Vessel Cleaning Procedure

VESSEL CLEANING PROCEDURE
Project No.:
Revision :A
Description:Issue for review
Rev. Date :16 September 2011
1.0
Page : 1 of 9
PURPOSE
Vessel cleaning involves entry into confined that can introduce suffocation, physical entrapment,
and chemical exposure hazards into the workplace. This procedure is designed to help
supervisors manage the risks associated with confined space entry by establishing minimum
requirements for confined space operations.
Supervisors may, at their discretion, establish more restrictive requirements based on their
knowledge and assessment of the hazards associated with work conducted in confined spaces.
Any variance from this procedure shall be specified on the confined space entry permit and
authorized by the Area Superintendent or equivalent level of management responsible for the
facility.
2.0
DEFINITIONS
2.1
Approved Confined Space Entry Permit

Is a permit signed by the Area Superintendent (or equivalent level of management
responsible for the facility), or designee. Approved permits are signed on the Work &
Methods Approved line. In lieu of signing a permit, the Area Superintendent can give
verbal authorization by issuing a unique permit control number. This number shall be
entered by Person-in-Charge (PIC) requesting the work on the permit on the line
labeled Work & Methods Approved. The person giving the verbal authorization shall
maintain a log of the authorizations given. Copies of verbal authorization logs with
copies of the entry permits verbally authorized shall be kept for one year after the date
of work.
2.2
Confined Spaces
Include all areas or pieces of equipment where:
2.2.1
The space is large enough and designed to allow an employee to enter and
perform work; and
2.2.2
One or more of the following also apply:

(a)
(b)
(c)
(d)
EJ Joint Venture Sdn Bhd
The interior atmosphere is hazardous (or has the potential to become

hazardous) or the interior contains electrical or mechanical hazards
capable of causing serious injury; or
Entry or egress is difficult, impaired or restricted.
Any airborne contaminant present at a level capable of causing
immediate and often serious health consequences.
Any other condition recognized as immediately dangerous to life or
health.

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Revision :A
Page : 2 of 9
In addition to atmospheric hazards, confined spaces often contain physical or

mechanical hazards, such as unguarded machinery, exposed electrical circuits, or
materials which can engulf an entrant. The risk posed by a mechanical or physical
hazard is amplified inside a confined space since an injured person may not be able to
self-rescue.
Examples of confined spaces are: pipelines, tunnels, tanks, vessels, and floating roof
tanks (when the roof is 5 feet or more below the top of the shell), heaters,
compartments, ducts, sewers, pits, cellars, or any similar-type locations.
2.3
Confined Space Entry Plan

Is a written pre-work plan that complies with this procedure and specifies:
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
2.3.6
2.3.7
2.3.8
2.3.9
2.4
The scope of work to be performed prior to, during, and after the confined
space entry (e.g., opening, testing, ventilating, cleaning operations; inspection
of the space prior to closing it).
The PIC of the confined space entry, and the responsibilities of all
departments/groups involved in the entry.
The frequency and type of atmospheric testing required, and the area to be
tested.
The personal protective equipment required during the confined space entry.
Safety watch procedures and personnel.
The names of personnel qualified to use self contained breathing apparatus
(SCBA) to perform confined space operations.
Personnel that the safety watch should contact in an emergency, the means of
raising an alarm, and the need for a rescue method (i.e. harness with lifeline),
based on the size and configuration of the confined space, to be used in the
event a worker becomes disabled while inside and must be removed.
Lock-Out/Tag-out requirements and procedures for process, and
mechanical/electrical energy isolation (Lockout and Tagout Procedures).
Hot Work permitting requirements, if hot work is planned, or if pyrophoric (e.g.,
iron sulfide) material could exist inside the confined space.
Hazardous Atmosphere
Is an atmosphere capable of causing injury, illness, or disablement due to the presence
of flammable, toxic or otherwise injurious substances, or due to oxygen deficiency or
enrichment. Refer to Table 1 in Section 8 for protective equipment requirements and
access restrictions pertaining to the most common hazardous atmospheres.
2.5
Person-in-Charge (PIC)
A confined space entry is designated by the appropriate Superintendent to be
responsible for the safe completion of the work.

