be outside the line opening affected
area at all times.
3.2 Bleeder – Valve controlled small diameter openings in piping provided for draining,
washing, injection, product transfer, or facilitating clearing or purging.
3.3 Blind / Slip Blind / Stopper Plate – A metal plate designed for isolating process
piping, equipment and vessels to control hazardous energy sources. Plates must
be designed and constructed to meet the applicable pipe standard. Both maximum
operating pressure and material of construction should be verified prior to placing
into service.
3.4 Cleared Process Confirmation (CPC) – This determination shall be conducted once
all line openings have been completed. Equipment Owner/Operator, Maintenance
Supervisor or Westlake Construction Host/Contact confirms applicable visual or
quantitative verifications. Once all verifications have been confirmed a CPC shall
be documented.
3.5 Maintenance/Construction Supervisor – The person who is responsible for
supervising the work crew that is performing the process piping, vessel, equipment
openings or physical process line cut(s).
3.6 Equipment Operator – An A Operator, B Operator, C Operator, or D Operator
assigned to an area or unit who operate the process related piping, vessels and
equipment.
3.7 Equipment Owner – The Lead Operator or Operations Supervisor assigned to an
area or unit who operate the process related piping, vessels and equipment.
3.8 Hazardous Material - For the purpose of this procedure the term hazardous material
shall mean any substance that is corrosive, toxic, flammable, reactive, represents a
biological hazard, organic combustible dust or is under pressure greater than 10
psi, is above 120° or below 32° Fahrenheit (Note: This definition also includes plant
utilities such as air, nitrogen, and process water when they meet the criteria listed).
3.9 Initial Line Opening – The initial line opening to include a physical cut on a process
piping, vessel or other process related piece of equipment for a single permit for a
single system.
3.10 Line Opening Affected Area – The area barricaded around the process piping,
equipment or vessel to be opened. The affected area shall be barricaded with red
barricade tape at a minimum of 10’ radius from the point of the opening for line
openings at grade. For elevated line openings, the line opening affected area shall
be barricaded with red barricade tape at each level at a minimum of 15’ radius
(minimum 10’ at working level). Factors such as material, operating pressure and
temperature, weather conditions, vehicle and/or pedestrian traffic may warrant the
increase of the barricaded area.
 WESTLAKE CHEMICAL CORPORATION
DOCUMENT #: 4301-06-315A
LAKE CHARLES
SAFETY & HEALTH
REVISION DATE: 2/13/2018

DOCUMENT NAME: SAFE PROCESS PIPING, EQUIPMENT

& VESSEL OPENING PROCEDURE PAGE: 3 of 14

3.11 Line Opening Field Review – The review will take place at the job site and be led by
the Equipment Owner/Operator or Operations Supervisor. The individual
responsible for supervising the work crew (Maintenance/Construction Supervisor)
shall also be present for the field meeting. A review of the LOTO will be conducted
as well as identifying each line opening location. The equipment owner shall
physically mark all line opening locations as per 4.2.1.5 with green barricade tape.
3.12 Pre-Job Safety Briefing – Detail review of the permit or Job Ready Tag and line
opening activities and requirements by the Maintenance/Construction Supervisor
with all the work crew. This review shall be conducted in the field at the job site and
be documented.

3.13 Process Equipment – Any process related piping, pipelines, bleeders, tanks, vessel,
towers, columns, reactors, valves, pumps, blinds or any other equipment in process
service.
3.14 Process Piping, Equipment & Vessel Purging/Flushing – The use of water, air,
steam, nitrogen, vacuum, chemical washing, a combination of these or other
approved material connected to a low point bleeder or high point vent to flush or
purge a section of process piping, piece of equipment or vessel prior to
completinga line opening.
3.15 Process Piping, Equipment or Vessel Safe Closing – The closing or reassembly
ofprocess piping, equipment or vessel that contained or contains a hazardous
material.
3.16 Process Piping, Equipment or Vessel Safe Opening – The act of physically
opening, physically cutting into or breeching the integrity of closed process
piping,equipment or vessels that normally or last contained a hazardous material.
This includes loosening bolts, nuts, and fasteners, opening manways, removing
equipment from service, installing or removing blinds.
3.17 Quantitative Verification – The use of a device or process to measure process
hazard materials to provide a numeric or positive indication of process
conditions.Examples include the use of instrumentation specific to the chemical
hazard (Gas meters), chemical indicators (Color metric tubes or tape/paper),
surface temperature of the external piping and measuring internal conditions
(Thermal Imaging).
3.18 Minimum PPE Requirements for Line Breaking & Equipment Opening –
Corporatedocument EHSS-13-REF.001.
3.19 Visual Verification – This verification can only be completed after a line opening has
been completed. It is a visual confirmation that process piping, equipment or vessel
is free of a hazardous material.
 WESTLAKE CHEMICAL CORPORATION
DOCUMENT #: 4301-06-315A
LAKE CHARLES
SAFETY & HEALTH
REVISION DATE: 2/13/2018

