Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
1. Purpose
The purpose of this procedure is to establish guidelines for all contractors performing
hydroblasting, water cutting or any other work involving the use of high pressure water on the
BASF McIntosh, Alabama site. This procedure is designed to improve communications
between site operations and contractors providing the hydroblasting/cutting services as well
as other contracted or contractor employees who may be affected by the hydroblasting/
cutting operation.
2. Definitions
2.2. Automation
Automatically controlled operation of an apparatus, process or system by mechanical
or electronic devices that take the place of human labor. Examples are automated
feed, automated indexing, and automated manipulation or any of these combinations.
Non-automated examples include shot gunning and hand fed lance assemblies. Non-
automated activities require a formal review and approval.
2.11. Hydroblasting
The process of cleaning surfaces with high pressure water, at or above 5,000 psi or
greater than 5 gpm, with or without the addition of other liquids or solids.
2.13. Indexing
The act of positioning or adjusting the cleaning nozzle into the device or equipment
being cleaned.
2.14. Lancing
An application whereby a hose fitted with a nozzle is inserted into and retracted from
the interior of a tube of a pipe or tubular product.
2.15. Moling
An application whereby a hose fitted with a nozzle is inserted into and retracted from
the interior of a tube and has a self-propelling nozzle for cleaning the internal surfaces
of pipes or drains.
2.16. Nozzle
A device with one or more orifices through which the water discharges from the
system. The nozzle restricts the area of flow of the fluid, accelerating the water to the
required velocity and shaping it to the required flow pattern. Nozzles are also
commonly referred to as bits, tips or orifices.
2.21. Shotgunning
A hand held application whereby an assembly of a lance and a nozzle can be
manually manipulated in virtually all planes of operation.
2.22. Stinger
A short section of rigid tubing used on the nozzle end of the flex lance that prevents
the lance from reversing directions inside the piping or equipment.
2.23. Snorkel
A section of pipe or tubing extending from the anti-withdrawal device or feeding
mechanism within 1 or less of the tube sheet which contains the lance and tip and
guides it into the pipe or tube being cleaned.
3. Scope
This procedure applies to the BASF McIntosh site. This procedure applies to all personnel
involved in or affected by hydroblasting and high pressure water cutting on the McIntosh site.
BASF Corporation Title: McIntosh Hydroblasting and High Pressure Cutting Procedure
McIntosh Function: Safety
Procedure No.: MC032.128 Page: 4 of 17
4. Procedure
4.2.1. When all other measures have been exhausted and automation is not
feasible, a formal review shall be performed for hydroblasting shotgunning
and hand fed lancing in accordance with section 4.8. of this procedure.
NOTE: A pre-job BASF required checklist shall be completed prior to
the beginning of any job. This checklist must be completed jointly by
the hydroblasting supervisor and a BASF supervisor and signed off by
the hydroblasting crew supervisor and a BASF supervisor. See
Attachment 1 for this checklist.
4.2.2. During and at the completion of the job, the hydroblasting crew is responsible
for controlling debris/waste and maintaining good housekeeping practices on
the job site. This includes, but is not limited to, the elimination of slip, trip and
fall hazards including proper hose placement and proper disposal of trash,
contaminated PPE and chemical/product wastes generated from the cleaning
service.
4.2.3. The hydroblasting company shall comply with all BASF and state and federal
environmental policies, laws and procedures.
4.2.4. Barricading of the pump(s) and the job site hazards is required on every job
and should be placed accordingly to restrict unauthorized personnel from
entering the work area. Barricading should also include the end point of the
operation. The hydroblasting company shall provide barricade tape that
reads Danger Hydroblasting or identifies in some clear and concise
manner that the area is a hydroblasting area. The area can be barricaded
with red chain(dependent upon high pressure hydroblasting water cutting or
pressure washing-RED) or yellow chain (pressure washing as defined in this
procedure at 2.17-YELLOW). A tag on the barricade should identify the
hydroblasting supervisor or person of authority (this can be a trained
attendant) for the cleaning job. Permission to enter the barricaded work area
should be granted only from the approval of the hydroblasting supervisor,
person of authority or trained attendant(s). The barricaded area shall
BASF Corporation Title: McIntosh Hydroblasting and High Pressure Cutting Procedure
McIntosh Function: Safety
Procedure No.: MC032.128 Page: 5 of 17
encompass all of the hoses in use at the hydroblasting work area. When
working above ground level, barricades will be required below.