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Production Supervisor or Foreman, Facilities Engineering Project Engineer or Inspector,

or Camp Services Supervisor or Foreman.
2.6
Superintendent
Is the Production Operations Area Superintendent (or equivalent level of management
responsible for the facility).
3.0
RESPONSIBILITIES
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
The PIC of the confined space entry operation shall develop a confined space entry
plan. The operations Staff can assist with development of confined space entry plans
upon request. The PIC shall sign the plan and review it with the Superintendent for
approval.
The PIC shall ensure that written copies of the approved confined space entry plan are
given to affected employees, contractors, and the facility owner. The PIC shall review
the confined space entry plan and permit requirements at a safety meeting with
personnel involved in the confined space entry before starting the work.
The Superintendent, or designee, shall be responsible for approving entry permits.
The PIC will ensure that all necessary permits, Do Not Enter, and Do Not Operate
tags are posted at confined space job sites for the permitted interval of work, and that
expired permits are removed.
The PIC shall ensure that safety watch personnel are adequately trained in the
following:
3.5.1 Safe entry and rescue methods
3.5.2 Gas detector operation, and
3.5.3 SCBA (or airline respirator) use.
For guidance on safety watch training requirements, and training documentation and
verification.
The PIC shall ensure that personnel using respiratory protection (e.g., safety watch and
those entering the confined space) have a clean face-mask seal without obstruction by
facial hair, glasses, or any other obstacle that may prevent a good seal. Also, before
starting work, safety watch and personnel entering the confined space shall ensure that
access manways are large enough for entry while wearing required personal protective
equipment.
The PIC shall ensure that necessary personal protective and gas testing equipment (as
defined in the confined space entry plan) is available at the job site before starting
confined space entry operations.
The PIC is responsible for enforcing the requirements of the approved permit, the
requirements of the confined space entry plan, and must personally supervise the initial
entry. The PIC may delegate site supervision to the contractor supervisor after checking
the job site at the beginning of each working day, or at shift change, but must remain
within radio/phone contact at all times.
Operations will provide a safety watch when mutually agreed between parties.

Project No.:
Revision :A
3.10
3.11
3.12
4.0
Page : 4 of 9
Operations will provide and calibrate MSA-361, Watchman Multigas and Orion Multigas
detectors upon request.
The safety watch will remain on site during the entire confined space entry operation,
and will continuously observe the work (except when gas testing) and be ready to call
for help and intervene if necessary.
The need for additional safety watches will be determined by the PIC and documented
in the confined space entry plan. The PIC is responsible for providing additional safety
watches.
PRECAUTIONS
Risk assessment must issued before any person enters a confined space, tank or vessel, a
confined space entry permit shall be available and the following checks shall be done.
5.0
The atmosphere in the confined space, tank or vessel shall be checked with portable
detection equipment to know the level of oxygen and presence of any toxic, flammable and
explosive gases. No entry is permitted until the levels are safe.
These checks shall be done by competent persons authorized by the Company.
Adequate ventilation with fresh air shall be available throughout the job. A competent
person shall conduct frequent tests if flammable materials are being used.
A person shall be positioned at the entrance of the confined space whose sole responsibility
shall be to communicate and get the message to the persons inside.
The person shall raise an alarm in the event of any emergency.
Personnel entering the confined space shall wear appropriate PPE including safety belt or
harness with lifeline attached and suitable respiratory apparatus
Barricade system should be implemented
Blower / extra fan to be use when confine space entry will be conducted.
Drill shall be conducted before execution the job.
CONFINED SPACE ISOLATION AND VESSEL CLEANING PROCEDURE

5.1
5.2
5.3
5.4
The confined space shall be emptied, flushed or purged of flammable or toxic liquids or
gases and should be opened (all man way covers removed) to ventilate toxic and
flammable gases prior to entry.
When a space has been opened, but not approved for entry, a "DANGER DO NOT
ENTER" tag must be hung at each opening. If any openings are left uncovered and
unattended, the openings must be barricaded (e.g., with tape or wire) to prevent
unauthorized entry.
All pipelines to and from the confined space shall be isolated and blinded. Threaded
lines shall be disconnected and plugged as close to the confined space as possible.
Blinds shall be installed at the closest flange to the confined space.
If blinds cannot be installed to isolate the confined space, a "double block and bleed"
arrangement is acceptable with approval by the Area Superintendent or equivalent level

