BFLP & Sabina Petrochemicals 2012 Turnaround EHS Manual

BFLP & Sabina Petrochemicals
2012 Turnaround
EHS Manual
Port Arthur 2012 TAR EHS Manual Page 2 of 77
G-P-ME-010 Annex 6.5 Issue January, 2012
(3)-5.2 EHS Manual Revision 00
Preparer: Approver: Approver:

TAR EHS Coordinator PA EHS Manager TAR Director
Document Revision Change Table

Revision Revision Description Revised Revision
Number By Date
New
Topic Page
Introduction 5
Port Arthur Responsible Care Policy 7
1. Organization, Coordination and Responsibility
1.1. EHS-Organization Chart (Planning and Execution Phase) and Role 8
Description, Interaction with site EHS Organization and Contractors
1.2. EHS Objectives, EHS Performance Indicators 11
1.3. EHS Communication, Jour Fix 11
1.4. EHS Documentation 11
1.5. Incident and Accident Analysis and Reporting 12
1.6. Personnel Tracking & Security 13
1.7. EHS Budget and Cost Management 14
1.8. Recruiting EHS Personnel 15
1.9. Evaluation and Lessons Learned 15
2. Risk Management Process

2.1. Collection of Impacting Items for the Risk Evaluation 16
2.2. Identification of High Risk Jobs and Jobs with Hazardous Potentials 20
2.3. PPE Concepts 25
2.4. Management of Interaction Risks 26
2.5. Perform Job Safety Analysis 26
2.6. Discovery Work and Additional Work 27
2.7. Risk Evaluation for Temporary Facilities 27
3. Permit Management
3.1. TAR Permit System 28
3.2. System Isolation 37
4. EHS Implementation
4.1. EHS Management Concept 42
4.2. EHS Plan 42
4.3. EHS Manual 42
4.4. Safety 43
4.5. Health 47
4.6. Environmental 52
4.7. Training 59
Topic Page #
5. Consumable and Equipment Management
5.1. EHS Consumables 62
5.2. EHS Equipment 62
5.3. EHS Warehouse 62
6. Emergency Response
6.1. On-site/Off-site Response Units 64
6.2. Alarm and Evacuation Plan 65
6.3. Installed Safety Devices 70
7. Contractor Management
7.1. EHS Aspects for Contracting Strategy 72
7.2. Selection of Contractors 72
7.3. EHS Performance of Contractor 74
7.4. Contractors EHS Personnel 74
8. Port Arthur Environmental Health & Safety Procedures

8.1. Contractor Safety Manual 75
8.2. Emergency Response Plan & Procedures 75
8.3. Health & Safety Procedure Table 76
8.4. Environmental Procedure Table 77
8.5. Other BASF Port Arthur Procedure Table 78
8.6. TAR EHS Forms 78
INTRODUCTION
This manual illustrates turnaround project organization and communication, and states the general rules
and regulations that apply during the Port Arthur BFLP – Cracker and Sabina – C4 Turnarounds. The
manual’s accepted standards and procedures for BASF- employees, contract personnel, and contractors
are the minimum requirements to perform a safe well-planned execution of all the planned activities.
The following Manual has been developed to specify safety responsibilities required by BASF of
contractors performing work associated with a Turnaround. This Manual establishes minimum
acceptable safety standards and identifies hazards that are potentially present at the BASF Port Arthur
Site. This Manual is an overview of the most important procedures followed here at BASF; for detailed
information concerning OSHA Regulations, site specifics, etc. contact a BASF EHS representative.
During normal operation and prior to shutdown:

• Accommodations for temporary buildings, equipment staging, and an increase in workforce
numbers by utilizing open areas throughout the site which may include designated parking areas.
• Fabrication and welding will be allowed in all operating units.
• There will be no restriction on the size of the workforce or the number of concurrent hot work
permits issued in all operating units.
• Welding on in service hydrocarbon lines, hot taps or stopples may be required and will be
considered.
• Complete all pre-turnaround work in accordance with the milestone plan.
In order to keep the duration of the turnaround execution to a minimum, the BFLP & Sabina process
facilities will be decommissioned and recommissioned in different phases. This means that equipment
operability and planned/scheduled maintenance will be available at different times to execute the various
activities. As a result, certain areas of the process may be operational while maintenance activity is
ongoing in other areas. It is therefore of vital importance that all activities (operations and maintenance)
during the 2012 turnaround are only carried out at an appropriate time and managed through a work task
permitting process.
Duration / Timing
• Duration of the Sabina-C4 turnaround will be 55 days. Plant shutdown will begin April 9, 2012.
• Duration of the BFLP-Cracker turnaround will be 50 days (C2 out – C2 in). Plant shutdown will
begin April 18, 2012. This includes a shutdown period of 11 days, work period of 35 days, and
restart period of 4 days.
Note: Certain utilities and waste treatment functions will remain operable to satisfy refinery and/or
regulatory requirements.
During the Shutdown the following activities will be carried out:

• Regulatory inspection of pressure equipment
• Repair/replacement of process equipment
• Catalyst inspection / replacements
• Electrical / instrumentation repairs and upgrades
• Rotating equipment inspection, repair/replacements
• Control Room / DCS improvements
• EHS improvements for equipment isolation, clearing/cleaning
• Capital Project process changes and/or improvements
TAR Critical Path maintenance activities have been identified and will require a 24-hour work schedule.
a) C2 Splitter Re-tray
b) Flare Header Tie-ins
c) Charge Gas Compressor Repairs
All expansion project work will be stopped and placed in a hold status until Turnaround is completed.
During the Shutdown, Turner Industrial Group will execute the tie-ins and equipment modifications for the
Cracker expansion.
The Port Arthur Facility will be subdivided into two separate areas (Cracker & C-4) during the Shutdown
each area will have its own execution organization. All activities will be directed by a common scheduling
management system (RMS), which includes the decommissioning and commissioning of all process
facilities.
Expected number of personnel that will be involved in the Turnaround;

• BASF/JV Partners/Contract/Contractor personnel refer to 2012 TAR Execution Organization Chart
• Total Contractors (1500 to 1750 people max)
The Responsible Care Policy for the BASF Port Arthur Site’s BFLP/Sabina partnerships encompasses
health, safety, security and environmental protection. Our site policy supports the BASF Corporation
Responsible Care Policy Statement in its belief and implementation of the following principles:
• The health and safety of our employees, customers, suppliers and neighbors and the protection of
the environment are valued above all else.
• Accidents and incidents are preventable through continuous improvement and the personal
commitment of all employees.
• The foundation of all EHS programs at the Port Arthur Site are based on management’s
commitment and responsibility and employee’s acceptance of responsibility for their safety and the
safety of their fellow employees.
• Site Responsible Care efforts are based on a framework of goals, objectives, procedures and
measurements that meet or surpass regulatory requirements, and thereby, are based on the
philosophy of long-term sustainability.
The Site’s approach to implementing these principles is as follows:

• We operate our facilities and produce products that can be used and disposed of safely and without
unreasonable risk to the public or the environment.
• We utilize technologies that:
• Support our customers and suppliers in ensuring the safe and environmentally sound handling
of our products.
• Minimize the impact of our operations on society and the environment during production,
storage, transport, use and disposal of our products.
• Utilize raw materials and energy resources in an efficient and responsible manner.
• We foster an open and honest dialog with employees, customers, the public, suppliers,
government, and the scientific community regarding activities conducted at the site to apprise them
of our results and assure them of our continued dedication.
• We are committed to the Responsible Care® Guiding Principles to seek continual improvement in
our integrated Responsible Care Management System® to address environmental, health, safety
and security performance.
Each site employee must realize and accept responsibility for EHS performance and continuous
improvement. Employee Responsible Care performance shall receive the same consideration as any
other work requirement when overall job performance is being evaluated.
The Port Arthur Site Leadership Team recognizes that only through the efforts, dedication, and
cooperation of each employee, supported by management, can our Responsible Care objectives be
obtained.
Juergen Fuchs John Lycan Brad Hopper Archie Myers

SVP Port Arthur Site 2012 TAR Director EHS Manager TAR EHS Coordinator
1. Organization, Coordination and Responsibility
1.1. EHS-Organization Chart (Planning and Execution Phase) and Role Description,
Interaction with site EHS Organization and Contractors
EHS Turnaround Coordination

Archie Myers EHS TAR Coordinator 960-5642
Mark Screen Environmental Engineer 960-5033
Angela Hodgkinson Waste Coordinator 960-5237
Andrew Garcia EHS Training Coordinator 960-5277
Jason Gengo Medical Response Coordinator 960-5447
Port Arthur Site EHS Personnel

Brad Hopper EHS Manager 960-5274
David Smith C4 – Safety Coordinator 960-5218
Tom Davis Cracker – Safety Coordinator 960-5211
Mike Van De Hoef C4/Cracker – Safety Coordinator 960-5269
Tim Masterson C4/Cracker – Safety Coordinator 960-5008
Ryan Yoes Cracker – Environmental Coord 960-5632
Mark Screen C4 – Environmental Coord 960-5033
Chris Megas C4/Cracker– Environmental Coord 960-5047
Waste Transport
During the 2012 turnaround the following people are intended to be the primary contacts
for signing Manifest:
• Angela Hodgkinson (days) – ext 5237
• Ryan Yoes (days) – ext 5632
• Mark Screen (days) – ext 5033
• Robert Grissom (days) – ext 5207
• Chris Megas (nights) – ext 5348
Safety, Environmental, and Emergency Response Coverage

The BASF EHS Dept. will coordinate with the applicable Contractor and any additional
Safety Representatives assigned to this project. BASF will provide emergency response
personnel as required.
Report emergencies by calling ext. 5555 or 5293 or radio by contacting the Shift
Coordinator on channel A-13 or Site Safety personnel on channel C-1.
EHS Service TAR Execution Organization
Page 9 of 77
Issue January, 2012
Revision 00
Port Arthur EHS 2012 TAR Organization

2/13/2012
TAR Director NTU

John Lycan Texas HUB EHS
Manager
Leonard Schooler
Site EHS Manager

Brad Hopper
TAR EHS Training

TAR EHS Coordinator
Coordinator
Archie Myers
Andrew Garcia
NTU NTU
Site EHS Admin OH Nurse
I/H Specialist
Marla Dearing Denise Thames
Bob Brennecke
Safety Coordinator
Environmental Specialist Environmental Specialist Environmental Specialist Environmental Specialist Safety Coordinator Safety Coordinator
Cracker / C 4 Area
Cracker / C 4 Area Cracker Area C 4 Area Cracker Area C 4 Area
Mike Van De Hoef (N)
(Contract) Chris Megas (N ?) Ryan Yoes Mark Screen Tom Davis (D) Dave Smith (D)
Tim Masters (N)
Field Safety Tech Cracker/Cold Field Safety Tech Field Safety Tech
Cracker Area NORM Monitoring C 4 Area Cracker/C4 Area
(6 - Contract) Sun Tech (3 - Contract) (3 - Contract)
Revision 00
(3)-5.2 EHS Manual
General Contractor On-site Leadership and EHS Personnel
JV Industrial Companies (JVIC)

Project Manager Russell Hagar O – 409-960- C – 832-556-9305
Safety John Khun C – 832-205-4247
Turner Industrial Group (TIG)

Project Manager
Site Manager Rex Cowart O – 409-960-5807
Corporate Safety James LaFleur O – 409-719-4145
Safety Manager Billy Moore O – 409-960-5311
Safety Carrol Burris
Safety John Paterson
Safety Luis Cisneros
Safety Michael Engle
BASF Port Arthur On-site EHS & Contractor Contact List

Revision 00
(3)-5.2 EHS Manual
EHS Objectives, EHS Performance Indicators for BFLP Cracker / Sabina C4;
Environmental
• There will be no RQ releases and/or NOE’s, NOV’s from the turnaround.
• Compliance with requirements for flaring minimization on shutdown / restart.
Health
• No BASF / Contractor personnel exposures above the occupational exposure limits for
Benzene / Butadiene.
Safety
Safety goal is based on actual on-site hours worked for BASF, Contract, and Contractor
personnel during the duration of BFLP Cracker / Sabina C4 Turnaround.
• Zero incidents resulting in days away from work injuries
• TRIR of 0.60 or less (6 OSHA recordable injuries for 2,000,000 hours worked)
Reliability
• The expected post turnaround reliability is for continuous operation until the next
scheduled turnaround in 2018.
Quality
• C4 post turnaround startup of the plant will not have interruptions directly related to the
quality of work performed during the turnaround. Work performed during the
turnaround will not prevent reaching 100% production capacities on time.
• Cracker post turnaround startup of the plant will not have interruptions directly related
to the quality of work performed during the turnaround. Work performed shall not
prevent achieving previous ethylene production rates within 10 days of on-spec
production.
1.2. EHS Communication, Jour Fix

A 2012 TAR Execution EHS Meeting Schedule will be provided to all affected personnel
and posted at communication points throughout the site.
1.3. EHS Documentation

Relevant Environmental Health and Safety 2012 Turnaround documentation will be
managed and maintained on a designated shared group drive Y:\TA Group\2012 BFLP
Cracker TA\05_EHSQ, Port Arthur Site web page, and the site’s electronic data
management system Documentum.
Revision 00
(3)-5.2 EHS Manual
1.4. Incident and Accident Analysis and Reporting

All investigation and reporting of accidents, incidents, or near misses at the BASF Port
Arthur site will follow the requirements of site procedure PA-020-0008 Accident Incident
Investigation.
A designated TAR Accident/Incident Investigation Coordinator will be assigned per shift to

work with BASF and Contractor Companies that are involved with the reported incident to
ensure:
• All reports are entered into the Accident Incident Management System (AIMS) and
completed in a timely manner.
• Proper incident classification is listed including identification of A/B incidents
• Incident description clearly describes in enough detail what happened to help
everyone that reviews this incident not only understand the incident but how this
incident may impact similar work activities.
• All Contributing and Root Causes are identified
• Corrective Actions adequately address all contributing/root causes for the incident
Each day the incidents reported for that day will be reviewed by BFLP TAR Leadership
and Site EHS, site communication for reported incidents will be determined by this group.
Methods that will be utilized during turnaround to communicate incidents to contractors:
• Be discussed during the daily meetings held between BASF EHS and the Contractor
Safety Representatives, additional communications will be provided to Contractor
Management/Supervision. Each Contractor Company will be responsible for
communicating these findings down through their organization to ensure adequate
corrections and understanding is achieved.
• Timeout for Safety Message – BFLP and/or Contractor Leadership Group to stop work
activity and congregate the work group(s) to deliver a safety message.
Revision 00
(3)-5.2 EHS Manual
1.5. Personnel Tracking & Security

Security at the BASF FINA & Sabina Petrochemicals facility is to manage and control
access of restricted areas it is not intended to protect personal property. BASF FINA &
Sabina Petrochemicals is not responsible for lost or damaged personal items.
BASF Port Arthur Security Command Center contact information: Phone 409-960-5294
(in-house ext. 5294) or BASF Radio Channel C-2.
• 24/7 Security Provided
• Gates
• Patrols
• Video Surveillance
All contractor access to the BASF FINA Petrochemicals Port Arthur property including
parking area will be by authorized personnel who meet the following criteria.
• Contractor personnel must badge-in and badge-out every time they go through the
security gates and wear issued ID badges (ISTC & BFLP Contractor) in a visible
manner at all times. Exception to wearing ID badges may be permissible during actual
work activities where loose objects may cause health and safety concerns or damage
(visual & electronic reading capability) to badges may occur.
• Only the person issued the BFLP Contractor badge is allowed to use that badge. No
one is allowed to swipe another employee’s badge for accessing or exiting the site.
• Contractor suppliers will also be required to obtain vehicle passes from the Security
Command Center located at gate 99. (Vehicles and persons are subject to inspection)
This pass must be returned upon exiting the plant.
• All Contractor employees must park in designated parking lots.
• All Contractor supervision shall park in their designed areas only.
• No contractor company vehicles are allowed to park in BASF employee parking lots.
• Speed limit on BASF FINA Petrochemicals property is 14.5 mph on outer roads and
7.5 on inner plant roads.
• No cameras (includes cell phones with cameras) will be allowed on site without written
permission of BASF management. (see PA-020-0037)
• No alcoholic beverages or illegal drugs will be allowed on company property at any
time. All illegal drugs found will be confiscated, turned over to the Pt. Arthur Police
Dept. and the persons involved will be removed from the site.
NOTE: All BASF Security requirements for accessing 32nd Street parking area (across
from the TOTAL Refinery) will apply.
Revision 00
(3)-5.2 EHS Manual
Contractor Badge Request