DOCUMENT NAME: SAFE PROCESS PIPING, EQUIPMENT

& VESSEL OPENING PROCEDURE PAGE: 4 of 14

4.0 Safe Process Piping, Equipment & Vessel Opening Procedure

4.1 Pre Line Opening Job Preparations
Equipment Owner/Operator
4.1.1 Prior to any line opening involving process piping, equipment or vessel’s
allprocess systems involved in the opening shall be shut down and all
potential energy isolated and de-energized per the LOTO Procedure.
4.1.2 All process piping, equipment or vessels shall be drained, depressured and
or purged utilizing standard operating procedures to ensure all systems are
as clear as possible of any potential hazardous materials.
4.1.2.1 There may be several options for clearing, purging and
depressurizing a system containing a hazardous material and
willbe dependent on the system layout and design. Standard
operating procedures should always be followed. Some options
may include but are not limited to the following:
4.1.2.1.1 High Point vents and Low Point drains
4.1.2.1.2 Purging/Flushing with Steam, Water, Air or Nitrogen
4.1.2.1.3 Vacuuming

4.1.3 Ensure process piping, equipment or vessel temperatures have cooled to a

temperature to allow for safe work.
4.1.4 Ensure heat tracing has been turned off or is protected for safe work.
4.1.5 Survey the process piping, equipment or vessel system to ensure that the
area where the openings are to occur will be adequately supported to
withstand forces / weight or unwanted movement when openings are
completed.
WARNING:
 Due to the design of some process piping, equipment and vessels,
hazardous material may be trapped and present due to low points and
high points (gases lighter than air). These should be noted and
communicated during both the permit and job briefing processes.

 If a section of process piping, equipment or vessel containing a hazardous

material cannot be depressured, cleared or purged then Section 5 of this
procedure shall be followed.

 Care should be taken when closed valves are used as isolation devices as
they have the potential to leak allowing hazardous materials to continue to
flow and potentially build pressure.
 WESTLAKE CHEMICAL CORPORATION
DOCUMENT #: 4301-06-315A
LAKE CHARLES
SAFETY & HEALTH
REVISION DATE: 2/13/2018