4.2.5. At least one wheel on any staged mobile equipment must be double chocked
against accidental movement when parked on location.
4.2.6. Whip locks shall be used on all pressured hose connections to prevent the
hose from whipping in the event the coupling breaks or becomes
disconnected.
4.2.7. A trained attendant is required to be present for all operating equipment at all
times. The attendant must be close enough to shut down the equipment in an
emergency.
4.2.8. All jobs require a line-of-sight between the equipment attendant and the hose
end equipment operator. If direct line-of-sight cannot be achieved, radio
communication or use of an additional trained attendant for line-of-sight must
be used to assist in quickly de-energizing the equipment.
4.2.9. All hoses should be routed and protected in a manner that prevents vehicular
damage and personnel exposure to the hoses. When possible, roadways
should be barricaded for vehicular and pedestrian traffic where hoses cross
roadways. See 4.2.4. above.
4.2.10. All personnel, when the system is under pressure, shall not be within 6 of
pressurized connections unless the equipment is shielded or guarded in
some manner (including weep holes).
4.2.11. To help prevent injuries from a lance or line mole hose reversing under
hydraulic pressure, it is required to clean the tube sheet and the first 6
(inches) of the tubes or the first 24 of the piping with a shotgun connected to
an indexer or similar automated device, so that proper engagement with the
lance or line mole can be achieved before high pressure is applied.
4.2.12. All equipment being cleaned shall be adequately shielded against flying
debris/chemicals and high pressure water stream that could pose a potential
injury or exposure to someone. Examples include but are not limited to
plywood, metal sheeting or water blast curtains
4.2.14. An anti-withdrawal device must be used on all flex lances, rigid lances and
line moling jobs. The anti-withdrawal device must be securely attached to the
equipment being cleaned.
BASF Corporation Title: McIntosh Hydroblasting and High Pressure Cutting Procedure
McIntosh Function: Safety
Procedure No.: MC032.128 Page: 6 of 17
4.2.15. When flex lancing or line moling, the lance/hose must have a hard stop for
the maximum length of travel.
4.2.16. All non-rotating equipment high pressure hose assemblies must include whip
checks to protect personnel from excessive movement of hoses in case of a
hose rupture or a blown end fitting.
4.2.17. Hose shrouds shall be designed so that they can withstand the full rated
service pressure of the system for maximum personnel protection and are not
intended to only perform water management duties in the event of a hose
rupture.
4.2.18. The Back Thrust Force for a hydroblasting operator shall not be greater than
1/3 of his/her body weight. Rotating operators in and out of the job is also
recommended because of the physical demand of the job duration.
4.2.19. Only the nozzle operator shall manually control the dump system. When a
foot valve is used, it must be placed within a frame that will guard the valve
from being accidentally operated and that is sturdy enough, so that it will not
accidentally moved or knocked over when it is used. Where the water dumps
through a dump system and is not immediately released to the open air, but
passed into a dump line, the dump line must be secured, so that it does not
whip when activated. Also ensure that the dump system is clear of
obstructions.
4.2.20. Indexing is not allowed while the lance is energized unless the indexing is
automated and controlled from a remote location.
4.3.1. All high pressure pumps provided by the hydroblasting company must be
equipped with a relief system that allows for the relief of the pressurized
system. This pressure must be set at 1.2 times the pressure of the lowest
rated component of the system operating at the time.
4.3.2. All rigid or stiff lance assemblies shall include use of a minimum 3 (feet)
shroud to protect the employee(s) handling the end of the rigid or stiff lance.
The construction of the shroud, for example such as a double
S.S. braided shroud, shall be sufficient enough to help ensure the safety of
the employee against serious injury from a potential hose rupture. A visual
inspection shall be made of the shroud prior to each use. The hose shroud
shall be inspected for inner and outer integrity, such as excessive wear and
breakdown of reinforcement wire braiding, at a minimum on a quarterly basis.
These quarterly inspections must be documented and records made available
BASF Corporation Title: McIntosh Hydroblasting and High Pressure Cutting Procedure
McIntosh Function: Safety
Procedure No.: MC032.128 Page: 7 of 17
to the BASF McIntosh site upon request. Prior use inspections shall be
documented on a pre-work checklist before each job.