Each person requiring access to the Site will need to obtain a Port Arthur Contractor
Badge from Site Security. Submit a list of names and each person’s last four digits of their
social security number to the Project Manager or your site’s contact person at least 48
hours prior to your company’s start date. A current ISTC badge with specific training must
be presented to the Security staff before a BFLP Port Arthur Contractor Badge will be
assigned. Contractor must contact the Industrial Safety Training Council (ISTC) to
schedule their personnel.
Requirements for BASF FINA & Sabina Petrochemicals:

• Background Check Graded and SSN Verification
• Current BASIC PLUS™ or BASIC PLUS REFRESHER™
• Employees serving as Firewatch are required to attend BEST Complex Firewatch and
Fireguard Training
Per our current contract with ISTC all security requirements must be satisfied before safety
training will be allowed to begin.
To request ISTC Safety Training or Security Clearance waiver for emergency/special

circumstances only;
• ISTC Safety Training waiver – Contact Site Safety to request and make arraignments
to ensure each person that enters our site understands our site specific minimum
safety requirements (A/I reporting, E/R actions, hazards, etc…)
• Security Background checks and S/S verification waiver – Contact Site Security
Supervisor (M. Williams) to request security requirements waiver.
Contractor Vehicle Entry Request

Submit the number of vehicles and the names and the person that will be driving to the
Project Manager or your site’s contact person at least 48 hours prior to your company’s
start date.
Personal and Vehicle Security Checks

All contractor personnel and contractor vehicles that enter/exit the Port Arthur Site consent
to security checks.
1.6. EHS Budget and cost management

The Pt. Arthur Site consists of two Ventures: BFLP and Sabina.
Both BFLP and Sabina is a 60%/40% venture between the BASF Corporation and Total
Petrochemicals USA, Inc. This venture is operated by the BASF Corporation with
technical and financial oversight by both parent companies / partners. BFLP portion of the
Site consists of the Cracker, Pygas, Utilities, and OCU (Olefins Conversion Unit) units.
Sabina portion of the Site consists of the Butadiene, INALK, and C4 OSBL units.
The TAR EHS budget and cost management will follow the requirements of the TPEP
2012 Cost Management Plan.
Revision 00
(3)-5.2 EHS Manual
1.7. Recruiting EHS personnel

Additional field safety technicians will be provided through a specialty contractor company.
The selection process will follow normal Procurement requirements for third party service
provider selection.
Turnaround Safety Experience

At least two prior refinery/petrochemical facility turnarounds working as a Safety Field
Technician conducting job site safety inspections/audits.
• Prefer contractor company personnel with 3 years of employment but not mandatory,
• Provide documentation that identifies personnel selection through a third party/sub-
contractor.
Qualification/Training
Preferred minimum of 10 years experience in related petrochemical work activities,
completion of OSHA general industry (CFR 29-1910) and/or construction (CFR 29-1926)
occupational health and safety training course(s) related to job site hazard recognition
safety inspection/audits for; Hazardous energy isolation, hot-work (metal welding-grinding-
thermal cutting), confined space entry, elevated work/fall protection, housekeeping, and
crane hoisting and rigging.
Work Requirements
• Ensure all jobs are executed in compliance with BASF EHS rules and guide-lines.
• Coaching safety behavioral and/or enforcing site Zero Tolerance Policy.
• Conduct daily safety inspections/audits to ensure all unsafe acts and conditions are
immediately addressed.
• Ensure all hazard assessments and permitting requirements are being followed.
• Inspecting and controlling housekeeping.
• Extended periods of time out in the field walking throughout assigned process area(s)
and as needed climb stairs/ladders to elevated work areas.
• Informing the Area EHS Coordinator about the results of the safety inspections/audits
and any observed deficiencies and means for correcting.
1.8. Evaluation and Lessons Learned

A review of previous BASF Cracker Turnarounds (Nanjing 2010, Port Arthur 2006/2007)
was completed will incorporated several of the identified improvements related to safe
work permitting and communication lessons learned during 2012 TAR execution phase.
A review of defined TAR EHS process/programs will be conducted following the

conclusion of the 2012 Turnaround.
Revision 00
(3)-5.2 EHS Manual
2. Risk Management Process
2.1. Collection of Impacting Items for the Risk Evaluation
Confined Space Entry into an Inert Atmosphere

The action by which a person passes through an opening into a confined space that has
been filled or is filled with an inert gas such as nitrogen. This constitutes an IDLH
environment where proper set-up and execution of work and safety systems is critical. At
the Port Arthur Site, Inert Entries are used for the unloading and loading of potentially
pyrophoric catalyst, packing or desiccants. These entries are done in nitrogen
environments.
During the 2012 Turnaround Inert Entry will be required when removing or loading
catalyst, packing or desiccants that is pyrophoric in nature and could create a fire when
coming in contact with an oxygen concentration high enough to support combustion.
Compliance with Port Arthur Site procedure PA-020-0052 Inert Confined Space Entry is
mandatory.
Confined Space Entry – Welding, Thermal Cutting, Grinding

Welding activities in Confined Spaces that are not sufficiently ventilated can result in the
exposure to toxic welding fumes and asphyxiation from the accumulation of inert welding
gases. Prior to welding and burning, all hoses associated with welding and burning
equipment shall pass an acceptable leak test performed by persons who operate/own the
equipment.
For more information on welding in confined spaces see PA-020-0004 Confined Space
Entry Procedure and PA-020-0060 Metal Welding, Thermal Cutting, Grinding.
Congested Work Area

Detailed planning of job tasks to avoid worker congestion will be a priority. Maintain
awareness to all work ongoing in your area. Follow all color coded barricade requirements
per BASF Port Arthur.
Catalyst/Desiccant Changes
Catalyst/Desiccant in heavy hydrocarbon services has the potential for spontaneous
combustion when exposed to air much like the Pyrophorics. The catalyst located on this
site that have this potential include: Charge Gas Dryers (S-2601), Pygas 2nd Stage
Reactors (R-5502), Gas Fractionator (T-1401) and C4 complex reactors. Site clearing
procedures, which may include inert entry in a nitrogen atmosphere, address these
concerns along with Project Safety Reviews, Job Safety Analysis and by the Management
of Change (MOC) process.
Revision 00
(3)-5.2 EHS Manual
Electrical Shock
All electrical sources should be checked in addition to welding leads, cutting torch hoses
and all other tools and materials.
All electrical equipment used inside a confined space shall be:
• Consistent with the area classification,
• In good conditions, and
• Grounded or double insulated.
• A ground fault circuit interrupter shall be used for all electrical hand tools.
Site specific Hazardous Energy Isolation Procedure PA-020- 0001 will be communicated
to contractor employees during ISTC orientation and by their employer’s safety
representatives. BASF will conduct safety audits to ensure compliance.
Elevated Work
Special care and awareness should always be practiced when working jobs on elevated
structures or platforms. Even the smallest of objects dropped from an elevated structure
has the potential of causing severe injury and death adherence to Site procedure PA-020-
0054 Falling Object Prevention must be followed. If at all possible work should be
scheduled that removes as much of this potential as possible. However when this cannot
be avoided good communication and work practices is a must in protecting people from
potential falling objects. Everyone involved in this work is responsible from the technician
writing the permit to the maintenance crews performing the work. The technician must
inform the crews working on the structure of the importance of maintaining control of their
tools and materials and the dangers they pose to crews working beneath them. Areas
should be barricaded and warning labels attached to inform and warn anyone in the area
of the ongoing elevated work.
Falling Objects
Barricade below each level where an object has the potential to fall. Ensure adequate toe
boards and additional netting (mesh, screen or wire) is in place at all times while working
from scaffolding. Use proper storage of tools and equipment to reduce the chance for
falling objects. Use proper rigging techniques for handling of material/equipment.
• Mesh will be used from handrails to platform in areas where there will be “stacked”
workers working above each other. This will prevent incident things from being
dropped where probability of someone being below is high
• Mesh will be used from handrails to platform on platforms or scaffold where there will
be materials stored or being handled a lot. The most common area this would be work
on tower platforms.
• Mesh will be used from handrails to platform on decks if materials are going to be
stored/stacked uncontained higher than the toe rail if it is within 4 feet of the edge.
• Containment shall be used to contain small object like bolts, hand tools, etc. on
elevated areas.
• Red Barricade tape should be used as needed for overhead work and lifting. Tape
should have Red tags or signs indicating overhead hazard.
• Flagging and spotting shall be used during lifts.
Revision 00
(3)-5.2 EHS Manual
Falls
Fall prevention is the first priority utilizing rigid barricade or covers for floor openings
Compliance with Site specific Fall Protection Procedure PA-020-0010 is mandatory.
Flying Objects
The proper use of PPE to protect employees from flying objects such as hardhats with
face shields and/or goggles is mandatory. The proper application of barricade tape and
physical barricades may also be used. Refer to Site specific General Site Safety Rules
Procedure PA-0200026; Section 4.6.15 for instructions for barricading hazardous areas.
Heat Stress
Compliance with Port Arthur Site procedure Heat Stress Awareness Procedure PA-020-
0061 is mandatory. The following risk factors shall be considered when there is potential
for employee exposure to high temperatures:
• Age, obesity, personal protective equipment, strenuous work levels,
dehydration/electrolytic imbalance, lack of acclimatization, alcohol,
diseases/conditions, and medications.
It is the responsibility of all contractors to develop and implement a heat stress protection
program that adequately protects contractors from heat related disorders.
All heat related disorders require evaluation by the Site Medical Responders or Site
Medical Department for BASF employees.
Heavy Rigging
Compliance with Site specific Hoisting, Rigging, and Critical Lifts Procedure PA-020-0023
is mandatory. Competent persons will conduct inspection of rigging equipment. Use tag
lines when lifting with hoist or cranes. Designated qualified crane flagman trained in
approved hand signals will be required.
Housekeeping
Work areas will be kept free from debris or conditions that could contribute to slips, trips
and falls. Welding leads, extension cords and hoses shall be positioned overhead where
feasible.
Hot Taps / Stopples

Hot Taps, Stopples, and Freeze Plugs shall only be installed on piping that cannot be
safely cleared and/or isolated due to operational and/or system design constraints, Hot
Taps and Stopples represent a potential danger to personnel and to plant operations. Any
Hot Tap and/or Stopple must be part of an approved MOC, and shall require a PSSR prior
to being put into service. This procedure shall apply to all units/plants located at the Port
Arthur Site. All Hot Tap/Stopple installation work requests must be reviewed for potential
risk. This review is required even for nonhazardous fluid service.
The Port Arthur Site’s Hot Tap & Stopples Procedure PA-020-0014 establishes a clear set
of guidelines to be followed when performing Hot Tap and Stopple installations in piping
systems that cannot be safely cleared and isolated to make an out-of-service tie-in.
Revision 00
(3)-5.2 EHS Manual
Initial Line Breaking

The Port Arthur Site line breaking procedure establishes standard work practices and
procedures for initial safe opening of and ensuing work on flanges, pipes, valves and
equipment which contained or may have contained hazardous materials, thermal hazards
(hot or cold) or may have been under pressure.
Routine production activities (e.g. filter cleaning, hose connection or disconnection, and
process sampling) may be performed by qualified operations personnel without completion
of a safe work permit provided that current equipment-specific operating procedures are
utilized which cover the identification and control of hazards.
NOTE: For a more detailed description and requirements for initial opening of process
equipment see EHS Procedures PA-020-0005 Line Breaking
Noise
Even when process units are out of service, noise exposure is a significant problem. In
turnarounds noises sources included welding machines, light plants, compressors,
grinders, and other powered equipment. To control these sources, place engine driven
equipment as far away as possible. Ensure adequate mufflers are installed on equipment.
Provide hearing protection to all workers and require it to be worn. Hearing protection is
available to all employees and contractors. Only ANSI approved hearing protection
devices will be used.
Refer to Site specific Hearing Conservation Procedure PA-020-0011; Section 4.5. for
Noise Reduction Rating requirements for hearing protection.
Nitrogen
Nitrogen is a colorless, odorless and tasteless gas. The principle hazard associated with
nitrogen is the potential for asphyxiation. Nitrogen is used on Site to help clear the
systems of explosive and toxic materials.
NOX (Also called blue ice)

A generic term for the species that can be formed from the nitrogen oxides carried along in
the chilling train of the cracker. The major species that are carried into the chilling train
and/or formed in the Cold Box are NO, NO2, N2O3, N2O4, ammonium nitrate, ammonium
nitrite and NOx /diolefins gums. These components could become unstable on elevated
temperatures. The Site will deal with this substance be conducting a Methanol Wash of
the areas where these components could accumulate.
Pedestrian and Bicycle Traffic

Pedestrians and bicycles have the right of way on designated roadways. Personnel should
always be aware of their surroundings and cognizant of miscellaneous vehicles in all areas
of the Port Arthur Site.
Revision 00
(3)-5.2 EHS Manual
Radiation Sources in Confined Spaces

Confined Spaces involving radiation sources should be locked out before the confined
space permit is issued to the maintenance department. These radiation sources are a
form of hazardous energy that must be isolated just as all hazardous liquid, vapor and
thermal energy sources. Refer to Site Safety Procedures PA-020-0033 Radiation Safety
and PA-020-0001 Hazardous Energy Isolation for control of isolation
instructions/requirements.
Pinch Points
Communications between employees will be stressed to avoid exposure to pinch points.
Use proper gloves for the application as required.
Refractory Work
Exposure to refractory ceramic fibers (RCF) and crystalline silica may be likely in the
furnace and steam producing areas of the Site. RCF and crystalline silica are inhalation
hazards and must be controlled. General exhaust ventilation (air movers or natural draft if
sufficient) should be located to exhaust the equipment. Additional breathing protection
from ½ face breathing respirators may be needed depending on the circumstance.
Scaffolding
Scaffolds shall be furnished and erected in accordance with 29 CFR 1910.28 – Safety
Requirements for Scaffolding and 29 CFR 1926 Subpart L – Scaffolds and Port Arthur Site
specific Scaffolds Procedure PA-020- 0015. All scaffolds will be inspected by a competent
person and tagged accordingly. Scaffolds erected in excess of six feet shall have mesh,
screen or wire barricades to prevent objects from falling from the scaffold platform.
Vehicular Traffic
Compliance with site traffic regulations is mandatory. Follow posted speed limits, road
barricades and ensure vehicle entry permits are acquired before entering process areas.
2.2. Identification of High Risk Jobs and Jobs with Hazardous Potentials
C2 Splitter Re-tray
A hazard assessment and safe work concept was developed by TAR EHS Coordinator
and reviewed by Project Manager and Construction Manager for approval. The hazard
assessment reviewed and identified potential safety hazards and risk related to separate
crews performing internal and external maintenance task at different tower elevations
simultaneously. Overhead/Stacked work activities within a confined space will require a
written specific procedure to be in place that will identify, manage and communicate
hazards related to this type of confined space entry and work activity.
• Before lower level confined space entry may begin protective barriers must be in
place. These barriers must be designed to provide adequate protection of lower level
workers from the impact of dropped or falling objects from above work crews.
• If hot work activity is required protective barriers must also provide adequate protection
against welding, cutting and grinding hot work sparks and slag to lower levels of the
tower.
Revision 00
(3)-5.2 EHS Manual
• Hot Work in a confined space will follow requirements of PA-020-0004 Confined Space
• Dropped objects within the tower that strike/land onto a protective barrier must be
reported to BASF and actions to these types of incidents should follow the same
investigation criteria as any other reported falling object incident.
For a more detailed description and requirements to manage this work activity reference
the BFLP C2 Splitter Re-tray Hazard Assessment document.
C4 Columns Upgrade (USE-303119)