DOCUMENT NAME: SAFE PROCESS PIPING, EQUIPMENT

& VESSEL OPENING PROCEDURE PAGE: 5 of 14

4.2 Line Opening Job Planning

4.2.1 Job Site Preparation
Equipment Owner/Operator
4.2.1.1 The line opening affected area shall be barricaded with red
barricade tape at a minimum of 10’ horizontal radius from the point
of the opening for line openings at grade.
4.2.1.2 For elevated line openings the line opening affected area shall be
barricaded with red barricade tape at each level to include the
grade level which should be at a minimum of 15’ horizontal radius.
Factors such as material, operating pressure and temperature,
weather conditions, wind direction, vehicle and/or pedestrian traffic
may warrant the increase of the barricaded area.
4.2.1.3 Shielding may be used when the use of barricade tape is
impractical to protect nearby personnel, piping and equipment.
4.2.1.4 Each opening should be individually evaluated to ensure the
minimum distances stated are sufficient to protect nearby
personnel. The use of posted warning, danger or keep out signs
may also be warranted based on the job planning process.
4.2.1.5 Each individual opening location shall be identified by using green
barricade tape.
4.2.1.6 Emergency safety shower and eyewash locations must be
identified and operability verified. If a fixed emergency safety
shower or eyewash is not located near the line opening area, a
portable ANSI approved safety shower/eye wash station must be
set up near the line opening area but outside the barricade.
4.2.2 Job Permitting
Equipment Owner/Operator or Maintenance/Construction Supervisor
4.2.2.1 Only employees who are AUTHORIZED shall write and issue
permits.
4.2.2.2 Follow established work permitting process (Safe Work Permit and
Job Ready Tag) to ensure a permit is issued for all openings on
process piping, equipment and vessels that contained a
hazardous material.
4.2.2.3 The safe work permit and the Job Ready Tag shall be completed
and reviewed to ensure all applicable requirements and potential
hazards have been documented. Items to consider as potential
hazards:
 WESTLAKE CHEMICAL CORPORATION
DOCUMENT #: 4301-06-315A
LAKE CHARLES
SAFETY & HEALTH
REVISION DATE: 2/13/2018

DOCUMENT NAME: SAFE PROCESS PIPING, EQUIPMENT

& VESSEL OPENING PROCEDURE PAGE: 6 of 14

4.2.2.3.1 Detailed description of the task of job and location

4.2.2.3.2 Prior contents contained in the process piping, equipment
or vessel
4.2.2.3.3 Required PPE as outlined in Minimum PPE Requirements
for Line Breaking & Equipment Opening.
4.2.2.3.4 Required RED BARRICADE tape noting perimeter
distance and location(s) or shielding requirements
4.2.2.3.5 Document that each line opening location has been
physically identified in the field
4.2.2.3.6 Any containment or spill cleanup requirements
4.2.2.3.7 The duration of the permit for all Line Openings
4.2.2.4 The Line Opening Field Review as defined in 4.3 must be
revalidated if the line opening activities have not commenced
within 2 hours from the time when the permit to work was initially
issued.
4.3 Line Opening Field Review
Equipment Owner/Operator and Maintenance/Construction Supervisor
4.3.1 A Line Opening field review will be conducted for all line openings involving
process systems that last contained a hazardous material.
4.3.2 The review will take place at the job site and be led by the Equipment
Owner/Operator. The individual responsible for supervising the work crew
(Maintenance/Construction Supervisor) shall also be present for the field
meeting.
4.3.3 The Line Opening Field Review shall verify and validate all energy isolation
completed by the equipment owner. They will complete a deenergization
verification process to include going through each isolation point to verify
that each energy source is completely deenergized, deactived and isolated
from the energy source, locks are in place, valves or blinds are in the correct
position and review of all purging, flushing and draining activities.

4.3.4 All parties involved in the Line Opening Field Review must agree and
document that the job preparation is complete and permit is ready to be
issued and or completed.
 WESTLAKE CHEMICAL CORPORATION
DOCUMENT #: 4301-06-315A
LAKE CHARLES
SAFETY & HEALTH
REVISION DATE: 1/4/2017
DOCUMENT NAME: SAFE PROCESS PIPING, EQUIPMENT &
PAGE: 7 of 14
VESSEL OPENING PROCEDURE