4.3.3. Anti-withdrawal devices used on tube sheets during rigid or flex lancing, must
include the use of a snorkel device that does not exceed 1 clearance from
the tube sheet. In vertical tube sheet applications, to prevent the potential of
a water cut to the foot, that gap between the snorkel and the tube sheet, must
be protected by a physical barrier to prevent contact with the lance operator.
Among these potential devices is a 4 X 4 X 12 piece of angle iron or a 2 X
4 X 12 board.
NOTE: This shielding is not required if indexing is automated.
4.3.4. In addition to use of anti-withdrawal devices when line moling, a stinger must
be attached to the end of the nozzle which is at least 1.5 times longer than
the I.D. of the piping being cleaned. The rigidity of the compression fitting
and nozzle length can be included in the overall stinger length requirement.
NOTE: Special consideration shall be given to tees in the line being
cleaned when the tee in the line is larger than the main line being
cleaned. Additional length of stingers maybe required to prevent
accidental reversal of the line mole assembly in the piping.
4.3.6 All high pressure hoses and flex lances used for line moling must be marked
at a minimum 24 from the end compression fitting. This visual marking will
minimize the potential for a serious water cut when the line mole on the hose
end is exiting toward the end of the pipe.
NOTE: This is not applicable with automated processes.
4.3.7. All shotgun whip hoses must be shrouded to protect the shotgunner against
accidental rupture of the whip hose. Shotgun shrouds must be constructed,
for example such as of double S.S. braided material, in a manner that
protects the shotgunner against a serious water cut. The protective shroud
must be a minimum of 6 in length. The whip hose shroud shall be visually
inspected prior to each use. The hose shroud shall be inspected for inner
and outer integrity, such as excessive wear and breakdown of reinforcement
wire braiding, at a minimum on a quarterly basis. These quarterly inspections
must be documented via a company specific checklist or other record and
records made available to the BASF McIntosh site upon request. Prior use
inspections shall be documented on a pre-work checklist before each job.
Hoses must have tags/bands, etc. to reflect the current testing period.
BASF Corporation Title: McIntosh Hydroblasting and High Pressure Cutting Procedure
McIntosh Function: Safety
Procedure No.: MC032.128 Page: 8 of 17
4.3.8. The length of the shotgun shall be a minimum of 66 in overall length from the
shoulder brace (butt stock) of the gun to the end of the nozzle when used in a
manual (non-automated) application.
4.3.9. High pressure hose and fittings, connection fittings and couplings shall be
manufactured to be compatible with the hose. All components of the system
should be compatible with the service pressure of the pump and only fittings
marked with the maximum allowable working pressure (MAWP) shall be
used. Fittings designed for pressure less than the service pressure of the
pump shall never be used in a higher pressure application. NPT or pipe
thread connections shall not be used at pressures greater than 15,000 psig.
4.3.11. When roto jet nozzles are in operation inside a vessel, the entry point where
the hose enters the vessel must be securely covered to prevent the jet from
exiting the vessel. Suspending the roto jet nozzles with a rope is not
acceptable.
The BASF McIntosh site is committed to improving the safety of all high pressure
water cutting operations performed on the site. As much as conceivably possible,
manual high pressure water cutting activities shall be replaced by automated cutting
equipment. Due to the corporate requirement for automation, any manual high
pressure cutting work must go through a formal review and approval each and every
time a non-automated cutting operation occurs. Formal review and approval shall be
documented via the Change Management database.
NOTE: All high pressure cutting shall be performed under a safe work permit.
4.4.1. During and at the completion of the job, the hydroblasting crew is responsible
for controlling debris/waste and maintaining good housekeeping practices on
the job site. This includes, but is not limited to, the elimination of slip, trip and
fall hazards including proper hose placement and proper disposal of trash,
contaminated PPE and chemical/product wastes generated from the cleaning
service.
4.4.2. The hydroblasting company shall comply with all environmental policies and
procedures.
4.4.3. Barricading of the pump(s) and the job site hazards is required on every job
and should be placed accordingly to restrict unauthorized personnel from
entering the work area. Barricading should also include the end point of the
BASF Corporation Title: McIntosh Hydroblasting and High Pressure Cutting Procedure
McIntosh Function: Safety
Procedure No.: MC032.128 Page: 9 of 17
4.4.4. Job plans must be established and approved by the responsible BASF
supervision for all high pressure cutting work before work execution. At a
minimum this shall include basic job steps, parameters and safeguards
4.4.5. All high pressure water cutting will be through the use of an automated track
system.