Process Hazard Analysis Step Review I & II was completed on July 25, 2011 for the three
columns that will be worked simultaneously.
• Before lower level confined space entry may begin protective barriers must be in
place. These barriers must be designed to provide adequate protection of lower level
workers from the impact of dropped or falling objects from above work crews.
• If hot work activity is required protective barriers must also provide adequate protection
against welding, cutting and grinding hot work sparks and slag to lower levels of the
tower.
• Hot Work in a confined space will follow requirements of PA-020-0004 Confined Space
• 1,3-Butadiene (BD) exposure assessment & PPE requirements will be determined by
initial monitoring for VOC’s and BD at the start of each shift.
• Pyrophoric substance which adheres to the packing and when opened to the
atmosphere tends to give off vapors. (Tower T-5231 was the only tower to experience
this in the 2007 TAR).
o There will be continuous monitoring for VOC’s, BD and Pyrophoric vapors as per the
TAR Site Specific vessel entry permit guidelines.
o Water will be applied to pyrophoric material and properly disposed of per the site
specific environmental guidelines.
o Air movers will be utilized during the time personnel are inside of the towers.
o Personnel will not be allowed to work in areas where there are pyrophoric vapor,
high VOC’s or high levels of BD are prevalent.
• Dropped objects within the tower that strike/land onto a protective barrier must be
reported to BASF and actions to these types of incidents should follow the same
investigation criteria as any other reported falling object incident.
the Sabina C4 BD Tower Repack Hazard Assessment document.
Revision 00
(3)-5.2 EHS Manual
Charge Gas & Flare Header Clearing

• Benzene (BZ) and 1,3-Butadiene (BD) exposure concerns
• TCEQ MSS air permit limits for venting BD/BZ to atmosphere concerns
the Port Arthur EHS Procedures PA-031-0006 VOC Process Equipment Clearing,
Cleaning and Routine Maintenance
Heater 100 – 900 Entry

When there is potential for exposure to Hexavalent Chrome dust the following PPE will be
required for entries into all Cracker Furnaces (H-100 – H-900):
• Tyvek with hoodie
• Boot covers (booty’s)
• Leather work gloves
• Full face air purifying respirator (APR)
The following protocol should be used when entering and exiting the heaters:
• The entrance of the confined space should be labeled with a confined space warning
sign and a hexavalent chrome warning sign (as required by OSHA standards). These
are located in the Hagemeyer Store.
• The internals of the heaters will be considered the “regulated area”.
• As the workers enter the confined space all PPE should be donned.
• No food (including tobacco products and gum) or drinking will be allowed in the
regulated area. (OSHA requirement).
• As the workers exit the confined space PPE should be immediately removed beginning
with the Tyvek suit, booties, gloves and respirator.
• The PPE should be bagged on site and labeled “Hexavalent Chrome contaminated
PPE Do Not Open.”
• Workers are to immediately wash their hands and faces before eating or drinking.
(OSHA requirement)
• New Tyvek suits, booties, gloves and respirator cartridges should be donned before
reentering the regulated area (inside the heaters).
The OSHA exposure limit (PEL) for Hexavalent Chrome is 5 micrograms per cubic meter
of air calculated as a 8-hour time weighted average (TWA) with a Action Level of 2.5
micrograms per cubic meter of air. These respiratory protection requirements will remain in
place until employee monitoring reveals the work areas and work tasks are below the
OSHA Action Level of 2.5 micrograms per cubic meter of air.
Revision 00
(3)-5.2 EHS Manual
High Pressure Water Cleaning (HPWC)

Personnel engaged in high-pressure water cleaning operations will have satisfactorily
completed a training course provided by the employer, which includes safety
considerations and equipment operation before cleaning on company sites. Personnel
assigned to ultra-high pressure cleaning operations must meet the training and experience
requirements (200 hours of actual) and be able to provide training documentation upon
request. The training course shall include as a minimum the topics listed below. Personnel
shall be retrained annually.
• The cutting action of the high pressure water stream and its potential hazards to the
operator
• The selection and proper use of personal protective equipment
• Operation of high pressure water systems and auxiliaries
• Operation and purpose of all safety devices
• Proper methods for connecting, handling and inspecting hoses and equipment
• Emergency conditions and procedures
• Training of high pressure water cleaning operators must include a skills demonstration
process
All contractor employees involved in high pressure water cleaning must be a full-time
employee of the service company and meet the training requirements outlined above.
Contractors must be able to provide all qualifying documentation to site personnel upon
request.
Use of ultra-high pressure water (where the pump pressure exceeds 20,000 psi / 1,360.5
bar) cleaning methods requires a pre-job plan.
• Water cleaning contractors used for ultra-high pressure water cleaning operations shall
have equipment designed and constructed for this application and must have
established procedures.
• All equipment associated with high pressure and ultra-high pressure water cleaning
equipment must be subject to a defined inspection and testing program.
• Operators of ultra-high pressure water cleaning equipment must complete equipment
specific training prior to the use of the equipment on a BASF site.
Water cleaning contractors shall provide equipment inspection and testing records upon
request. All high pressure water cleaning equipment must be maintained according to
design standards by qualified personnel.
When hose drops exceed ten (10) feet, the hose shall be securely tied off to a rigid
support to limit the pull due to the weight of the hose. All hoses must be protected from
damage due to vehicle traffic.
Prior to authorization of a work permit, a High Pressure Water Cleaning Checklist must be
completed by a designated company representative.
Provisions for spill containment and clean-up of hydraulic and /or lube oil spills shall be
established.
Revision 00
(3)-5.2 EHS Manual
Pyrophoric Areas of Concern

Polymer, coke and other heavy deposits all have the potential for spontaneous combustion
when exposed to air. Site clearing procedures address these concerns by using either-
chemical cleaning agents, steam stripping or a combination of both to neutralize these
deposits. Additional precautions include:
• To protect against unplanned ignitions, once opened, equipment with risk should be
kept wet by water if needed once a shift until cleaned or confirmed clean by operations
when opened for initial inspection or work.
• Lighting and other heat sources within vessels and large piping should be positioned
where they do not become in contact with polymer deposits and create a source of
heat. Heat that could cause ignition of these deposits.
Equipment with the potential of containing pyrophoric materials include:

• Charge Gas Dryers (S-2601) during desiccant change out
• Pygas 2nd Stage Reactor (R-5502) during catalyst change out
• Gas Fractionator (T-1401)
• All Charge Gas Exchangers
• Depropanizer bottoms & reboilers
• Debutanizer bottoms & reboilers
• Pygas towers and vessels
• Butadiene Section of the C4 complex.
• All other equipment that see heavier hydrocarbon components
Special attention should be given to these pieces of equipment even after the equipment
has been opened for a long period of time. The pyrophoric materials can dry out over time
and ignite long after the equipment has been opened to the atmosphere. Keeping this
material in wet conditions will help to control these potential hazards. Contact BASF
Operations personnel for additional information and safeguards related to pyrophoric
materials.
QA/QC Testing
Hydro Pressure Testing
Requirements for ensuring hazard and risk control measures are identified and followed
for this activity is addressed in the Port Arthur Site Mechanical Procedure PA-P-ME-401
Pressure Tests for Integrity after Construction or Leaks after Maintenance.
X-Raying Welding
Communications between Area Owner/Operator and Contractor performing this service
must be established and maintained throughout the x-ray inspection process. To ensure
proper communication between all affected personnel is maintained:
• All x-ray inspection work activity will require a Safework permit be issued by the Area
Owner/Operator.
• Areas of potential exposure to radiation must be physically barricaded and visual
warning signs of radiation hazard posted at all sides of the restricted area.
• All other work within the identified radiation hazard area must be stopped and
personnel evacuated from this area.
Revision 00
(3)-5.2 EHS Manual
2.3. PPE Concepts

Each Contractor Company is responsible for providing and requiring the use of the
appropriate personal protective equipment necessary for the Contractor's employees to
perform their job in compliance with federal standards, BASF Safety Rules and
procedures. The Contractor Company is also responsible for maintaining, testing and
operating equipment according to manufacturer specifications, as well as BASF and
federal requirements.
Minimum PPE for Plant Process Entry

 Eyeglasses or safety glasses with rigid side shields. ANSI Z-87.1-1989 approved
 Plastic shell hardhat with an adjustable headband worn with bill forward. Specifically
they shall meet Type 1 design for impact at a minimum and Class G, E, C for electrical
protection. ANSI Z89.1-1997 approved.
 Protective footwear (safety shoes) meeting the specifications of ANSI Z-41.1994 or
ASTM F2413-05 and having a ¼ inch heal and meeting the electrical hazard rating
shall be worn in all operating portions of the plant, in designated areas in the
Maintenance Building and in the Warehouse.
 When inside all process areas, employees must have chemical splash goggles in their
possession. Chemical goggles must meet the requirements for impact protection
required by the current version of US/ANSI Z87.1 Goggles shall not be affixed to the
hardhat in any way while being worn.
 Suitable hearing protection must be worn in all areas of the plant so designated.
Hearing protection is also recommended for all work inside the plant.
 Flame Retardant Clothing (FRC) – shirt (long sleeve), pants, coat/jacket. FRCs must
be worn in designated areas at all times. There are no exceptions. FRCs supplied by
Contractors must be in good condition free of tears, holes and meet or exceed NFPA
1975-90 Standard for Station/Work Uniforms.
 The use of work gloves (leather, cotton) is required whenever contractors are
performing work tasks where there is no potential for chemical contact. If required
chemical protective gloves must be made of a suitable material that will provide the
best protection possible. Latex gloves shall not be used, except where there is not
other material of construction that is suitable to protect against the hazard. To prevent
skin contact with latex, use double–glove techniques where possible.
NOTE: Additional PPE requirements are detailed in Safety and Health Procedure PA-020-
0017 Personal Protective Equipment and the Site’s PPE grids. To obtain a copy of the
Site’s PPE Grids please consult with your company’s BASF contact person.
Revision 00
(3)-5.2 EHS Manual
2.4. Management of Interaction Risks

EHS reviews of new projects and changes in equipment and/or the process will be
directed by Site Management of Change (MOC) and Pre-Startup Safety Review (PSSR)
procedures. These procedures are to be followed to ensure the safe design, installation,
maintenance and operation of the new equipment and/or processes. Both procedures
were developed to satisfy the regulations found in OSHA 29 CFR 1910.119 Process
Safety Management of Highly Hazardous Chemicals (PSM).
Management of Change (MOC) #PA-020-0029

• The purpose of the Management of Change (MOC) procedure is to establish minimum
requirements for managing the installation of, and/or modifications to equipment,
facilities, procedures, chemicals and technology at the Port Arthur Facility. The
Management of Change procedure does not apply to a Replacement-in-Kind.
• The MOC will be used to determine the Impact on Health and Safety the proposed
change will have regarding weighing the different hazards that have be identified. The
three processes used by the MOC to identify the hazards are: Risk Level Assessment,
Mode of Failure and Step Review. If the review finds the risks acceptable the Project
work can begin. This review will also determine what level of risk each MOC fall under.
The level of risk (Level 1 & 2 or Level 3 & 4) will determine what Pre-Startup Safety
Review (PSSR) form will be used when the Project work is complete.
• The MOC Coordinator has the responsibility of ensuring the MOC is completed.
Pre-Startup Safety Review (PSSR) #PA-020-0028

• After the completion of the Project work, and before Startup, a Pre-Startup Safety
Review must be completed. The purpose of the PSSR is to confirm that the design and
construction of the new or modified process was completed in accordance with the
safety concept and the work meets all company and government standards. It also
confirms that the information concerning the new or modified covered process has
been properly documented and communicated. These reviews are accomplished by
the use of checklists. The PSSR Checklist will fall into one of two categories
depending on the risk level assigned by the MOC.
• For Level 1 & 2 changes, the PSSR team shall use a condensed checklist found in the
procedure.
• For Level 3 & 4 changes, the PSSR team shall use the full checklist found in the
procedure.
• The MOC Coordinator has the responsibility of ensuring the PSSR is completed before
the Startup and use of the change.
2.5. Perform Job Safety Analysis

Port Arthur Site‘s work permitting process for workers other than those who operate the
plant will address process equipment and process area hazards analysis.
Contractors are required to perform a job specific safety analysis (JSA) to address
hazards that are inherent to maintenance activities such as but not limited to; PPE for task,
tool inspections, work area layout, weather, mobile equipment and power tool usage,
elevated work, etc…
Revision 00
(3)-5.2 EHS Manual
2.6. Discovery Work and Additional Work

The TAR Management Team has designated specific personnel chosen for their particular
expertise to help address large unscheduled/unplanned TAR maintenance activities that
may develop during the 2012 Cracker and C4 shutdown. This Team will evaluate the best
course of action needed to address equipment repairs and/or replacement items that the
Area Execution Team needs assistance to resolve..
2012 Turnaround Discovery Work Team – See Turnaround Organizational chart “TAR
Support” for details.
Permitting discovery work will be handled though a manual hand written permitting permit
process. Each identified required permit (safe work, hot work, confined space entry,
etc…) will be permitted buy Operations as described in section 3.1 of this document.
2.7. Risk Evaluation for Temporary Facilities

Will follow current site facility siting requirements which outlines the minimum distance to
be maintained between a plant/units or systems that contain liquefied flammable gases,
and sources of ignition and the minimum distance to be maintained between a plant or
units or systems, which might involve an explosion hazard, and occupied buildings. The
primary focus of Port Arthur’s Facility Siting procedure is the safety of personnel, which
should not be compromised for any building location.
Submit a list of temporary building and employee staging requirements to the Project
Manager or your site’s contact person at least 2 weeks prior to your company’s start date.
After receiving permission for bringing temporary buildings on site you must request a
Facility Sitting review and approval permit. Permit must be posted inside building in a
location that is easily visible for inspection.
List requirements as number and size of:
 Office space(s), Lunch / Employee staging area
 Construction Material / Equipment / Tool Trailer(s)
 Field Shop/Fabrication area(s)
NOTE: For a more detailed description and requirements of the Port Arthur facility,
equipment, and occupied buildings siting process see section 8. Port Arthur EHS
Procedures to access PA-020-0034 Facility and Equipment Siting.
Revision 00
(3)-5.2 EHS Manual
3. Permit Management
3.1. TAR Permit System:

The 2012 BFLP and Sabina Turnaround permitting process will follow existing site
established procedures. Certain approved additions to this process are:
• Certain sections (header, job/task description, chemical hazards, PPE requirements)
of the safe work permit will be preprinted and included in Operational job packages.
• Area field permitting locations will be established to better support/control permitted
work activities during the turnaround. The ten (10) permitting stations will issue all
required permits for thirteen (13) process and site areas. The field area permit
locations are color coded to help with owner/operations identification and coordinate
with maintenance work packages.
Sabina C4 Areas and Four (4) Permitting Stations