Equipment Owner/Operator
4.3.5 The equipment owner shall complete the Line Opening Field Review and
associated requirements of section 4.3 with the Work Crew if the Work Crew
will be working under the direct supervision of the Equipment
Owner/Operator.
4.4 Line Opening Pre-Job Safety Briefing
Maintenance/Construction Supervisor & Work Crew
4.4.1 A Line Opening Pre-Job Safety Briefing shall be completed for all openings
on process piping, equipment or vessels that last contained a hazardous
material.
4.4.2 The Maintenance/Construction Supervisor will complete the Job Safety
Briefing with the work crew at the job site.
4.4.3 All work crew members must be present for the Job Safety Briefing.
4.4.4 The Job Safety Briefing shall address but is not limited to the following:
4.4.4.1 Approach all process piping, equipment and vessel openings last
containing a hazardous material as having the potential of being
full and under pressure.
4.4.4.2 Detailed scope of work and visual confirmation of each identified
opening
4.4.4.3 Last Contained Hazardous Material
4.4.4.4 Equipment and Methods to safely complete each line opening
4.4.4.5 Location of emergency shower / eyewash stations
4.4.4.6 Primary paths of egress for evacuation and discuss wind socks
and wind direction
4.4.4.7 Red Barricade Tape requirements establishing line opening work
area
4.4.4.8 PPE requirements as per Minimum PPE Requirements for Line
Breaking & Equipment Opening for all work crew members
working inside the red barricade tape
4.4.4.9 Decontamination procedures specific for the potential hazards in
the event of an exposure
4.4.4.10 Ensure that all line opening crew members are aware of the
potential hazards of the last known hazardous material contained
in system and provide a SDS as needed for clarification.
4.4.4.11 Provide clear instruction on body position and line of fire
4.4.4.12 Discuss the proper way to open / break flanges – “down and
away”
4.4.4.13 If a leak or pressure is detected – be prepared to immediately
 WESTLAKE CHEMICAL CORPORATION
DOCUMENT #: 4301-06-315A
LAKE CHARLES
SAFETY & HEALTH
REVISION DATE: 1/4/2017
DOCUMENT NAME: SAFE PROCESS PIPING, EQUIPMENT &
PAGE: 8 of 14
VESSEL OPENING PROCEDURE

retighten bolts to secure the opening and immediately contact the

Maintenance/Construction Supervisor.
4.4.4.14 If any plugging is discovered or is suspected stop work and notify
Maintenance/Construction Supervisor.
4.4.5 If any abnormal conditions are identified, stop work and
notify Maintenance/Construction Supervisor.
4.4.6 The individual supervising the work crew shall visually verify that each
crew member has all the approved and required PPE donned correctly,
equipment and materials to complete the job safely.
4.4.7 The individual supervising the work crew must document that the Job
Safety Briefing has been completed. Each work crew member must
document thatthey participated in the Job Safety Briefing and understand
all requirementsand safeguards by signing the Safe Work Permit.
Operation Personnel
4.4.8 The operation supervisor must complete the Job Safety Briefing and the
requirements of section 4.4 with the Work Crew if the Work Crew will be
working under the direct supervision of the Operations Supervisor.

WARNING:
 Approach all process piping, equipment and vessel openings last containing a
hazardous material as having the potential of being full and under pressure until all line
openings are completed and a Cleared Process Confirmation has been completed by
operations or crew foreman or supervisor

4.5 Safe Process Piping, Equipment & Vessel Opening

Equipment Owner/Operator or Maintenance/Construction Supervisor

4.5.1 Either the Equipment Owner/Operator or Maintenance/Construction

Supervisor shall be present during the opening or physical cut for each
permitted job involving process piping, equipment or vessel openings
that has or did last contained a hazardous material. This includes every
greentaped location.

4.5.2 Shall verify that all approved and required PPE is properly donned by
each of the work crew who will be working inside the barricaded work
zone.
4.5.3 Will ensure only authorized personnel are allowed inside the
barricadedwork area and are wearing the required PPE to enter the
work area.
4.5.4 Ensure the areas above, below and around the location of the
process piping, equipment or vessel opening(s) is appropriately
barricaded, applicable signage is in place and any non-essential
personnel in thesurrounding area are at safe distance.
 WESTLAKE CHEMICAL CORPORATION
DOCUMENT #: 4301-06-315A
LAKE CHARLES
SAFETY & HEALTH
REVISION DATE: 1/4/2017
DOCUMENT NAME: SAFE PROCESS PIPING, EQUIPMENT &
PAGE: 9 of 14
VESSEL OPENING PROCEDURE

4.5.5 Shall ensure that all members of the work crew working inside the
barricaded area stay suited in the approved and required PPE until the
line opening(s) are completed and a Cleared Process Confirmation (CPC)
can be determined by the Equipment Owner/Operator or
Maintenance/Construction Supervisor.