Project No.:
Revision :A
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
5.15
5.16
5.17
6.0
Page : 5 of 9
of management that is responsible for the facility. Block valves shall be locked and
tagged out. Gas tests shall be performed in the confined space at the line inlet. The
spool between the block valves shall be vented to the atmosphere and the vent carefully
checked to ensure it is not plugged.
Equipment in the confined space shall be electrically and mechanically isolated and
locked & tagged out.
Steam or hot oil coils inside the space shall be disconnected or locked and tagged out
at the point where they enter the confined space. Electrostatic grids shall be locked and
tagged out in the facility MCC room. A "DANGER DO NOT OPERATE" tag is required in
both cases.
All automated fire extinguishing systems in the confined space, such as CO2 systems,
shall be disarmed, locked, and tagged out. A DANGER DO NOT OPERATE tag is
required.
If several pieces of interconnected equipment must be isolated as a unit for a confined
space entry, each piece of the interconnected equipment must be depressurized,
opened to the atmosphere, and made safe for entry.
"DANGER DO NOT ENTER" tags shall be affixed at each opening whether or not it is
barricaded by tape or wire:
5.9.1 when it is not safe to enter the confined space,
5.9.2 prior to issuance of an entry permit,
5.9.3 at the end of a shift when the space is left open, or,
5.9.4 when an unsafe condition arises and entry permits are removed.
Radioactive sources, if present, shall have shutters closed and locked except during
use by trained radiography personnel.
Open-up the manholes and discard the spools as shown in the vessel isolation plan.
Spray degreaser into the vessels, set-up ventilation equipment (i.e. Air blower & Fume
extractor) and defuse remaining gas in the vessel.
Gastest and if result is acceptable, secure vessel entry permit and commence internal
cleaning using the High Pressure Water Jet equipment.
Note : Ensure at least two (2) watchman at the manhole with spare breathing
apparatus, whilst Cleaning is in progress inside the vessel.
Cleaning shall continue until the vessel is satisfactory clean.
Call for internal inspection (to be done by others)
Reinstate the vessel as and when the inspection is completed.
Conduct reinstatement test.
REQUIRED PERMITS
6.1
6.2
6.3
An entry permit is required for entry into all confined spaces. The PIC will indicate on
the entry permit the required types and frequency of gas testing to be performed.
No confined space shall be entered without an approved and posted entry permit.
An approved hot work permit is required for hot work, i.e., welding, cutting, chipping,
grinding, use of fans & lights, or any other work which could generate a source of
ignition.

Project No.:
Revision :A
7.0
CONFINED SPACE TESTING REQUIREMENTS

7.1
7.2
7.3
7.4
7.5
7.6
8.0
Page : 6 of 9
The safety watch (or other trained person under the direction of the safety watch) shall
test the atmosphere inside the confined space using Multigas and Orion Multigas
detectors. Test for the presence of combustible gas and for oxygen deficiency no less
than every 15 to 30 minutes, or as prescribed on the permit, for the duration of the
confined space operation (see Table 1). Gas tests shall start at the beginning of each
day (or shift change), or prior to re-entering the space if it has been vacated 30 minutes
or longer. Test results shall be recorded periodically (as directed by the PIC) in the
appropriate space on the entry permit and initialized.
The space should also be tested for hydrogen sulfide (see Table 1), and temperature, if
required on the entry permit. If ambient temperatures inside the confined space are
100oF (38oC) or higher, personnel are limited to 30 minutes inside, followed by a 15
minute rest break outside. The space shall also be ventilated with a jet eductor or fan.
The space should be tested for any other chemical or physical hazards identified on the
permit. Monitoring for other chemical substances (e.g., benzene) is done using detector
tubes or Drger CMS Analyzer by using Chips. Monitoring for naturally occurring
radioactive materials (NORM) should be considered for production / test separators and
other production equipment where produced sediments are concentrated.
Initial gas tests should be taken just inside the opening into the confined space using an
extendible wand. Tests must be taken at low spots in the space or in areas around
irregular surfaces and mixers, at line inlets and areas away from openings where
ventilation is restricted to assure that the most severe conditions are measured.
The safety watch must remain outside the confined space unless entry is required for
gas testing. If the safety watch must enter a confined space for gas testing, he must
designate an assistant to stay outside. Until the atmosphere inside the confined space
proves to be safe, the gas tester shall wear a disposable tyvek, airline respirator or
SCBA. A "DANGER DO NOT ENTER" tag shall be posted at the entrance of the
confined space until tests verify the atmosphere is safe and the entry permit is
approved. Entry into the space shall be controlled according to the test results shown in
Table 1.
Atmospheric tests shall be performed in the following order: oxygen deficiency,
flammability, and (if necessary) toxicity. It is also important to ensure that sampling is
representative of the total atmosphere in the space (e.g., sample at multiple depths in a
deep space). If air testing indicates a hazardous situation, contact the area operations
representative before proceeding.
Materials
8.1
8.2
8.3
8.4
Nitrogen for purging & reinstatement testing.