Area Color Code BRM Building Type & General Location
OSBL A – West Light Brown C4 Permitting Building – East of N & E Solvent
OSBL B – East Blue-Aqua Rd intersection
BD Dark Green Temporary Sea/Can – North of F-5270 in 901
pipe rack
InAlk Yellow Temporary Sea/Can – North of F-5402 in 901
pipe rack
OCU Purple Temporary Sea/Can – Intersection of 902 &
903 pipe rack
BFLP Cracker Areas and Six (6) Permitting Stations

Area Color Code BRM Building Type & General Location
Refrigeration Light Blue Temporary Sea/Can – West end of 91 pipe
rack
Charge Gas Light Green Temporary Sea/Can – Middle of area / North
of 92 pipe rack
Distillation Orange Temporary Sea/Can – Middle of 91 pipe rack
in this area
Pygas Pink Temporary Sea/Can – Middle of 91 pipe rack
in this area
Quench Brown Temporary Sea/Can – ENE of Heater #9 /
Heaters Red South of 93 pipe rack
Utilities Blue
Control Building – Cracker Permitting Room
Ground Flare Gray
NOTE: See drawing for general description of each area field permitting location.
Area C-4 / Cracker Safe Work Permitting Locations
NOTE: Contact the BASF High Voltage Electrical Group for Permitting Electrical Equipment Rooms
Revision 00
(3)-5.2 EHS Manual
BFLP & C4 Owner/Operator Permit Approvers

2012 Turnaround Operations SW/ HW / CSE Work Permit Approvers
Safe Work Permits

To provide safety precautions for work activities at the Port Arthur Site by:
• Ensuring clear communications about the work to be accomplished.
• Providing approval for the equipment owners.
• Identifying and communicating hazards related to the identified task.
• Providing protective measures to address the identified hazards.
• Providing specific communications on lockout/tagout of hazardous energy sources.
• Determining other permit requirements (Confined Space, Excavation Permits, etc.)
Safe Work Permits are an essential aid to make sure that tasks with special risks can be
planned and carried out safely. Because many tasks are performed by workers other than
those who operate the plant, clear and formal agreements are necessary. Prior to the start
of a particular work activity, a risk assessment or review of the hazards must be carried
out.
The Permit Issuer (Operating/Owning Department Representative) shall meet the Permit
Acceptor initially at the specific location where work will take place to review all pertinent
sections of the permit. If confined spaces, line breaking, hot work or Lockout/Tagout is
involved then an individual performing the work must meet with the Permit Issuer at the
work location.
A SWP shall be issued by the Operating/Owning Department for work such as:
• Work performed by Contractor Employee
• Service / Maintenance Work
• Work involving potential chemical exposure
• Non routine work/activities
• Maintenance or operations work performed by Operating/Owning Department not
covered by a Written Operating Procedure.
Exceptions: A SWP is not required for routine operations activities that are covered by
Written Operating Procedures. Examples of routine activities are: hose connects /
disconnects, filter change, sampling, etc.
Safe Work Permit Use

• The 4-eyes Principle is required for the issuance of a safe work permit.
• When monitoring must be performed, the Permit Issuer shall conduct or ensure
pertinent monitoring is completed as close as possible to the time that work will begin.
Testing shall be repeated if work doesn’t begin within an acceptable time (not to
exceed 2 hours).
• Permit Issuer shall ensure that hazards of the equipment being worked on have been
identified and protective measures have been taken.
• Permit Acceptor must sign the permit to acknowledge and agree to the conditions on
the permit.
• Revalidation of a Safe Work Permit is permissible if the initial permit conditions have
and will not change and all parts of the permit are reviewed.
Revision 00
(3)-5.2 EHS Manual
• Permit Acceptor must understand the spoken and written language in which the
permit is written.
• The Permit Acceptor has the responsibility to inform other workers working under the
permit about the hazards of the job and the requirements of the permit.
• Permit Acceptor must not transfer the permit to other personnel or shifts, unless the
permit is revalidated from the Permit Issuer.
• If any conditions change that are listed on the permit, then the Permit Acceptor must
communicate the changes to the Permit Issuer.
• By signing the permit, the Permit Acceptor verifies workers are trained in applicable
safe work practices, to use the equipment for the job and in how to properly use the
PPE necessary for the job.
• Permit Acceptor must ensure the permit is signed and returned at the completion of
work to an authorized Permit Issuer in the unit/department where issued and
communicate any problems encountered or left in the workplace.
Safe Work Permit Revalidation for Turnarounds

The Safe Work Permit issued at the beginning of a particular job task will be the permit
that authorizes the work to continue until the completion of the job. (Example: If a
particular job takes two weeks to complete the permit issued for that job will cover that job
for those two weeks.) The Safe Work Permit will have to be revalidated at the beginning of
each shift by equipment owner and services group. This is needed to verify the original
conditions of the permit have not changed. This document only addresses Safe Work
permitting which will include Low Energy / Vehicle Entry Hotwork. High Energy Hot Work
and Confined Space Entry permits will be reissued at the beginning of each shift. At no
time will maintenance work begin without a Safe Work permit. Each Service Group must
posses a current original Safe Work Permit and/or a revalidated Safe Work Permit.
NOTE: For a more detailed description and requirements of the Safe Work permitting
process see Port Arthur EHS Procedures PA-020-0003 Safe Work Permits.
Electrical Room Safe Work Permit

The procedure PA-P-EI-602 Electrical Room Safe Work Permits covers permitting of work
for the sites major electrical distribution equipment by the HV Electrical Technicians for
work within all Electrical Equipment Rooms at the Port Arthur Site. Rack rooms,
communication rooms and room containing electrical panels that feed utilization
equipment at voltages of 120/208 volts or less are excluded from this procedure.
Safety precautions for work activities in the sites electrical equipment rooms and on the
site’s major electrical distribution equipment by:
• Ensuring clear communications about the work to be accomplished.
• Providing approval from the equipment owner.
• Identifying and communicating hazards related to the identified task.
• Providing protective measures to address the identified hazards.
• Providing specific communications on lockout/tagout of hazardous energy sources.
Revision 00
(3)-5.2 EHS Manual
• Determining other permit requirements (Confined Space Permit, Excavation Permit,

etc.)
All work by maintenance, contract maintenance or other BASF servicing groups working
within the plant electrical rooms or on the sites electrical distribution equipment.
This procedure does not apply to:
• Other types of permits issued in conjunction with the work being done under the Safe
Work Permit (Vehicle entry, Critical Lift, etc.) for areas outside the electrical
equipment rooms.
• HV Electrical Department personnel performing operating and maintenance tasks
within their assigned electrical discipline.
• Qualified Shift I&E Maintenance Technicians who have been trained to operate
disconnecting device in the 4.16 kV Motor Control Centers and operate circuit
breakers in the 480 volt, 4.16 kV, 13.8 kV and 34.5 kV switchgear for the purposes of
electrical isolation.
• Qualified Production Department personnel who have been trained to operate a 480
volt Motor Control Center disconnect switch for the purpose of electrical isolation.
No revalidation of an Electrical Room Safe Work permit will be allowed a new Safe Work
permit must be issued at the beginning of each shift. All of the requirements of Section 4 of
the Safety and Health Procedure PA-020-0003 (Safe Work Permits) will apply for this
procedure with the following exceptions:
Approval and Revalidation of Safe Work Permits will be done by a HV Electrician.
Any additional permits that need to be issued to complete the work (i.e., Vehicle Entry,
Critical Lift, etc.) will be obtained through Operations.
The duration of the Safe Work Permits issued by the HV Electrical Department will
coincide with the shift hours that the Electrical Department is working.
All of the Safe Work Permits, along with any additional permits/documents, that have been
issued throughout the week will be sent to the Permit Room in the Control Room for filing.
These documents will be received in the Permit Room by 8:00 am on the first scheduled
work day of the next work week.
Approved BASF HV Electrical Safework Permit Issuers

- Dean Gentz
- Francis Orsot
- Gary Schauerman
- John Schexnayder
- Veryl Pink
Hotwork Permits
To establish standards for welding, cutting, brazing, grinding, or other activities which
require the use of open flames, or which may generate sparks, including electrical tools,
electronic equipment, and vehicles.
Revision 00
(3)-5.2 EHS Manual
Hot Work permits are not required:

• In the maintenance shop
• Temporary welding areas as designated by the EHS manager
• Substations
• Designated contractor lay down areas as approved by the EHS Manager for each
project.
LEL for Hot Work Activities within the Unit(s)

A Fire Guard is required whenever High Energy Ignition Sources i.e. welding, cutting,
grinding or other activities which require the use of open flames or spark generating
equipment.
• Sharing of Fire Guards on jobs that are adjacent to one another may be utilized as
long as line of sight and proper communications is maintained. Approval of a shared
Fire Guard must be granted by the Owning / Operating Department approving the
permit.
Note1: Some jobs in elevated process areas may require additional Fire Guards. If this
is determined, the Owning / Operating Department approving the permit will
note it on the permit.
Note 2: Some jobs, depending upon the complexity and location, may require that a
BASF representative be present. This will be determined and noted on the
permit by the Owning / Operating Department authorizing the permit.
For a more detailed description and requirements of the Port Arthur Hot Work permitting
process see EHS Procedures PA-020-0002 Hot Work Permits.
2012 TAR LEL Walker / Fire Guard Requirements (Approved PA-020-0002 procedure deviation)
LEL Escort for Vehicle Entry into the Unit(s)
Vehicle Entry is considered a Low Energy Ignition Source Hot Work.
• Plant Decommissioning/ Shutdown Phase – Plant conditions have not changed from
normal operations continue to follow PA-020-0002, Section 4.4.
o Have a properly checked/calibrated Combustible gas monitor and be trained in its
use.
o An initial atmospheric check is required where the vehicle will be operated.
o Blue Areas and plant roads outside of process areas containing flammable
materials do not require a Vehicle Entry permit.
o Red Areas require an LEL Walker to escort the vehicle in/out while continuously
monitoring atmospheric conditions.
o The vehicle escort shall maintain a distance of 30 feet ahead of the traveling
vehicle.
• Turnaround Execution Phase – When the BFLP Cracker and Sabina C4 facilities
including all ground and elevated flare systems have been cleaned/cleared the TAR
Site Leadership will evaluate the current conditions at this time to determine if the
elimination or containment of hazardous/flammable material in these process areas
still poses a credible fire/explosion risk,. If current conditions are acceptable the
change to and “LEL Rover” for atmospheric monitoring for low energy ignition source
work activity may begin under these conditions.
Revision 00
(3)-5.2 EHS Manual
o Communications from TAR Site Leadership to all affected personnel start date/time
of LEL Rovers.
o Low Energy Ignition Source is operations that produce low heat and little or no
sparks, such as electrical tools, hammering, lighting, sandblasting, vehicles, etc.
o An initial atmospheric check is required where the low energy ignition source will
be operated.
o LEL Rovers would actively walk major pipe alley and roadways within the unit(s)
and be able to travel their area of responsibility within a 10 to 15 minute timeframe.
o LEL detection of 10% or greater (meter alarm setting) will require immediate
shutdown of all low/high energy ignition source hot work in the affected area.
o Low/high energy ignition source hot work in the affected area may not restart/begin
until the cause of detection has been corrected.
• Plant Re-commissioning/Startup Phase – Revert back to normal site requirements for
vehicle entries and low energy ignition source operations.
Confined Space Entry Permits

Permits are required for spaces which can be bodily entered, have limited or restricted
means of egress, are not designed for continuous employee occupancy, and have one or
more of the following characteristics:
• Contain or have the potential to contain a hazardous atmosphere (such as having
held flammable, explosive, acidic, caustic, toxic materials) or where oxygen enriched
or deficient atmospheres or noxious odors may exist.
• Contain a material that has the potential for engulfing an entrant.
• Have an internal configuration such that an entrant could be trapped or asphyxiated
by inwardly converging walls or by a floor which slopes downward and tapers to a
smaller cross-section.
• Contain any other recognized serious safety or health hazards; such as ionizing
radiation, electric shock, temperature extremes, or moving parts.
Such spaces include, but are not limited to: tanks, tank trucks, tank cars, duct work, vats,
tubs, hoppers, bins, boilers, kilns, cooling towers, stacks, chimneys, sewers, trenches,
pits, manholes, elevated or ground flares, or other similar equipment/structures. This
may also include structures greater than four feet in height, or excavation that are
greater than four feet in depth that have limited or restricted means of egress.
NOTE: For a more detailed description and requirements of the Port Arthur Confined
Space Entry permitting process see EHS Procedures PA-020-0004 Confined
Space Entry.
Revision 00
(3)-5.2 EHS Manual
Excavation Permits
Excavation permits are required for any machine driven excavation equipment penetrating
any ground surface (concrete, dirt, gravel, etc.) at the Port Arthur Site. Examples of
excavation work requiring a permit are grass stripping, saw cutting, operating a machine
driven hoe or hoe ram, and a jack hammer. Hand excavations will normally be excluded
from this requirement, but must be considered on a case-by-case basis.
Excavation permits shall be in addition to, not take the place of, Safe Work Permits. For
excavations outside the Port Arthur property line, a notification to Texas ONE CALL (1-
800-545-6005) must be made 48 hours prior to digging.
NOTE: For a more detailed description and requirements of the Port Arthur Excavation
permitting process see EHS Procedures PA-020-0019 Excavation, Drilling and Pile
Driving.
Critical Lift Permits

A critical lift permit must be completed and approved prior to performing any critical lifts.
This permit form can also be used as an addendum to an already approved critical lift
permit, in order to manage and document the approval of “minor” changes to an already
approved critical lift permit. The addendum requires the same approval signatures, and is
to be attached to the original critical lift permit. However when the addendum to the Critical
Lift Plan documents only higher capacity cranes or rigging equipment the Shift Supervisor
alone may approve.
Safety considerations:
• Equipment Inspections
• Proper functionality of all controls
• Ensuring the lift plan is safe and does not overload the equipment
• Ensuring the loads are secure
• Rigging is adequate and tag lines are used
• Clearances are adequate for all movements
• Weather conditions are safe. Wind Speeds over 20mph require special precautions by
operator or a suspension of work.
• Has hazards in view or is always in direct communication with the spotter or signal-
man.
• The crane operator is ultimately responsible for the safe lifting of material/equipment.
This hoisting and rigging/critical lift procedure is intended to ensure proposed lifting
equipment and associated rigging accessories are technically acceptable to perform lifts
with-in predefined boom angle, weight, and wind speed limits, and to make everyone
involved in lifts aware of company and regulatory requirements that must be adhered to
when making a lift. It also documents that there are no other reasonable alternatives to
executing the work, other than by performing a critical lift. It is NOT intended to authorize a
critical lift from an operational safety perspective. Final critical lift authorization is obtained
through the safe work permit process.
Revision 00
(3)-5.2 EHS Manual
Prohibited Lifts cannot be permitted and will not be allowed. Listed are recognized
“Prohibited Lifts”.
• Any lift over personnel or occupied portions of buildings; or
• Any lift in which the load exceeds 100 % (NOTE: Crane load charts are limited to
85% of the actual crane capacity) of the load chart of a crane excluding annual
recertification of fixed location cranes; or
• Soil or ground conditions are such that the stability of the crane during a lift cannot
be guaranteed.
• Using a “friction” type crane for any lift
NOTE: For a more detailed description and requirements of the Port Arthur Critical Lift
permitting process see EHS Procedures PA-020-0023 Hoisting, Rigging, and Critical Lifts.
3.2. System Isolation
Hazardous Energy
All activities shall be performed, to the extent possible, under a Zero Energy State that has
been verified, at a minimum, by Operating/Owning Department personnel. The Port Arthur
facility utilizes a Master Isolation Procedure to identify and control hazardous energy.
Master Isolation Procedure (MIP) is a hazardous Energy Source control process that may
be used for control of multiple isolation points/devices. Since the Master Isolation Plan
relies primarily upon administrative means to control the release of potential hazardous
energy, additional steps for Verification of Zero Energy State are required to ensure that
protection comparable to Lockout is maintained during work covered by this procedure.
There must also be a mechanism to achieve personal acceptance of the Hazardous
Energy Isolation by each Authorized Employee (Work Crew Accountability Form - WCAF)
When Zero Energy State verification is not possible, proper PPE and/or additional
administrative/engineering controls shall be utilized to minimize exposure to hazards.
Personnel shall not perform maintenance activities involving the control of hazardous
energy sources without prior written authorization in the form of a Safe Work permit issued
by an Operating/Owning Department Permit Issuer.
NOTE: For a more detailed description and requirements for the control of hazardous
energy see EHS Procedures PA-020-0001 Control of Hazardous Energy
Revision 00
(3)-5.2 EHS Manual
Barricades
Danger areas must be identified and managed while these conditions exist. Limited or NO
access must be communicated to all affected personnel. An accepted practice in our
industry is the usage of barricade warning tape to rope off an area to ensure personnel do
not wander into a potential hazardous condition. Barricades and barricade tape will be
used whenever hazardous or possible unsafe conditions exist in a particular area of the
plant. Each barricade will be constructed to have four sides and each side will be tagged
to describe the owner and area hazard. Barricades will only be removed when the job is
complete or when the hazard no longer exists.
Wooden Barricade – Access way closed (normally used for plant roadways and process
unit travel pathways). Do not enter without permission, utilize an alternate route.
Caution/Hazard Barricade Tape – To help communicate potential hazards and