4.4.7. All hoses shall be inspected prior to use and pressure tested on a quarterly
basis (minimum). Records of inspections/testing shall be maintained by the
hydroblasting company, contract/contractor companies using hydroblasting
equipment and BASF personnel using hydroblasting equipment.
Inspection/testing shall be documented and available for BASF review when
requested. Tags, bands, etc. shall be used to indicate hose inspection/testing
dates.
4.4.8. Track cutting systems will be firmly attached to include a secondary method
of attachment.
4.4.10. Prior to starting the cut, ensure that the portion of the structure to be cut is
properly supported so that it will remain suspended when the cut is finished.
If the portion of the structure to be cut is not rigged, determine with the
customer contact how much of the structure to leave uncut until the support is
in place.
4.4.11. The largest orifice to be used for hydro cutting is .022 inches.
The BASF McIntosh site is committed to improving the safety of all pressure washing
operations performed on the site. While pressure washing activities are generally
BASF Corporation Title: McIntosh Hydroblasting and High Pressure Cutting Procedure
McIntosh Function: Safety
Procedure No.: MC032.128 Page: 10 of 17
performed at a much lower pressure than hydroblasting or high pressure water cutting
activities, there are still inherent dangers associated with this work that shall be
addressed by personnel responsible for authorizing the work and personnel
performing the work. All personnel performing pressure washing work shall be
properly trained on the equipment which shall be operated by the personnel. These
personnel include BASF personnel, hydroblasting company personnel and any other
contractor, contract or sub-contractor personnel performing this type of pressure
washing work at the McIntosh site. While pressure washing is typically performed at
lower service pressures, the below special precautions must be followed.
NOTE: All pressure washing shall be performed under a safe work permit.
4.5.1. During and at the completion of the job, the pressure washing crew is
responsible for controlling debris/waste and maintaining good housekeeping
practices on the job site. This includes, but is not limited to, the elimination of
slip, trip and fall hazards including proper hose placement and proper
disposal of trash, contaminated PPE and chemical/product wastes generated
from the cleaning service.
4.5.2. The pressure washing crew shall comply with all environmental policies and
procedures.
4.5.3. Pressure washing does not include line moling or lancing type activities.
4.5.4. Pressure washing units shall be inspected prior to use and operated per the
manufacturers recommendations. Periodical system inspections shall follow
the manufacturers recommendations or site/company procedures.
Alterations or modifications are not permitted. The maximum operating
pressure of the pressure washer shall be posted/available on the machine.
4.5.5. PPE shall address the hazards associated with pressure washing, which
could include but is not limited to water cuts, chemical contact, noise,
respiratory consideration for Legionnaires disease and chemicals, and any
other recognized hazards for the task.
4.5.6. Job plans must be established for all pressure washing activities before work
execution. At a minimum, this should include basic job steps, parameters,
and safeguards. If a Job Hazard Analysis (JHA) is performed on a
specific pressure washing job, then this JHA must be reviewed each
time the job is performed. A copy of the JHA must be on the job site
attached to the SWP issued for that job. Not all pressure washing jobs
can be covered by a single JHA; therefore, each different job must have
a JHA, if this is the method to be used for review of the job prior to
starting work.
4.5.7. Barricading of the pump(s) and the job site hazards is required on every job
and should be placed accordingly to restrict unauthorized personnel from
entering the work area. Barricading should also include the end point of the
BASF Corporation Title: McIntosh Hydroblasting and High Pressure Cutting Procedure
McIntosh Function: Safety
Procedure No.: MC032.128 Page: 11 of 17
4.5.10. All component parts and fittings shall be checked for correct size and rating
for the unit.
4.5.11. Pressure hoses shall not be bent or pinch as this may cause internal damage
that is not easily identified during pre-job inspections. Do not use tools such
as pliers, wrenches, vise grips, etc. directly on the hose portion, as these
tools may cause internal damage.
4.5.12 All hose assemblies shall be inspected for the following criteria:
4.5.12.1. Assemblies shall be free from external damage such as broken
wires or excessive braids showing.
4.5.12.2. All end fittings and couplings are in good order and satisfy pressure
rating for the unit operating pressure.