WARNING:

 The following DO NOT CONSTITUTE a Cleared Process Confirmation for

4.5.6 Once all line openings have been completed the Equipment
process piping, equipment or vessels that last contained a hazardous chemical:
Owner/Operator or Maintenance/Construction Supervisor will verify the
applicable tests to deem a Cleared Process Confirmation. NOTE – the
1. Flushing
person and Purging
conducting theseprocess piping,
verifications equipment
must be donnedandinvessels
the approved and
2. Opening and rodding low point drains
required PPE while working inside the barricaded work area.
3. Opening high point vents
4.5.7
4. Some examples
Vacuuming of methods
process piping, that can be used
equipment to perform to determine if a
or vessels
process piping, equipment or vessel is in a state of “Cleared Process” are
 the following:
If there is discovery or suspicion of plugging, line opening activities should be
stopped and operations
4.5.7.1 Gases personnel consulted.
– utilize the Section
appropriate 5 of this
calibrated gasprocedure shall be
followed. instrumentation/meter and perform gas sampling at or in the
opening(s) themselves and surrounding areas.
4.5.7.2 Visual – A visual confirmation that process piping, equipment or
vessel is free of a hazardous material
4.5.7.3 Temperature – utilize the appropriate calibrated instrument to
monitor surface or internal temperatures
4.5.7.4 Chemical indicators – utilize color metric tubes / pumps or “color
changing” tape/paper to measure characteristics of the specific
hazardous material
4.5.8 Based on the results of the Visual and or applicable Quantitative
verifications validate a Cleared Process Confirmation.
4.5.9 The Cleared Process Confirmation shall be documented on the permit by
signature.
4.5.10 The Equipment Owner/Operator or Maintenance/Construction Supervisor
shall then assess what level of PPE is required to complete the remaining
job activities and provide instruction to the work crew.
Work Crew
4.5.11 Shall ensure prior to line opening work beginning that personal LOTO
requirements have been completed and verified.
4.5.12 Understand all items discussed during the Job Safety Briefing.
4.5.13 Ensure approved and required PPE is donned and worn in its entirety while
working within the barricaded work area until the Equipment
Owner/Operator or Maintenance/Construction Supervisor has verified a
Cleared Process Confirmation and approved a change in appropriate PPE
and documented this change on the Job Ready Tag.
 WESTLAKE CHEMICAL CORPORATION
DOCUMENT #: 4301-06-315A
LAKE CHARLES
SAFETY & HEALTH
REVISION DATE: 1/4/2017
DOCUMENT NAME: SAFE PROCESS PIPING, EQUIPMENT &
PAGE: 10 of 14
VESSEL OPENING PROCEDURE

4.5.14 Follow safe process piping, equipment and vessel opening methods as
detailed in Appendix 1 – Safe Line Opening Method Guidelines.
4.5.15 Immediately contact the Maintenance/Construction Supervisor if any
abnormal condition arises.
5.0 Abnormal Process Piping, Equipment or Vessel Opening
Conditions

5.1 This section addresses uncommon tasks associated with line openings that
may have to be completed on an irregular basis.
5.2 If there is discovery or suspicion of plugging the Maintenance/Construction
Supervisor should stop all line opening activities and consult operations
personnel.
5.3 If there is a section of process piping, equipment or vessel that can’t be
depressured the Maintenance/Construction Supervisor should consult
operations personnel.
5.4 A team of experienced site personnel will need to evaluate each potential
plug and or section of process piping, equipment or vessel that can’t be
depressured individually and shall provide approval prior to any plug
removal or pressure relieving activities. NOTE: A new permit may be
required for each plug removal or relieving of pressure from sections of
piping, equipment or vessels that can’t be depressured.
5.5 The pressure shall be removed releasing the potentially stored pressure in
the safest and most controlled fashion.
5.6 The suspected plugged line or section of process piping, equipment or
vessel should be isolated from “in-service” piping by valves or in-line blinds
as close as possible to the suspected plug or isolating the smallest section
of pressurized piping following the LOTO procedure.
5.7 This procedure shall be followed for all line openings.
5.8 The following methods should be considered as part of the team’s analysis
to remove the plug or relieve pressure.
5.8.1 Using bleeders to relieve pressure on both sides of the suspected
plug
5.8.2 Opening / Breaking flanges to relieve pressure on both sides of the
suspected plug
5.8.3 If no bleeders or flanges are present, drilling holes in pipe on both
sides of the plug to relieve pressure. Once pressure has been
relieved, cut the pipe using “cold cut methods” at the location of the
drilled pilot holes.
 WESTLAKE CHEMICAL CORPORATION
DOCUMENT #: 4301-06-315A
LAKE CHARLES
SAFETY & HEALTH
REVISION DATE: 1/4/2017
DOCUMENT NAME: SAFE PROCESS PIPING, EQUIPMENT &
PAGE: 11 of 14
VESSEL OPENING PROCEDURE

