Line breaking, also known as line breaking and blanking, is a procedure used to
safely open or break a process line (such as a pipe or conduit) for maintenance,
cleaning, or inspection purposes. This is a high-risk activity that involves the
potential release of hazardous substances, so it requires strict safety protocols.
Here's a step-by-step procedure for line breaking, considering best practices and
safety guidelines:
### Step-by-Step Line Breaking Procedure
1. *Preparation and Planning*
- *Identify the Line*: Determine the exact location and contents of the line to be
broken.
- *Hazard Assessment*: Conduct a thorough hazard assessment to identify
potential risks, such as chemical exposure, pressure release, or flammable
substances.
- *Permit*: Obtain the necessary work permits, including a hot work permit if
welding or cutting is involved.
2. *Communication*
- *Notify Affected Personnel*: Inform all affected employees and adjacent work
areas about the planned line breaking operation.
- *Signage*: Place warning signs and barriers around the work area to prevent
unauthorized access.
3. *Isolation*
- *Shut Down*: Shut down the system and isolate the line to be broken. Ensure all
energy sources, including electrical, mechanical, hydraulic, and pneumatic, are
properly isolated.
- *Lockout/Tagout (LOTO)*: Apply LOTO devices to ensure the line remains isolated
during the procedure. Follow all LOTO procedures as per OSHA standards (29 CFR
1910.147).
4. *Depressurization and Draining*
- *Depressurize*: Carefully depressurize the line to release any residual pressure.
This may involve opening vents or drains.
- *Drain*: Drain any residual fluids or gases from the line. Use appropriate
containment methods to prevent spills or releases.
5. *Verification*
- *Test for Zero Energy State*: Verify that the line is fully depressurized and
drained. Use gauges or other instruments to confirm there is no residual pressure.
- *Purge/Clean*: Purge the line with an inert gas (e.g., nitrogen) or water to
remove any hazardous residues, if necessary.
6. *Personal Protective Equipment (PPE)*
- *Select Appropriate PPE*: Ensure all personnel involved wear suitable PPE, such
as chemical-resistant gloves, safety goggles, face shields, flame-resistant clothing,
and respiratory protection, based on the hazard assessment.
7. *Line Breaking*
- *Prepare Tools and Equipment*: Gather all necessary tools and equipment for the
line breaking operation. Ensure they are in good working condition.
- *Position Personnel*: Position personnel safely, considering wind direction and
potential splash zones.
- *Begin Line Breaking*: Slowly and carefully open the line. Start with the
loosening of bolts or clamps at the connection points, allowing any residual material
to vent slowly.
8. *Containment and Control*
- *Contain Spills*: Use spill containment measures such as absorbent pads, trays,
or temporary berms to manage any released material.
- *Monitor for Leaks*: Continuously monitor the area for any leaks or spills and
address them immediately.
9. *Completion*
- *Cap and Secure*: Once the line is broken, cap or blank the open ends to
prevent contamination or unintentional release.
- *Clean Up*: Clean the work area and dispose of any hazardous waste according
to regulatory guidelines.
- *Remove LOTO*: After confirming the work is complete and the area is safe,
remove LOTO devices following proper procedures.
10. *Documentation and Review*
- *Record Keeping*: Document the line breaking procedure, including hazard
assessments, permits, and any incidents that occurred.
- *Post-Job Review*: Conduct a review meeting with involved personnel to discuss
what went well, any issues encountered, and improvements for future operations.
### Additional Considerations
- *Emergency Preparedness*: Have an emergency response plan in place in case of
an accidental release or exposure.
- *Training*: Ensure all personnel involved are trained and competent in line
breaking procedures and emergency response.
- *Supervision*: Have a competent supervisor oversee the line breaking operation to
ensure compliance with safety protocols.
Following these steps helps ensure the safety of personnel and the environment
during line breaking operations.