manage/control access into these identified areas. The Port Arthur Site utilizes four types
of barricade tape; Caution, Hazardous for overhead work, Danger Hazardous Area for
Benzene/Butadiene exposure potential and DO NOT ENTER.
Installation of barricade tape at the Port Arthur Site requires the proper tag be placed on
each leg at the intended access point of the barricaded area. The owner (installer) is
responsible to manage their constructed barricade (ensure all legs are maintained per the
original intent) until the need for barricading an area has been eliminated, at which time
the owner (installer) is responsible for removing all posts, tape, tags, etc.
.
NOTE: If two or more service groups are utilizing one or all legs of a barricaded area each
service group is required to tag the barricade leg(s) that are being shared. The barricade
leg(s) being shared will not be taken down until all tags have been removed.
Revision 00
(3)-5.2 EHS Manual
Barricade Tape Description Table

Yellow/Black Caution Tape.
Identifies upset/changed condition and/or
work ongoing in area. Enter only after
hazard has been identified.
Red Tape.
Identifies hazardous condition or
Overhead Work. Do not enter without
owner’s permission.
Red tape with “Danger, Hazardous

Area.”
Identifies Benzene or Butadiene Area. Do
not enter without permission and proper
PPE.
Red with Black Stripes tape.

Identifies dangerous condition. DO NOT
ENTER. Only BASF Operations/Owning
Department or EHS has authority to use
this tape.
NOTE: Barricade Tape this is specific to a work task is acceptable, example: Radiation,
Hydroblasting, etc..
Tags
The Port Arthur Site utilizes many types of tags as an administrative process to identify
owner’s intent and communicate potential hazardous and control measures. The
placement of a Tag on a piece of equipment or barricade requires personnel to follow all
written instructions of the tag and never operate equipment, proceed past a restricted point
or remove any tag that is not directly under your control. Contact the tag’s owner if you
need assistance or clarification of what is permissible.
Revision 00
(3)-5.2 EHS Manual
Barricade Tag Description Table

Yellow Barricade Tag
To be used with Yellow/Black Barricade Caution Tape.
Establishes barricade tape owner and identifies and
upset/changed condition. Enter after hazard has been
identified and all PPE requirements have been met.
Tags to be properly secured on all sides of barricade
area (4-sides – 4 tags)
Red Barricade Tag

To be used with Red, Red Hazardous Area and Red &
Black Barricade Caution Tape.
Establishes barricade tape owner and identifies a
dangerous condition which requires controlled and
limited access. Enter only with owners permission and
after all hazards have been identified and all PPE
requirements have been met. Tags to be properly
secured on all sides of barricade area (4-sides – 4
tags)
Revision 00
(3)-5.2 EHS Manual
Port Arthur Process Tag Table

Isolation Tag - (For use to identify Hazardous
Energy Isolation)
An Isolation tag and a means of attachment
(plastic tie-wrap), which is securely fastened to
an energy isolating device in accordance with an
established procedure, to indicate that the energy
isolating device and the equipment being
controlled may not be operated until the tagout
isolation device is removed in accordance with
Site Hazardous Energy Isolation Procedure PA-
020-0001
Danger Tag (Do not use for Lockout / Tagout)

Placed on equipment where the use or operation
of the equipment may cause injury or equipment
damage. A “Danger” tag is not to be used as an
Energy Isolation tag.
Process Information Only Tags

Process Information Only tags are used to
convey process information.
Revision 00
(3)-5.2 EHS Manual
4. EHS Implementation
4.1. EHS Management Concept

The EHS Management Concept for the 2012 Port Arthur Turnaround followed the
guidance set forth by the Technical Community – Global Maintenance Procedure G-P-ME
010 Turnaround Management Process / EHSQ Management (issue date Feb 2010).
G-P-ME 010 EHS Management Concept for PA 2012
4.2. EHS Plan

The EHS Management Plan for the 2012 Port Arthur Turnaround followed the guidance
set forth by the Technical Community – Global Maintenance Procedure G-P-ME 010
Turnaround Management Process / EHSQ Management (issue date Feb 2010).
G-P-ME 010 EHS Management Action Plan for PA 2012
4.3. EHS Manual

The EHS Manual for the 2012 Port Arthur Turnaround was developed based on the
established and approved site standards/procedures currently used or developed
specifically for the turnaround. Section 8 of this manual lists all EHS
standards/procedures, guidance documents and forms that may/will be utilized for the
2012 Cracker and C4 Turnaround.
When certain conditions are not addressed by existing BASF Corporate or Port Arthur Site
specific EHS procedures the 2012 TAR Core Team will create a 2012 Turnaround
procedure or request for a Temporary deviation to an existing procedure to ensure any
hazardous conditions will be identified, managed, and communicated effectively.
Temporary Deviations must be requested in writing utilizing the PA-020-0027 deviation

request form. Deviations are only valid until the termination date/time stated on the
deviation request form. The request form must be filled out completely, including the
reason for the deviation and protective measures to be implemented. The deviation
request must be reviewed and approved by the personnel specified on the request form
prior to beginning work. The Operations Manager is the final sign-off of approval. The OM
must ensure all required notifications and signed approvals have been completed before
signing the form as approved.
Refer to PA-020-0027 Procedure Deviation procedure for more details regarding the
requirements of requesting a procedure deviation.
Revision 00
(3)-5.2 EHS Manual
4.4. Safety
Audits – Daily TAR Field Verification of Safe Work/Area Requirements

The following are the requirements for safety field audits conducted during turnaround:
A designated Safety Field Audit Form has been developed to review 14 key safety
performance elements that are intended to help recognize potential hazardous conditions
and maintain focus related to job scope risk by all involved during the work activity.
For Contractors:
• Contractor Foreman/Supervisors shall conduct two audits per shift utilizing the
appropriate TAR audit checklist.
• Contractor Safety Representatives shall conduct two audits per shift utilizing the
appropriate TAR audit checklist.
• Site Contractor Leadership Members shall conduct one audit per week the specific
subjects to be audited will be those areas identified to have been the most problematic
for the week. This will be determined by the BASF EHS Dept.
• Audit Forms will be turned in to the BASF EHS Dept. along with a summary of
deficiencies found during the day. This will be done at the Daily Contractor Safety
Meeting.
• Audit deficiencies will be reviewed at the Daily Contractor Safety Meeting. Contractor
Safety Representatives are expected to not only present the deficiencies but also
solutions to the problems.
• Those items found to be problematic will be addressed by the Contractor Safety
Representatives during toolbox safety meetings at the beginning of each shift.
• BASF EHS Dept. may schedule different types of audits/various topics deemed
necessary during the outage. ANY IDLH (Immediate Danger to Life and Health)
infractions are subject to call for a work stoppage in that area or job and immediate
corrective action will be mandatory.
For BASF Managed Personnel:

• TAR Contracted EHS personnel shall conduct three audits per shift in the area they
are assigned to utilizing the appropriate TAR audit checklist. Completed audit forms
will be turned into the BASF EHS Dept. along with a summary of deficiencies found
during the shift.
• Field Safety Audits will be conducted by a variety of BASF personnel. Completed
audits will be turned into the Area Operation’s permitting buildings, ten total (six
located throughout the Cracker and four in C4) or BASF EHS personnel (see EHS
Org. Chart page 9 of this manual). Field boxes will be labeled “Safety Field Audits”.
BASF EHS personnel will collect these audits and evaluate the findings
• BASF TAR Leadership and Site EHS personnel will participate, monitor, review, etc.
the TAR audit system.
Revision 00
(3)-5.2 EHS Manual
Communication of Safety Field Audits Results

• The areas of concern will be listed on a summary form for TAR Leadership to review.
Communications for areas of concern and identified corrections will be discussed
during the daily meetings held between BASF EHS and the Contractor Safety
Representatives.
• Additional communications will be provided to Contractor Management/Supervision.
• Each Contractor Company will be responsible for communicating these findings down
through their organization to ensure adiquate corrections and understanding is
achieved.
Bicycles
Only BASF company approved bicycles are allowed for employee usage on company
property and/or work related activities.
Reference Port Arthur Site Procedure PA-020-0026 General Safety Rules, section 4.1.1.
for more details related to bicycle proper usage, maintenance and inspection
requirements.
Energy Sources used in Confined Spaces

Confined Space Jobs are isolated from all external energy sources to protect entrants
working or inspecting a confined space. Special care must be taken not to introduce
addition hazards while working within a confined space. Refer to Site procedure PA-020-
0004 Confined Space Entry for more detailed instructions/requirements.
Fatigue Management
Turnaround work schedules for process safety sensitive decision personnel will follow the
ANSI/API Recommended practice 755 – 2010.
This recommended practice (RP) provides guidance to all stakeholders (e.g. employees,
managers, supervisors, contractors) on understanding, recognizing and managing fatigue
in the workplace.
Work Hours Scheduled for Outages

Start-ups and planned shut-downs (including partial of a process is a critical time in
operations and due consideration should be provided so safety critical personnel are well
rested and fit for duty.
The hours of service limits for outages for 10-hour shifts are as follows:
• Work sets shall not exceed 14 consecutive calendar days.
• There shall be a minimum of 36 hours off after a work set. Time off beyond 36 hours
shall be addressed at the plant level.
• During outages, individuals tend to work fixed shifts. 36 hours between work sets
provides for 2 consecutive sleep opportunities, thereby allowing workers to remain on
their established circadian cycle, rather than encouraging night shift workers to revert
Revision 00
(3)-5.2 EHS Manual
to night sleep on their off days, which likely would occur with longer time between work
sets.
• Shifts are routinely scheduled for 10 hours and holdover periods should not exceed 2
hours and, where possible, occur at the end of the day shift.
The hours of service limits for outages for 12-hour shifts are as follows:
• Work sets shall not exceed 14 consecutive day or night shifts.
• There shall be a minimum of 36 hours off after a work set. Time off beyond 36 hours
shall be addressed at the company or plant level.
• During outages, individuals tend to work fixed shifts. 36 hours between work sets
provides for 2 consecutive sleep opportunities, thereby allowing workers to remain on
their established circadian cycle, rather than encouraging night shift workers to revert
to night sleep on their off days, which likely would occur with longer time between work
sets.
• Shifts are routinely scheduled for 12 hours and holdover periods should not exceed 2
hours and, where possible, occur at the end of the day shift.
Nitrogen Safety
Nitrogen is a colorless, odorless and tasteless gas. The principle hazard associated with
nitrogen is the potential for asphyxiation. Nitrogen is used on Site to help clear the
systems of explosive and toxic materials. During large turnarounds nitrogen may be bled
down to the atmosphere. This could pose serious problems to personnel walking or
working in the surrounding area if they are not aware of informed of this potential. When
blowing down large amounts of nitrogen the area Operations Technician must monitor the
affected area with calibrated meters to measure the affected area. Barricades (Red /
Black Tape) and warning signs must be posted (in the safe area) to inform personnel
passing by of the dangers within the barricaded area. Area technicians when working
around nitrogen should also use caution and proper PPE.
Nitrogen as back up for Plant Air Supply

The Port Arthur site plant air system is backed up by nitrogen. Therefore, plant air shall not
be used:
− As breathing air
− To power air-driven tools in a confined space
− To ventilate confined spaces
When plant air back-up system is activated (nitrogen introduced into header system) an
alarm located in the control room will be activated by Interlock I-7501 and alerts Utilities
Control Operator. The Control Operator will immediately announce a “Radio All-Call”
message communicating that the plant air system is now operating with nitrogen gas. This
announcement triggers work stoppage in all Analyzer House locations and initiates an
immediate review of permitted confined space entries.
Revision 00
(3)-5.2 EHS Manual
Operating Automotive & Powered Mobile Equipment

• The driver of a vehicle on company business on or off site is responsible for its proper
use. It is the responsibility of the individual that operates a vehicle with defective
safety equipment or inspection sticker out of date to take the vehicle out of service and
report the defect to appropriate supervision. Obey all traffic signs. Stop, look both
ways at all STOP signs
• Maximum Plant speed limit is 14.5 mph for perimeter roadways, process roadways is
7.5 mph (must have vehicle entry permit to access)
• Riding in back of pickup trucks is prohibited
• Vehicles within process boundaries must look backwards and sound horn before
backing out
• Seatbelts required while operating/riding in vehicles
• Cell phone use while driving is prohibited
• If emergency horn sounds pull over to side of the road, turn off vehicle, leave keys in
ignition, proceed to nearest assembly point and check in
• Riding on powered industrial mobile equipment is permitted only when adequate safety
provisions such as seats, platforms or rails are provided for passengers.
• Vehicle and powered industrial mobile equipment (fork trucks, manlifts “JLG’s”,
personnel/equipment carries “gators”, cherry-pickers, cranes, etc….) fuel tanks must not
be filled while engine is running. Immediately report any fuel spill(s) to EHS
Environmental Radio Channel C-1.
• All vehicle accidents must be reported immediately to BASF and/or Contractor
Supervision as appropriate.
• Site Employees, contractors and visitors who operate personal vehicles inside the
plant must comply with Human Resource Procedure PA-010-0012 Personal Vehicle
Usage in the Plant, and to the applicable requirements detailed in this Section.
Pedestrian Traffic/Travel
Only approved means of travel is by an approved vehicle or foot.
• Walk on designated sidewalks
• Sidewalks are reserved for pedestrian traffic only.
• Yield to pedestrians
Temporary Lighting
Per OSHA 1926.405(a)(2)(ii)(G); Portable electric lighting used in wet and/or other
conductive locations, as for example, drums, tanks, and vessels, shall be operated at 12
volts or less. However, 120-volt lights may be used if protected by a ground-fault circuit
interrupter. Temporary lighting shall be provided by one of the following means:
• Intrinsically safe flashlights
• Approved low voltage (12 volt) or 120-volt lights/extension cords equipped with a
functional ground fault circuit interrupter.
• Voltage regulator devices shall be located outside of the confined space.
• Temporary lighting shall be equipped with guards to prevent contact with the bulb.
Revision 00
(3)-5.2 EHS Manual
Severe Weather / Hurricane Plan