4.5.12.3. Only threaded hose connections are to be used at the pump
connection.
4.5.13. All hoses shall be tested on a quarterly basis. This testing shall be
documented and records made available to BASF when requested. Tags,
bands, etc. shall be used to indicate hose inspection/testing dates.
4.5.14. Any electrical equipment in the immediate area of the pressure washing
activity that presents a hazard to the operator or could damage equipment will
be de-energized, shielded, or otherwise made safe.
4.5.17. Pressure washing wand triggers assembly shall not be locked in position and
if equipped with a locking mechanism, such a locking mechanism shall be
removed or disabled.
4.5.18. The system shall be completely flushed with sufficient water to remove any
contaminants before installing the nozzle.
BASF Corporation Title: McIntosh Hydroblasting and High Pressure Cutting Procedure
McIntosh Function: Safety
Procedure No.: MC032.128 Page: 12 of 17
4.5.19. Equipment shall not be left unattended when in operation nor under pressure.
4.6.2. Once equipment is staged, all hose assemblies shall be inspected for leaks
and/or damage.
4.6.3. All high pressure hoses with outer rubber or plastic covering construction and
assemblies, including shotgun whip hoses/assemblies, must be quarterly
tested to the working pressure (WP) of those hoses at a minimum. Hoses
must have tags/bands, etc. to reflect the current testing period.
4.6.5. All pressure relief systems on pumps shall be inspected and tested, at a
minimum, on a quarterly basis. This includes a visual inspection to verify the
overall physical condition of the pressure relief systems. Visual evidence of
the inspection frequency is required. Documentation of the inspections shall
be maintained and shall be available to BASF McIntosh upon request.
4.7.1. All hydroblasting companies shall have a training program. This training
program shall include but is not limited to energy isolation of equipment,
confined space entry, correct body positioning for tasks, using shotguns, flex
lancing, rigid lancing, line moling, fall protection and installation of anti-
withdrawal safety devices at a minimum. All hydroblasting personnel working
at the BASF McIntosh site shall be familiar with and understand the Big 5
Permit requirements. Documentation of this training shall be maintained by
the hydroblasting company and shall be available to BASF McIntosh upon
request.
BASF Corporation Title: McIntosh Hydroblasting and High Pressure Cutting Procedure
McIntosh Function: Safety
Procedure No.: MC032.128 Page: 13 of 17
4.7.2. All hydroblasting companies shall have a written energy isolation procedure
which addresses effectively isolating and de-energizing water cleaning and
cutting equipment when it is serviced, repaired, installed, relocated, manual
indexing (exposed to the nozzle end), etc. Documentation of this training
shall be maintained by the hydroblasting company. Documentation of this
training shall be available to BASF McIntosh upon request.
4.7.4. All hydroblasting companies shall have a heat stress and work/rest policy for
employees. All employees shall be trained on the policy. All training shall be
documented and available to BASF McIntosh upon request.
4.7.5. Job plans must be established for all hydroblasting activities prior to work
beginning. This should include, at a minimum, basic job steps, parameters
and safeguards.
4.7.7. Personal protective equipment (PPE) must be worn on the job per the
hydroblasting company and BASF site/unit requirements. PPE requirements
can be downgraded when using automated equipment and the downgrade
meets BASFs approval.
4.8.1. The Management of Change (MOC) database shall be used to document the
approval of any non-automated work to be performed at BASF McIntosh.
4.8.2. An assessment of the particular job where non-automated work shall take
place must be completed. The assessment shall identify any and all
additional safeguards required to safely perform the non-automated work.
The following information must be entered into the MOC database:
4.8.2.3. What actions will be taken to manage the risk and protect workers
during hydroblasting activities (MOC form, Tab 3 Risk, Mode of
Failure).
4.8.2.4. What steps or actions will be put in place to prevent future non-
automated hydroblasting (MOC form, Tab 4 After startup enter an
ad-hoc action item).
5. Responsibilities
The BASF McIntosh site manager has the primary responsibility for the
implementation of this procedure.
6. References
7. Related Documents
8. Revisions
For additional photos of equipment please see the corporate procedure BC032.032.
BASF Corporation Title: McIntosh Hydroblasting and High Pressure Cutting Procedure
McIntosh Function: Safety
Procedure No.: MC032.128 Page: 16 of 17