5.8.4 In all cases the methodology chosen as well as a detailed work plan
shall be approved by the site team prior to any plug removal or
pressure relieving efforts.

6.0 References
6.1 OSHA 29 CFR 119(f)(4) – Process Safety Management of Highly
Hazardous Chemicals.
6.2 OSHA 29 CFR 1910.147 – Control of Hazardous Energy
6.3 EHSS-06-REQ.001 Control of Hazardous Energy Program Requirements

6.4 EHSS-13-REF.001 Minimum PPE Requirements for Line Breaking and

Equipment Opening
7.0 Training
7.1 Employees shall be trained in the safe process piping, equipment and vessel
opening procedure.
7.2 Upon initial hire and to the level of detail specific for position and or
assignments,
7.3 Retraining shall be conducted when employees deviate from this procedure
or show inadequacy of knowledge of this procedure.
8.0 Program Effectiveness
8.1 Shall institute a process that ensures this procedure is being adhered to in
the field and is effective. This process shall be documented including field
effectiveness observations and line opening permit audits. Corrective
actions shall be documented in Enablon and tracked to completion.
9.1 Distribution
B-II Shift Supervisor’s Office
 WESTLAKE CHEMICAL CORPORATION
DOCUMENT #: 4301-06-315A
LAKE CHARLES
SAFETY & HEALTH
REVISION DATE: 1/4/2017
DOCUMENT NAME: SAFE PROCESS PIPING, EQUIPMENT &
PAGE: 12 of 14
VESSEL OPENING PROCEDURE

APPENDIX 1
Safe Line Opening/Break Method
Guidelines
Process piping, equipment and vessels last containing a hazardous material must be assumed to
be full and under pressure until the line openings are completed and a Cleared Process
Confirmation has been completed by the crew foreman or supervisor.
All work crew members working inside the barricaded work area shall be suited with the
approvedand required PPE specific to the hazardous material. Shielding will be utilized when
required.

WARNING:
 Bolts that have become corroded or seized which need to be
replaced shall be completed one at a time prior to Line Opening
activity.

 Line Opening Activities may begin once all the damaged bolts have
been replaced and are secure

 Additional Permitting may be required such as a hot work permit if

bolts need to be burned or cut off.

 Hot Bolting – Sites will follow their local procedures and best
engineering practices for all Hot Bolting activities.

A. Safe Line Opening / Break – 4 Bolt Flanges

1. Position your body on the opposite side out of the “line of fire” of where you plan
to loosen the first bolt as shown below in figure 1.
2. While in this position, loosen the first bolt (bolt position “1” in Figure 1) slowly “down
and away” making sure not to fully remove the nuts and or bolt.
3. Try to determine if the process piping, equipment or vessel is still under pressure by
LISTENING for the sound of escaping gas and WATCHING for liquid. Caution should
also be given for systems that might be under vacuum.
4. If no pressure is detected or leakage is observed, continue to loosen a second bolt
“away” from your body position, again making sure not to fully remove the nuts and
or bolt. Again, Listen and Watch for pressure and or leaking material.
5. The use of a spreader bar or other device may be utilized to spread the flanges to
break the seal if required. Bolts shall not be removed until the flange gasket seal
is broken.
6. If no leakage occurs, loosen remaining 2 bolts keeping nuts on all bolts until
insidecondition can be verified not to be under pressure, vacuum or is leaking.
 WESTLAKE CHEMICAL CORPORATION
DOCUMENT #: 4301-06-315A
LAKE CHARLES
SAFETY & HEALTH
REVISION DATE: 1/4/2017
DOCUMENT NAME: SAFE PROCESS PIPING, EQUIPMENT &
PAGE: 13 of 14
VESSEL OPENING PROCEDURE

7. Once a safe condition is observed all nuts can be removed.

8. NOTE – Always be prepared to retighten the nuts and secure the process system in
an emergency or in the case of an abnormal condition.
9. The same method should be followed on flanges which have additional bolt holes
– always loosen first “down and away”.