The Port Arthur Facility Severe Weather and TAR Hurricane Plan describes methods of
early detection capabilities, means of site-wide communications and details for personnel
plan of action in the event of severe weather, tornados, lightening storms, and a Hurricane
that will make landfall along the upper Texas or Southwestern Louisiana coast.
For more specific information regarding severe weather and hurricane preparedness refer
to: Port Arthur Facility Severe Weather Plan / 2012 TAR 2011 Hurricane Plan
4.5. Health
Medical Emergency Response

See Section 6.1 On-site/Off-site Response Units (Medical Response) of this manual.
Medical Occupational Injury or Illnesses

The BASF Port Arthur Site medical facility will provide its normal day to day medical
services of employee care related to occupational injuries and illness by providing medical
and administrative services to ensure compliance with regulatory and policy requirements,
manages workers' compensation cases, administers the site return-to-work process,
coordinates employee physical exams and other medical treatments or health monitoring.
NOTE: Employee medical clearance physicals during 2012 turnaround (March 15th
through June 15th) will be suspended. No disciplinarily actions will be taken as
stated in site procedure PA-020-0063 Mandatory Medical Surveillance for those
employees affected by this temporary suspension. Site Medical scheduling
employee medical clearance physicals either before or immediately after the
turnaround, additional medical staff resources will be required to minimize non-
compliance impact.
Medical Non-Occupational Injury or Illnesses

Sick leave due to personal (non-occupational) injury or illness, and return to work during
the turnaround will follow the requirements of Port Arthur Site Human Resource procedure
PA-010-0020 Notification of Absence and Tardiness. Permission should be obtained from
your supervisor (or designee) by the employee in advance of any absences from work.
When situations arise, which make advance notice impossible, your immediate supervisor
(or designee) must be contacted as soon as possible so job coverage can be arranged.
Failure to notify your supervisor could result in disciplinary action.
For absences of four (4) work days or more, please reference BC004.042 Attendance and
Absenteeism Procedure.
Revision 00
(3)-5.2 EHS Manual
Industrial Hygiene Work Description

Personal industrial hygiene (IH) monitoring for benzene, 1,3 butadiene (BD), and other
hydrocarbons will be performed for operating technicians when process units are cleared
and drained. Monitoring for benzene, BD, hydrocarbons, crystalline silica, refractory
ceramic fibers, chromium(VI), and welding fumes will be performed for BASF and contract
maintenance workers (who perform tasks that are similar to those performed by BASF
employees, or whose tasks may affect BASF employees) as process equipment is opened
and during confined space entries. The monitoring strategy will be determined by the
BASF NTU/MSS industrial hygienist (IH), who will also perform field monitoring with the
assistance of a contract industrial hygiene technician. Laboratory analysis of field samples
will be performed by BASF ACCE. Monitoring results will be communicated to BASF
employees via email and to contract employees via their EHS representative. In addition
to IH monitoring, the BASF IH will observe field tasks to ensure proper use of PPE and to
determine if additional personal or area monitoring for chemical substances or physical
agents (heat, noise, and radiation) is warranted.
2012 TAR Industrial Hygiene Monitoring Schedule
Benzene and 1,3-Butadiene

During initial entry procedures for confined spaces, Operation Technicians will evaluate
the vessel/equipment for the presence of hydrocarbons using LEL meters and Ultra Rae
meters (for benzene and butadiene). If no detectable hydrocarbons are present, there is
minimal risk for exposure to hydrocarbons from the process streams. However this does
not exempt authorized entrants from wearing respiratory protection. Other activities being
performed in or around the confined space may contaminate the atmosphere inside the
confined space and therefore must be recognized, evaluated and controlled.
The presence of Benzene or Butadiene will require the use of Respiratory Protection when
levels are within the ranges referenced below in the Respiratory Protection Selection
Guide. For more specific information on these two chemicals see the following
procedures: PA-020-0043 Butadiene Compliance and PA-020-0041 Benzene Compliance.
Revision 00
(3)-5.2 EHS Manual
Air Purifying Respirator Cartridge/Canister/Filter Change-out Schedule

Chemical CHANGE OUT SCHEDULE
Benzene End of shift or 4 hours of continuous
usage, whichever comes first.
1,3 Butadiene or streams that contain 1,3 End of shift or 1 hour of continuous
Butadiene usage, whichever comes first.
Ethylbenzene or streams that contain End of shift or 1 hour of continuous
Ethylbenzene usage, whichever comes first.
Naphthalene or streams that contain End of shift or 1 hour of continuous
Naphthalene usage, whichever comes first.
Toluene or streams that contain Toluene End of shift or 1 hour of continuous
Xylene or streams that contain Xylene End of shift or 1 hour of continuous
Particulates, including refractory ceramic End of shift.
fibers, silica, and welding fumes
Respiratory Protection Selection Guide

Chemical ½ Mask Full-face Full-face SCBA or SAR with
APR APR SAR 5min escape bottle
Benzene < or = 5ppm – 25 25ppm – >500ppm or Unknown

5ppm ppm 500ppm concentrations
Butadiene < or = 10ppm – 50ppm – > 1000ppm or Unknown
10ppm 50ppm 1000ppm concentrations
VOC with < or = 20ppm – 100 ppm – > 2000ppm or Unknown
no 20ppm 100ppm 2000ppm concentrations
detectable (Basis:
levels of Naphthal
Benzene or ene)
Butadiene
APR = Air Purifying Respirator / SAR = Supplied Air Respirator / SCBA = Self Contained Breathing Apparatus
Noise Exposure
ANSI approved hearing protection will be used. The minimum Noise Reduction Rating
(NRR) for any ear plug used will be no lower than 30 NRR. Provide hearing protection to
all workers and require it to be worn. Hearing protection is available to all employees and
contractors. Hearing conservation is covered in ISTC training as well. For areas at the Port
Arthur facility that will require usage of hearing protection, see Port Arthur Hearing
Protection Required Area map on next page.
Port Arthur Site Required Hearing Protection Locations
Page 49 of 77
Issue January, 2012
Revision 00
Revision 00
(3)-5.2 EHS Manual
Naturally Occurring Radioactive Material (N.O.R.M.)

N.O.R.M. exists in the propylene areas of the Cracker and C4 units. External radiation
surveys are to be conducted to identify the presence of N.O.R.M. in the equipment.
Process scale with N.O.R.M. can deposit on internal surfaces of equipment. See PA-020-
0021 N.O.R.M. Procedure for details.
Hexavalent Chromium Compliance

Potential for Cr(VI) exposure exists for the tasks such as:
Hot work (torch cutting, welding) on metals. The higher the chromium content, the more
likely the exposure to Cr(VI).
• Cutting, welding, or disturbing chromate-based paints.
• Handling catalysts that contain Cr(VI).
• Handling potassium dichromate, zinc chromate, or other chromate compounds in
laboratories or manufacturing operations.
• Handling chromic acid (chromic trioxide).
BASF or Contractor employers shall perform initial industrial hygiene monitoring to

determine the 8 hour TWA exposure to Cr(VI) for any task where there is potential for
Cr(VI) exposure. Monitoring shall be based on a sufficient number of personal breathing
zone samples for the employee(s) expected to have the highest exposure to airborne
Cr(VI). Additional industrial hygiene monitoring shall also be performed if there are any
changes in processes, raw materials, equipment, personnel, work practices, or control
methods that may result in new or additional exposures to Cr(VI). In order to determine
employee exposure, historical monitoring data or objective data may be used instead of
(or in addition to) the data from air monitoring. For more information regarding
information/requirements of Hexavalent Chromium Compliance see Site procedure PA-
020-0059.
Additional Hazard Recognition, Identification and Control Information

A hazard assessment has been completed for the Port Arthur Site. Based on the hazard
assessments, site specific PPE requirements were established. PPE grids have been
developed for plant operations which summarize the minimum PPE requirements for each
chemical that personnel may encounter during routine, maintenance and emergency
operations.
Personal Protective Equipment requirements are managed by site procedure PA-020-

0017 along with support PPE Table documents that establish minimum PPE for related
hazard per specific task. All PPE used on the Port Arthur site must conform with
applicable ANSI and NFPA standards.
The BASF Port Arthur Site has an active Hazcom program managed by Site Procedure
PA-020-0022. In addition the Site has developed additional BFLP and Sabina HAZCOM
Tables that provide hazard information related to on-site process chemicals in a format
that details chemical type, area and equipment specific locations, physical hazards and
target organ health hazards.
Revision 00
(3)-5.2 EHS Manual
4.6. Environmental
BFLP / Sabina TCEQ Permit Requirements
Air Emissions - Maintenance Start-up and Shutdown (MSS) – Process Equipment or

Systems In VOC Service: De-pressuring, emptying, and/or degassing” required LEL
readings of each system will be documented on the clearing logs in each
decommissioning package.
NOTE: The Clearing logs MUST be returned to the Environmental TAR Specialist (Mark
Screen) with-in 30 days of turnaround completion.
The process equipment or systems, in VOC service, shall be depressurized to a control

device or a controlled recovery system prior to venting to atmosphere, degassing, or
draining liquid.
• If mixed phase materials must be removed from process equipment, the cleared
material shall be routed to a knockout drum or equivalent to allow for managed initial
phase separation. Control must remain in place until degassing has been completed or
the system is no longer vented to atmosphere.
• All liquids from process equipment or storage vessels must be removed to the
maximum extent practical prior to opening equipment to commence degassing and/or
maintenance. Liquids must be drained into a closed vessel unless prevented by the
physical configuration of the equipment. If it is necessary to drain liquid into an open
pan or sump, the liquid must be covered or transferred to a covered vessel within one
hour of being drained.
• Facilities/Systems shall be degassed using good engineering practice to ensure air
contaminants are removed from the system through the control device or controlled
recovery system to the extent allowed by process equipment or storage vessel design.
The facilities/systems to be degassed shall not be vented directly to atmosphere,
except as necessary to establish isolation of the work area (blinding) or to monitor
VOC concentration following controlled depressurization. The venting shall be
minimized to the maximum extent practicable and actions taken recorded.
• The facilities/systems being prepared for maintenance shall not be vented directly to
atmosphere until the VOC concentration has been verified to be less than 1 percent of
the lower explosive limit (LEL) per the site safety procedures.
• If the process equipment/system is purged with a gas, two system volumes of purge
gas must have passed through the control device or controlled recovery system before
the vent stream may be sampled to verify acceptable VOC concentration prior to
uncontrolled venting. The sampling point shall be upstream of the inlet to the control
device or controlled recovery system. The sample ports and the collection system
must be designed and operated such that there is no air leakage into the sample probe
or the collection system downstream of the process equipment or vessel being purged.
If there is not a connection (such as a sample, vent, or drain valve) available from
which a representative sample may be obtained, a sample may be taken upon entry
into the system after degassing has been completed. The sample shall be taken from
inside the vessel so as to minimize any air or dilution from the entry point. The
facilities shall be degassed to a control device or controlled recovery system until the
Revision 00
(3)-5.2 EHS Manual
VOC concentration is less than 10,000 ppmv or 1 percent of the LEL. Documented
site procedures used to de-inventory equipment to a control device for safety purposes
(i.e., hot work or vessel entry procedures) that achieve at least the same level of
purging may be used in lieu of the above.
Sampling Method Requirements (Method 21 & LEL)

• Air contaminant concentration shall be measured using an instrument/detector meeting
one set of requirements specified below. (3/11) The following method is the same
method our LDAR contractor utilized for fugitive emissions monitoring.
• VOC concentration shall be measured using an instrument meeting all the
requirements specified in EPA Method 21 (40 CFR 60, Appendix A) with the following
exceptions:
• The instrument shall be calibrated within 24 hours of use with a calibration gas such
that the response factor (RF) of the VOC (or mixture of VOCs) to be monitored shall be
less than 2.0. The calibration gas and the gas to be measured, and its approximate
(RF) shall be recorded. If the RF of the VOC (or mixture of VOCs) to be monitored is
greater than 2.0, the VOC concentration shall be determined as follows: VOC
Concentration = Concentration as read from the instrument*RF
• Sampling shall be performed as directed by this permit in lieu of section 8.3 of Method
21. During sampling, data recording shall not begin until after two times the instrument
response time. The date and time shall be recorded, and VOC concentration shall be
monitored for at least 5 minutes, recording VOC concentration each minute. The
highest measured VOC concentration shall not exceed the specified VOC
concentration limit prior to uncontrolled venting.
Lower Explosive Limit Measured with a Lower Explosive Limit Detector.

• The detector shall be calibrated monthly with a certified pentane gas standard at 25%
of the lower explosive limit (LEL) for pentane. Records of the calibration date/time and
calibration result (pass/fail) shall be maintained.
• A daily functionality test shall be performed on each detector using the same certified
gas standard used for calibration. The LEL monitor shall read no lower than 90% of
the calibration gas certified value. Records, including the date/time and test results,
shall be maintained.
• A certified methane gas standard equivalent to 25% of the LEL for pentane may be
used for calibration and functionality tests provided that the LEL response is within
95% of that for pentane.
The BASF Port Arthur Facility has developed a specific site EHS procedure to ensure all
requirements for de-pressuring, emptying, and/or degassing VOC process equipment /
systems will be constantly followed to ensure compliance with TCEQ air permit
requirements. Refer to PA-031-0006 VOC Pressure Equipment Clearing, Cleaning and
Routine Maintenance for more detailed information.
Revision 00
(3)-5.2 EHS Manual
REQUIRED DOCUMENTATION FOR VOC Equipment

Clearing & Cleaning Requirements
08/25/2011
Is equipment to NO Equipment clearing form
be cleared in VOC
does not apply.
service?
YES
Equipment clearing form

needs to be filled out.
[MIP generated]
Clear to flare until

NO
Are you going Complete equipment clearing form
<1.0% LEL YES
to isolate equipment & place in box in permit room.
&
by installing a blind? NOTE: NO deviation has occurred
<5.0 ppm BD / BZ
YES NO
Decision made to open

equipment to atmosphere
Complete equipment clearing form & above acceptable limits,
place in box in permit room. >1.0% LEL
or
>5.0 ppm BD / BZ
Complete form include