New studbolts and gasket required for the affected joints identified in the Vessel
Isolation Plan.
Fresh Water
Degreaser

Project No.:
Revision :A
9.0
Page : 7 of 9
Equipment to be used :
9.1
9.2
9.3
9.4
9.5
9.6
High pressure water jet complete with hoses and nozzles.

Breathing apparatus complete with oxygen bottle and one (1)
Set spare bottles.
Air Blower 6 dia. Discharge out flow.
Fume extractor 6 dia to 8 dia.
Hand Held lighting, explosion proof, AC.
Torch light (Exd type)
1 unit
2 set
1 unit
1 unit
2 EA
1 EA

Project No.:
Revision :A
Page : 8 of 9
ATTACHMENT
Table 1: Level of Entry Specifications for Selected Air Contaminants

Level of Entry
Contaminant
Oxygen
Respiratory Protection Required

Mechanical filter
SCBA or Airline
not allowed
16.5 to 19.5%
LEL *1
H2S
Benzene
Toluene
0%
10 ppm
1 ppm
50 ppm
not allowed
not allowed
> 1 to 10 ppm
51 to 250 ppm
< 10%
11 to 99 ppm
11 to 499 ppm
251 to 499 ppm
No Entry
Allowed
< 16.5% or >
23.5%
10%
100 ppm
500 ppm
500 ppm
Xylene
100 ppm
101 to 300 ppm
301 to 999 ppm
1000 ppm
Hydrocarbons
Carbon Monoxide
Sulfur Dioxide
300 ppm
25 ppm
2 ppm
301 to 50 ppm
not allowed
> 2 to 20 ppm
> 500 ppm

35 to 1499 ppm
21 to 99 ppm
10% LEL *2
1500 ppm
100 ppm
Methanol
200 ppm
200 to 250 ppm
251 to 5999 ppm
6000 ppm
Ammonia
25 ppm
not allowed
26 to 299 ppm
300 ppm
Chlorine
0 ppm
not allowed
> 0 to 9 ppm
10 ppm
Safe to Enter
19.5 to 23.5%
Comments
skin protection required to prevent contact

use chemical goggles or full facepiece for eye protection.
Methanol is toxic. If ingested or inhaled it can cause a wide
range of harmful effects, from sickness, heart and liver
damage to reproductive harm, blindness or death
*1 NOTE: Hot work is not allowed inside a confined space unless there is no LEL (0% reading) in the space
*2 NOTE: The upper limit for hydrocarbons (no entry allowed) is controlled by the LEL reading. No entry allowed if LEL is 10%.
DESCRIPTION:
Safe to Enter: Entry into confined space without respiratory protection is allowed for a maximum of 8 total hours exposure per day.
Respiratory Protection Required: No entry is allowed into the confined space without the proper level of respiratory protection.
No Entry Allowed: No entry is allowed into the confined space regardless of the degree of personal protection.
Comments Section: Skin and eye protection is required as indicated. Refer to MSDS for more specific information.

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VESSEL CLEANING PROCEDURE

Description:Issue for review

Rev. Date :16 September 2011

Approved Confined Space Entry Permit

One or more of the following also apply:

EJ Joint Venture Sdn Bhd

The interior atmosphere is hazardous (or has the potential to become