B. Safe Line Opening / Break – Threaded Connections

1. Position your body away from the “line of fire” and slightly loosen the fitting no more
than a few threads.
2. Try to determine if the process piping, equipment or vessel is still under pressure by
LISTENING for the sound of escaping gas and WATCHING for liquid around threaded
fitting. Caution should also be given for systems that might be under vacuum.
3. If no pressure is detected or leakage is observed, continue to loosen the threaded
fitting a few more threads making sure not to fully remove the fitting. Again, Listen and
Watch for pressure and or leaking material.
4. If no pressure is detected or leakage is observed, continue to loosen the threaded fitting
a few more threads making sure not to fully remove the fitting. Again, Listen and
Watch for pressure and or leaking material.
5. At this point gently jiggle the threaded connection. If no pressure or leakage is detected
move the threaded fitting.

Figure 1
 WESTLAKE CHEMICAL CORPORATION
DOCUMENT #: 4301-06-315A
LAKE CHARLES
SAFETY & HEALTH
REVISION DATE: 1/4/2017
DOCUMENT NAME: SAFE PROCESS PIPING, EQUIPMENT &
PAGE: 14 of 14
VESSEL OPENING PROCEDURE

APPENDIX 2
Chemical Minimum PPE Requirements for Line Breaking and Equipment Opening
WARNING – High temperature (>120 degrees F) and extremely low temperature
(<32 degrees F) materials pose additional hazards not addressed by this procedure
NOTE – Chemical Gloves, Chemical Suits, and Chemical Boots must be verified for compatibility with the
chemical(s) they could encounter.
Full-Face Supplied-Air Respirator, CPF 3 Chemical Suit, Chemical Gloves and
Chlorine Liquid Chemical Boots – Standby Operator with “ready to don” Full-Face Supplied-Air
Respirator. Verify line is clear before downgrading PPE.
Full-Face Supplied-Air Respirator, Medium Duty Chemical Suit, Chemical Gloves and
Chlorine Gas
Chemical Boots
Full-Face Supplied Air Respirator, CPF 3 Chemical Suit, Chemical Gloves and
Chlorinated Organics
Chemical Boots
Full-Face Air-Purifying Respirator, Medium Duty Chemical Suit with Hood, Chemical
Caustic
Gloves and Chemical Boots
Full-Face Air-Purifying Respirator, Medium Duty Chemical Suit with Hood, Chemical
Acid
Gloves and Chemical Boots
Full-Face Supplied-Air Respirator, CPF 3 Chemical Suit (Model 3T438), Chemical
Sulfur Chloride
Gloves and Chemical Boots – All skin must be covered.
Goggles and Face Shield, Cotton Coveralls under CPF 3 Chemical Suit,
Molten Sulfur
Thermal/Chemical Gloves
Steam or Condensate
Face Shield, Cotton Coveralls under Slicker Suit, Thermal/Chemical Gloves and
(unless cool to the Chemical Boots
touch)
Ethylene Full-Face Supplied-Air, Fire Retardant Clothing, Thermal or Work Gloves
Methane and Hydrogen Goggles and Face Shield, Fire Retardant Clothing
Nitrogen Full-Face Supplied-Air, Thermal or Work Gloves
Air Goggles
Chemical Slicker Suit with hood, Face Shield, Chemical Gloves and Chemical Boots.
Water below 120°
Note* Composition matters and may be downgraded
Other Materials Not
Refer to Corporate PPE Matrix and/or Safety Representative
Listed

This is the list of approved chemical protective clothing.

Medium Duty Suit with
Heavy Duty Suit with Hood Chemical Slicker w/Hood
Hood
Dupont Tychem CPF3* Dupont Tychem SL* Tingley Safetyflex (J41108 & 041008)
Dupont Tychem BR Kappler Zytron 200 River City Dominator (388JH & 388BF)