how long equipment
was purged / leaked to
atmosphere.
Create and submit an

Environmental AIMS report.
Incident Classification:
Permit / Regulatory Deviation
Open-Ended Lines (OEL) In VOC Service – Applicable TAR OELs will be identified
before the TAR utilizing operations planner P&ID. The OELs requirement monitoring will
be those components documented as being tagged open, not double blocked or blinded,
and adjacent to equipment/systems not yet cleared to 1% LEL. These components will be
monitored by the onsite LDAR contractor per MSS requirements.
Revision 00
(3)-5.2 EHS Manual
• Each open-ended valve or line resulting from a plant or unit turnaround shall meet the
following requirements
A. The plant or unit system(s) shall be isolated from feedstock sources using blind
flanges to prevent potential feedstock leakage into the plant or unit(s).
B. The open-ended valve or line shall be monitored once by the end of the 120 hour
period following the creation of the open ended line with an approved gas analyzer
and the results recorded. Leaks are indicated by readings of 500 ppmv.
C. If a leaking isolation valve is discovered on a flanged line, the leak must be
repaired within 24 hours or a cap, blind flange, plug, or second valve must be
installed on the line or valve. Alternatively, within 24 hours, the adjacent unit
system may be cleared to a control device so that the VOC concentration in the
adjacent system is less 1% of the LEL.
If a leaking isolation valve is discovered on a welded line the adjacent unit system shall be
cleared to a control device so that the VOC concentration within the system is less 1% of
the LEL. This clearing shall be completed within 20 days of the leak discovery.
Vacuum Truck Requirements – All vacuum trucks utilized during the TAR are to be
equipped with an MSS compliant control device/scrubber recovery system. The vendors
are required to comply with MSS Vacuum Truck requirements per their company
procedures.
NOTE: Required recordkeeping should be turned into TAR Environmental Specialist, Mark
Screen, x5033 at the end of each day shift.
The following requirements apply to vacuum and air mover tank operations to support
planned MSS at the Port Arthur site:
A. Vacuum pumps and blowers shall not be operated on trucks containing or
vacuuming liquids with VOC partial pressure greater than 0.50 psi at 95oF unless
the vacuum/blower exhaust is routed to a control device or a controlled recovery
system.
B. Equip fill line intake with a “duckbill” or equivalent attachment if the hose end
cannot be submerged in the liquid being collected.
C. A daily record containing the information identified below is required for each
vacuum truck in operation at the site each day.
1. Prior to initial use, identify any liquid in the truck. Record the liquid level and
document that the VOC partial pressure is less than 0.50 psi if the vacuum
exhaust is not routed to a control device or a controlled recovery system. After
each liquid transfer, identify the liquid transferred and document that the VOC
partial pressure is less than 0.50 psi if the vacuum exhaust is not routed to a
control device or a controlled recovery system.
2. For each liquid transfer made with the vacuum operating, record the duration of
any periods when air may have been entrained with the liquid transfer. The
reason for operating this manner and whether the “duckbill” or equivalent was
used shall be recorded. Short, incidental periods, such as those necessary to
walk from the truck to the fill line intake, do not need to be documented.
Revision 00
(3)-5.2 EHS Manual
3. If the vacuum truck exhaust is controlled with a control device other than an
engine or oxidizer, VOC exhaust concentration upon commencing each
transfer, at the end of each transfer, and at least every hour during each
transfer shall be recorded, measured using an instrument meeting the
requirements of Special Condition 35. A or B.
4. The volume in the vacuum truck at the end of the day, or the volume unloaded,
as applicable.
D. The permit holder shall determine the vacuum truck emissions each month using
the daily vacuum truck records and the calculation methods utilized in the permit
application. If records of the volume of liquid transferred for each pick-up are not
maintained, the emissions shall be determined using the physical properties of the
liquid vacuumed with the greatest potential emissions. Rolling 12 month vacuum
truck emissions shall also be determined on a monthly basis.
E. If the VOC partial pressure of all the liquids vacuumed into the truck is less than
0.10 psi, this shall be recorded when the truck is unloaded or leaves the plant site
and the emissions may be estimated as the maximum potential to emit for a truck
in that service as documented in the permit application. The recordkeeping
requirements in Special Condition 37.A through 37.D do not apply.
Frac Tanks
This permit authorizes emissions from the following temporary facilities used to support
planned MSS activities at permanent site facilities: frac tanks, containers, vacuum trucks
and portable devices identified in Special Condition 41. Emissions from temporary
facilities are authorized provided the temporary facility:
A. does not remain on the plant site for more than 12 consecutive months;
B. is used solely to support planned MSS activities at the permanent site facilities; and
C. does not operate as a replacement for an existing authorized facility.
The following requirements apply to frac, or temporary, tanks and vessels used in support
of MSS activities.
A. The exterior surfaces of these tanks/vessels that are exposed to the sun shall be white
or aluminum effective May 1, 2013. This requirement does not apply to tanks/vessels
that only vent to atmosphere when being filled.
B. These tanks/vessels must be covered and equipped with fill pipes that discharge within
6 inches of the tank/vessel bottom.
C. These requirements do not apply to vessels storing less than 100 gallons of liquid that
are closed such that the vessel does not vent to atmosphere.
D. The permit holder shall maintain an emissions record which includes calculated
emissions of VOC from all frac tanks during the previous calendar month and the past
consecutive 12-month period. The record shall include tank identification number,
dates put into and removed from service, control method used, tank capacity and
volume of liquid stored in gallons, name of the material stored, VOC molecular weight,
and VOC partial pressure at the estimated monthly average material temperature in
psia. Filling emissions for tanks shall be calculated using the TCEQ publication titled
“Technical Guidance Package for Chemical Sources - Loading Operations” and
Revision 00
(3)-5.2 EHS Manual
standing emissions determined using: the TCEQ publication titled “Technical Guidance
Package for Chemical Sources - Storage Tanks.”
E. If the tank/vessel is used to store liquid with VOC partial pressure less than 0.10 psi at
95oF, records may be limited to the days the tank is in service and the liquid stored.
Emissions may be estimated based upon the potential to emit as identified in the
permit applications.
Requirements for the use of Carbon Canisters, Plant Flare Systems – The Port Arthur
Site LDAR contractor will be responsible for the following TAR Carbon Canister
requirements.
NOTE: Required recordkeeping should be turned into TAR Environmental Specialist, Mark
Screen, x5033 at the end of each day shift.
Control devices required by this permit for emissions from planned MSS activities are
limited to those types identified in this condition. Control devices shall be operated with no
visible emissions except periods not to exceed a total of five minutes during any two
consecutive hours. Each device used must meet all the requirements identified for that
type of control device.
Controlled recovery systems identified in this permit shall be directed to an operating

facility process or to a collection system that is vented through a control device meeting
the requirements of this permit condition.
Carbon Adsorption System (CAS)

1. The CAS shall consist of 2 carbon canisters in series with adequate carbon supply for
the emission control operation.
2. The CAS shall be sampled down stream of the first can and the concentration
recorded at least once every hour of CAS run time to determine breakthrough of the
VOC. The sampling frequency may be extended using either of the following methods:
a. It may be extended to up to 30 percent of the minimum potential saturation time for
a new can of carbon. The permit holder shall maintain records including the
calculations performed to determine the minimum saturation time.
b. The carbon sampling frequency may be extended to longer periods based on
previous experience with carbon control of a MSS waste gas stream. The past
experience must be with the same VOC, type of facility, and MSS activity. The
basis for the sampling frequency shall be recorded. If the VOC concentration on
the initial sample downstream of the first carbon canister following a new polishing
canister being put in place is greater than 100 ppmv above background, it shall be
assumed that breakthrough occurred while that canister functioned as the final
polishing canister and a permit deviation shall be recorded.
3. The method of VOC sampling and analysis shall be by detector meeting the
requirements of Special Conditions 35A. or B.
4. Breakthrough is defined as the highest measured VOC concentration at or exceeding
100 ppmv above background. When the condition of breakthrough of VOC from the
initial saturation canister occurs, the waste gas flow shall be switched to the second
canister and a fresh canister shall be placed as the new final polishing canister within
Revision 00
(3)-5.2 EHS Manual
four hours. Sufficient new activated carbon canisters shall be maintained at the site to
replace spent carbon canisters such that replacements can be done in the above
specified time frame.
5. Records of CAS monitoring shall include the following:
a. Sample time and date.
b. Monitoring results (ppmv)
c. Canister replacement log
6. Single canister systems are allowed if the time the carbon canister is in service is
limited to no more than 30% of the minimum potential saturation time. The permit
holder shall maintain records for these systems, including the calculations performed
to determine the saturation time. The time limit on carbon canister service shall be
recorded and the expiration date attached to the carbon can.
The Plant Flare Systems

The heating value and velocity requirements in 40 CFR 60.18 (300 Btu rule) shall be
satisfied during operations authorized by this permit. Two innovative solutions will be
applied to maintaining required BTU value during the TAR:
• C4 LP/HP flares will be cleared with methane in order to be taken completely out of
service. Methane is not considered an air permit VOC and does not require 300 Btu.
Propane assist can be added to the BFLP flare is required.
• The flare shall be operated with a flame present at all times and/or have a constant
pilot flame. The pilot flame shall be continuously monitored by a thermocouple or an
infrared monitor. The time, date, and duration of any loss of pilot flame shall be
recorded. Each monitoring device shall be accurate to, and shall be calibrated at a
frequency in accordance with, the manufacturer’s specifications.
• The permit holder shall comply with Special Condition No. 13.B-E at all times,
including while venting emissions from MSS activities to the flares.
Spill Prevention, Control, and Countermeasures Plan

Federal regulations require the preparation and implementation of a Spill Prevention
Control and Countermeasure (SPCC) Plan for all non-transportation related facilities that
have the potential to discharge oil or oil-related substances to the navigable waters of the
United States or adjoining shorelines.
In summary, the plan will need to be consulted for any additional oil and fuel storage or
equipment that contains 55 gallons or greater. Contractors should provide their own
containment which will hold the amount of the tank plus the appropriate freeboard for
rainfall. Inspections are required before containment is released to grade. However, if
containments are handled via vacuum trucks, NO inspections are required.
For more detailed information regarding 2012 TAR SPCC requirements reference the
BASF Port Arthur Spill Prevention Control and Countermeasures Plan .
Revision 00
(3)-5.2 EHS Manual
Storm Water Pollution Prevention Plan

The Storm water Pollution Prevention Plan (SWP3) identifies potential sources of storm
water contamination, corresponding best management practices (BMPs) and good
housekeeping practices, and spill prevention procedures intended to minimize the
potential pollution of storm water.
This plan requires updating for any new lay down areas planned for the TAR. Some
inspections may be necessary.
For more detailed information regarding 2012 TAR SWP3 requirements reference the
BASF Port Arthur Stormwater Pollution Prevention Plan
Waste Management
Accumulation, monitoring/sampling, transporting and disposal of hazardous aqueous /
solid waste, non-hazardous, universal, general non-recyclable waste, empty containers,
salvaged equipment and recyclable material generated throughout the site (BFLP Cracker
& Sabina C4) during 2012 turnaround will be managed per site procedures;
• PA-TAR-0003 Management and Handling of TAR Incidental Waste
• PA-033-0002 Source Reduction and Waste Minimization Plan
• PA-033-0003 Site Recycling Program
• PA-033-0005 Waste Management Plan
• PA-033-0006 Hazardous Waste Training Plan
• PA-033-0008 Management of Empty Containers
• PA-033-0010 PA Salvaged Equipment and Materials
• PA-033-0011 Universal Waste
4.7. Training
The training objective is to ensure that key personnel have knowledge to lead and follow-
up all EHS activities required for a successful Turnaround.
• Inform all involved TAR Stakeholders of the safety rules for the 2012 Turnaround
• Establish a good working knowledge base for TAR Area Management Team(s) to
facilitate resolution of EHS issues during the TAR.
2012 TAR Execution Origination Training Schedule

• BASF Operations / Maintenance, MGM Elegante’ Hotel (Fountain View room),
Beaumont, Texas
o January 18, 2012
o February 1, 2012
• General Contractor Management, Supervision and EHS Personnel
o Before March 15, 2012
• Specific training for LEL Monitoring Equipment Usage will be required for all LEL
monitoring equipment users. Approved BASF Port Arthur Site training material will be
provided by BASF EHS Department.
Revision 00
(3)-5.2 EHS Manual
Contractor Required Safety Training

Port Arthur contractor safety training will be facilitated by the local area Industrial Safety
Training Council (ISTC). Contractor personnel must schedule and successfully
demonstrate skills of ISTC safety training courses (Basis Plus and BASF Port Arthur Site
specific training) in addition to Security Background screening and SSN verification.
ISTC Nederland location and contact info:

324 Hwy 69, Nederland, Texas 77627,
Ph. 409.724.2565 - Fax 409.724.2671,
6:30am to 4:00pm M-F
I.S.T.C Required Contractor Training Courses

Basic Orientation Plus)
Section 1 Purpose and scope of course
Section 2 Introduction to Basic Orientation Plus
Introduce and View “General Safety” Video
Review Course Topics
Owner Responsibilities
Employer Responsibilities
Employee Responsibilities
Problems and Doubts (Asking Questions)
Section 3 Hazard Communications
Introduce and View “Hazardous Communications” Video
Describe the “Right to Know” Law Under OSHA Regulations
Define Hazardous Material
Define Physical Hazards
Examples of Health Hazards
Describe the NFPA and HMIS Methods of Labeling
Discuss Marking and Labeling for Hazardous Materials
Describe Methods of Recognizing Hazards
Explain Material Safety Data Sheets (MSDS’s)
Section 4 Personal Protective Equipment
Introduce and View “Personal Protective Equipment” Video
Controlling Hazards
Assessment and Selection
Selection and Fitting Guidelines
Devices and Adjustable Features
Recognition of Hazards
Cleaning and Maintenance
Section 5 Respiratory Protection
Introduce and View “Respiratory Protection” Video
OSHA and NIOSH requirements
Respiratory Hazards
Types/Fitting of Respirators
Revision 00
(3)-5.2 EHS Manual
BASF Port Arthur Site Specific

Section 1 Hazard Communications
Right to Know
MSDS’s
Section 2 Process Overview
Hot Section
Cold Section
Utility Section
Pygas Section
C4 Plant
Section 3 General Work Procedures
Drug/Alcohol Free
No Firearms/Weapons Allowed
Intrinsically Safe Pagers/Radios
No Cell Phones Allowed
No Lighters/Matches Allowed
Expect a Clean/Orderly Work Site
No Horseplay/Fighting
Section 4 Entering the Facility
Badge System
Seat Belts
No Riding in Back of Trucks
Logo Needed on Non-BASF Vehicles
Site Contacts
14.5 MPH Speed Limit
Subject to Personal and Vehicle Searches
Section 5 PPE
Minimal PPE
PPE in Process Areas
No Facial Hair if Using SCBA or Breathing Air
Section 6 Emergency Procedures
Dial X5294 or X5555
Assembly Points (A- Gate 99, B- South of West Rd., C- South of East Rd.,
F- North Side 907 rack in C4 Complex)
Unit Emergency
Seek Shelter
Evacuate
All Clear
Work Crew Supervisors to account for all their workers and report
Alarm Test Each Monday at Noon
Safety Showers/Eye Wash Stations
Site Emergency Response Teams (Fire/Rescue/Medical)
Revision 00
(3)-5.2 EHS Manual
Section 7 Permits
Safe Work
Hot Work
Confined Space
Vehicle Entry
Excavation
Section 8 Lock/Tag/Try
Use of Locks and Tags Required
No Plant/Instrument Air to be used as Breathing Air or in Confined Spaces
to Power Air Tools
Section 9 Tools and Equipment
Only Qualified People to Use Specialized Tools
Employee Responsibility
Utility Hoses and Proper Use
Ladder Safety
Section 10 LEL Monitoring Equipment Usage
Closing
Each Employee is Responsible for Safety
Violation of Safety Rules is Grounds for Dismissal/Removal
Test for competency of all 10 site specific sections
….
5. Consumable and Equipment Management
5.1. EHS Consumables

This class includes all health and safety material/supplies: Hardhats, earplugs, safety
glasses, gloves, face/body protection, etc.
PPE Issuance for BASF Personnel and Nester Contractors

No expected change to availability or location during the 2012 Turnaround. Safety
equipment/material will be issued to BASF plant operations, maintenance, and Nester
Contractors from the onsite safety Warehouse which is managed by Hagemeyer.
PPE Issuance for TAR Contractors

Per contract agreement each General Contractor and their sub-contractor companies will
provide their own personal protective equipment during the 2012 TAR. Specialty PPE for
chemical, flammability, extreme thermal protection as identified on site PPE charts will be
provided by BASF and made available through a third party provider (Hagemeyer).
5.2. EHS Equipment

Breathing air equipment, fall protection, gas detection, explosion proof lighting.
A third party provider (Hagemeyer) has been contracted to provide General Contractor
and their sub-contractor companies personnel with this equipment.
Revision 00
(3)-5.2 EHS Manual
5.3. EHS Warehouse

The current Hagemeyer Safety Warehouse will stock and distribute all safety supplies for
BASF Personnel and Nester Contractors.
6. Emergency Response
This plan details response actions for protecting the health and safety of BASF employees,
contractors and community members, as well as safeguarding the environment and property. Port
Arthur Site designates all of the process and mechanical equipment, as well as the buildings and
property associated with the BASF FINA Cracker and the BASF FINA Sabina units. The Plan
addresses the following emergencies:
• Chemical spills or other releases to the environment
• Toxic/flammable vapor or gas releases
• Fires and explosions
• Medical Emergencies
• Emergencies at TOTAL Refinery that may affect the Port Arthur Site
Reporting Emergencies
• Call Control Room @ ext. 5555
• Call Security @ ext. 5294
• Contact Shift Coordinator on Radio channel A-13
• Contact Site Safety on radio Channel C-1
When reporting an emergency, remain calm and speak clearly / slowly and communicate the
following information:
• Where the emergency is occurring
• The nature of the emergency i.e. fire, gas release, medical, etc.
• The name and company of the person reporting the emergency.
For detailed Emergency Response resources and their capabilities refer to the Port Arthur Site’s
Emergency Response Plan.
The Port Arthur Site Emergency Response Plan satisfies the requirements of the following
Federal Regulations with regard to the development of emergency response plans:
• 29 CFR 1910.38 – Emergency Action Plans
• 29 CFR 1910.119 – Process Safety Management
• 29 CFR 1910.120 – Hazardous Waste Operations. and Emergency Response.
Revision 00
(3)-5.2 EHS Manual
6.1. On-site/Off-site Response Units
Emergency Responders
BASF FINA & SABINA will operate and maintain an around the clock on shift Emergency
Response Team (ERT). This ERT will be trained as an Advanced Industrial Exterior
Structural Fire Brigade and as a site specific Hazardous Material Technician Team to
address fires, and the release of flammable materials and or site specific hazardous
chemicals. ERT volunteers will also be trained in High Angle - Confined Space Rescue
and as a Medical First Responder.
Fire Brigade
All Fire Brigade members receive quarterly training and are mandated to attend Annual
Live Fire training at the Beaumont (previous Lamar University) Fire Training Grounds or
other comparable live fire training facilities.
Hazmat
Site personnel required to respond to hazardous materials releases are trained to the
“Technician Level” as designated by 29 CFR 1910.120 (HAZWOPER) Standard and to
meet BASF “ER Advisory Alert 1”. Mandated annual refresher training is conducted by a
BASF certified vendor to meet the ER Alert 1 competencies.
NOTE: For a more detailed description and requirements of the Port Arthur Detailed
Emergency Response Hazmat Procedure see Appendix E of the Site’s Emergency
Response Plan.
High Angle & Confined Space Rescue

The Site Rescue Team is comprised of volunteer personnel trained to respond to High
Angle and/or Confined Space rescue situations. Personnel receive an initial 40-hour Basic
initial class, which is supplemented by quarterly training classes to help maintain skills and
proficiency.
Written Rescue Pre-plans for Confined Space Entries are in place and required to be
reviewed before each initial CSE begins. A copy of Rescue Pre-plan will be provided to
contractors as part of a CSE safe work permit.
Medical Response
The Site 1st Responder Medical Response Team is comprised of volunteer personnel who
are trained to a 1st Responder level. Personnel receive an initial 40 hours Basic class,
which is supplemented by quarterly training classes to help maintain skills and proficiency.
1st Responder personnel are on each shift such that qualified emergency medical care is
available on a 24-hour basis. The on shift response of Medical 1st Responder personnel
will be in such a manner as to render initial First Aid services for minor and severe injuries.
The on site medical equipment used for all medical responses will be kept in the Rescue
Vehicle. The Rescue Vehicle may be used for a medical response call.. Also a shift
medical jump bag and Life Pak 500 AED will supplement this equipment. In Addition to the
Revision 00
(3)-5.2 EHS Manual
BASF Corporate Medical Treatment Protocols, information supplied by material safety

data sheets will be used to treat patients.
In addition to Site 1st Responder Medical Response Team a contracted medical response
unit (Accadian Ambulance Service) will be on-site to provide assitance for immediate
medical care. BASF Site 1st Responder Medical Response Team will be intial primary
responder in the event of a medical response call. Accadian Ambulance Service will
respond when requested by BASF. Accadian Medical Technicans may assist with non
response occuaptional medical needs (minor cuts, scraps, flushing/washing, band-aid
application, over-counter treatment, etc..) for BASF and contractor personnel.
NOTE: For a more detailed description and requirements of the Port Arthur Detailed
Medical Response Procedure see Port Arthur 2012 BFLP & Sabina Turnaround Additional
On-Site Medical Response Support and Appendix D of the Site’s Emergency Response
Plan and PA-021MD-0002 Medical 1st Responder Quality Assurance/Quality
Improvement Program
Mutual Aid
PA-021-0006
Mutual aid agreement between BASF FINA Petrochemicals LP / Sabina Petrochemicals
LLC Facility (BASF-PA) and the Sabine Neches Chief’s Association. The procedure details
what assistance will be offered and what assistance will be expected in the event of an
emergency. This agreement will be implemented during any mutual aid emergency which
requires a response of additional personnel and or equipment at the request of SNCA.
PA-021-0009
Mutual aid response agreement between BASF Port Arthur (BASF – PA) and TOTAL
Refinery as to what assistance will be offered in the event of an emergency. This
agreement will be implemented during any minor emergency which requires a quick
response of additional personnel and or equipment, but does not necessitate a call to the
Sabine Neches Chiefs Association.
6.2. Alarm and Evacuation Plan

Emergency horns are tested each Monday at 12:00 noon, with the ALL CLEAR signal
given first and last in the cycle. In the event of a unit/plant upset condition reaches the
level site personnel need to be notified so appropriate actions by all will commence the
site’s Emergency Alarm System will be activated.
All personnel on the site must go to a designated shelter or evacuate to an assembly area,
according to the Unit Emergency Plan.
If operating a motor vehicle in an area where an emergency signal is sounding, stop the
vehicle, shut off the engine, leaving keys in ignition and proceed to an assembly area on
foot. Be prepared to evacuate the area if necessary.
When evacuating an area, move crosswind or upwind from the affected area. Do not drive
into an area downwind of a gas release. Follow all instructions given by BASF personnel.
Revision 00
(3)-5.2 EHS Manual
Emergency Alarms
U – Unit Emergency = 1 Blast
S – Seek Shelter = 2 Blasts
E – Evacuate Site = 3 Blasts
Assembly Areas
There are four assembly points at the Port Arthur site all are equipped with an electronic
reader to scan BASF Employee/Contractor badges for Accountability/Head Count.
• Assembly Area – A: Gate 99, West side of Security Command Center
• Assembly Area – B: South/West end of the site (near Fire Water Pumps)
• Assembly Area – C: South Gate to Hwy 87 exit (near Fire House)
• Assembly Area – F: Northeast corner of C4 complex, where 907 Rack enters TOTAL
Gas Release Shelters for “Shelter-In-Place”

There are six shelter in place buildings at the Port Arthur site all are equipped with an
electronic reader to scan BASF Employee/Contractor badges for Accountability/Head
Count.
• Administration Building
• Maintenance Building Lunch Room
• Maintenance Trailer/Offices West
• Control Room Hallway in front of Conference Room
• Security Command Center
• Gate 103 Trailers
EVACUATION Muster Points”

• Gate 103 (West side of Trailer/Do Not Stay inside Trailers)
• AA Storage (Old Wal-Mart Via Hwy 87)
• 32nd St. (Walk inside fenced area or side of Hwy 366)
• Hwy 87 Crossover (By Fruit Stand)
• TOTAL (To 17th St. Via Assembly Area “F” Gate)
See BASF map for exact location.

Port Arthur Site Emergency Shelter / Assembly / Evacuation Locations
Page 66 of 77
Issue January, 2012
Revision 00
Revision 00
(3)-5.2 EHS Manual
Site Emergency Alarm and Instruction Codes

The Port Arthur Site employee alarm system is comprised of four different emergency
notification alarms. Each alarm consists of a series of ‘blasts’ followed by a message. The
site also utilizes a Radio ALL CALL notification system to make an announcement of the
situation and state the proper response action. The acronym “USE” is a training tool to
help personnel remember site alarms.
I. Unit Emergency - One steady Blast

Description:
• Blast, “Unit Emergency”, Blast (repeated)
Note: This alarm is also used in a Rescue emergency situation to ensure ALL other
on-going Confined Space Permits are cancelled and personnel know to exit the
space and report to an Assembly Area.
Actions:
• All permits are cancelled.
• Smoking in the plant is prohibited
• Security will close the gate to the site
• All plant vehicle traffic is stopped
• Building Warden, or person assuming duties (PAD) in each Gas Release Shelter
are to report to their station for a Headcount and to follow the posted instructions
• All non-essential personnel in the field will exit the operating areas of the plant via
an up/crosswind route and report to the nearest and most appropriate Assembly
Area
• All individuals upon arrival at a designated Assembly Area will scan their ID badge
for head count purposes and follow posted instructions
• ALL personnel NOT in a designated Gas Release Shelter WILL report (up/cross
wind) to a safe Assembly Area (A – B – C- F), scan their badge and wait for further
instructions. DO NOT enter process areas until permission is given by IC or ALL
CLEAR is sounded.
• For Personnel sheltering in one of the six designated buildings and reporting
directly to a Building Warden, or person assuming duties (PAD); Once reporting in
DO NOT go back to your workstation, stay at or near the badge scanning location
until released by the IC or the ALL CLEAR. If you sheltering in the control room
building DO NOT go into the Process Console area.
Communications:
• Operations will broadcast an announcement over the alarm system P.A. with the
o The area and equipment experiencing the emergency.
o The nature of unit emergency or rescue response activity.
• Follow up information will be communicated from Operations as instructed by the
Incident Commander when required.
Revision 00
(3)-5.2 EHS Manual
II. Seek Shelter – Two steady Blasts)

Description:
• Blast – Blast, “Seek shelter”, Blast – Blast (repeated)
Actions:
• All permits are cancelled.
• Security will close the gate to the site
• Building Warden, or person assuming duties (PAD) in each Gas Release Shelter
are to report to their station for a Headcount and to follow the posted instructions
• All non-essential personnel in the field will exit the operating areas of the plant via
an up/crosswind route and report to the nearest and most appropriate Assembly
Area
• All individuals upon arrival at a designated Assembly Area will scan their ID badge
for head count purposes and follow posted instructions
• ALL personnel NOT in a designated Gas Release Shelter WILL report (up/cross
wind) to a safe Assembly Area (A – B – C- F), scan their badge and MUST
EVACUATE the site to a SAFE / designated Muster Point (Gate 103 – Westside of
Trailer/Do Not Stay inside Trailers, Hwy 87 Crossover by Fruit Stand, TOTAL
Refinery to 17th St.).
• For Personnel sheltering in one of the six designated buildings and reporting
directly to a Building Warden, or person assuming duties (PAD); Once reporting in
DO NOT go back to your workstation, stay at or near the badge scanning location
until released by the IC or the ALL CLEAR. If you sheltering in the control room
building DO NOT go into the Process Console area.
Communications:
• Operations will broadcast an announcement over the alarm system P.A. with the
o The area and equipment experiencing the emergency.
o The nature of the emergency: fire, gas release, spill, etc.
o The known product/chemical involved
• Follow up information will be communicated from Operations as instructed by the
Incident Commander when required.
III. Evacuation of Site - Three steady Blast

Description
• Blast, blast, blast, “Evacuate the Site, blast, blast, blast (repeat)
Action:
• All permits are cancelled
• Security will OPEN Electronic Fence gate to the site/Traffic Swing Arm Gate to
remain CLOSED
• All personnel will report to the nearest Assembly Areas for site evacuation.
Revision 00
(3)-5.2 EHS Manual
• Personnel evacuating the site will meet at the designated Muster Points and notify
Security of their destination:
o Gate 103 (West side of Trailer/Do Not Stay inside Trailers)
o AA Storage (Old Wal-Mart Via Hwy 87)
o 32nd St. (Walk inside fenced area or side of Hwy 366)
o Hwy 87 Crossover (By Fruit Stand)
o TOTAL (To 17th St. Via Assembly Area “F” Gate)
• Upon reaching the Muster Point, personnel are to seek out a Building Warden (or
PAD) and organize for a head count and remain until the ‘All Clear’
Communications:
• Operations will provide further information via site radios Channel
IV. All Clear

Description:
• Long blast, “all clear” long blast (repeat)
Action:
• Emergency situation is over and all personnel may return to their work area.
• DO NOT assume the previous work permit is still valid.
• All suspended/interrupted work permits must be revalidated by Owning/Operating
Department before maintenance activity may begin.
• Security will open access to the site.
For detailed description of the site’s alarm systems and required actions for Emergency
Response and non-response personnel see Port Arthur Site’s Emergency Response Plan.
6.3. Installed Safety Devices
BFLP Cracker
Fixed systems – Safety Systems Manual describes in detail the operational functions of
these systems:
Fire and Gas Panel
 Combustible Gas Detectors (Including Benzene)
 H2S Detectors and NH3 Detectors
 O2 Detectors and CO Detectors
Fire Water Systems
 Fire-water Supply and Distribution
 Monitors and Hydrants
 Deluge Systems
Portable Fire Fighting Equipment
 Extinguishers
 Other Equipment
Fire Suppression Systems
 FM-200 System
 O2 System
Steam Curtain
Building HVAC Systems
Revision 00
(3)-5.2 EHS Manual
Safety Showers/Eyewash Stations

Emergency Shut Down System (ESD)
Quick Isolation and Shutdown System (QISS)
Employee Evacuation System
Chemical Mixing Matrix
Uninterruptible Power Supply (UPS)
Temporary / Portable systems

Usage and location of area portable atmospheric monitoring equipment that is intended to
help provide early detection of flammable and VOC vapors will be evaluated by area
owner/operations. Minimum requirements for detection alarms will be field audio/visual
alerts, local and/or remote analyzer readout of detectable vapors.
Sabina C4
Fixed systems
Fire Water Systems
 Fire-water Supply and Distribution
 Monitors and Hydrants
 Deluge Systems
Portable Fire Fighting Equipment
 Extinguishers
 Other Equipment
Fire Suppression Systems
 FM-200 System
 O2 System
Building HVAC Systems
Safety Showers/Eyewash Stations
Emergency Shut Down System (ESD)
Quick Isolation and Shutdown System (QISS)
Employee Evacuation System
Chemical Mixing Matrix
Uninterruptible Power Supply (UPS
Temporary / Portable systems

Usage and location of area portable atmospheric monitoring equipment that is intended to
help provide early detection of flammable and VOC vapors will be evaluated by area
owner/operator. Minimum requirements for detection alarms will be field audio/visual
alerts, local and/or remote analyzer readout of detectable vapors.
Revision 00
(3)-5.2 EHS Manual
7. Contractor Management
7.1. EHS Aspects for Contracting Strategy

N/A – same as section 7.2.
7.2. Selection of Contractors

All Contractor/Agency companies that are requesting to provide services to the BASF Port
Arthur Facility and are intended to support the scheduled 2012 Turnaround will follow
these requirements:
A. Pacific Industrial Contractor Screening (PICS)
Per BASF Corporate Procedure BC032.002 section 4.1.1 #2 & 3 state: All BASF sites
shall use PICS to facilitate the EHS qualification process for a Contractor/Agency
covered under this procedure. Relevant documentation of the EHS contractor approval
shall be maintained in the PICS database. Contractor/Agency companies working at
BASF locations covered under this procedure are required to ensure that any
subcontractors are registered in PICS and meet the same EHS qualifications criteria.
NOTE: Ensure Contractor/Agency Company provides BFLP/Sabina Procurement
representative a list of intended Subcontractor Company(s).
See Special Considerations Requirements for BFLP/Sabina TAR Contractor / Agency

EHS and Procurement Table for Port Arthur Site and contractor company review and
approval.
G-P-ME-010 Annex 6.5 Issue November, 2011
Special Consideration Requirements for BFLP/Sabina TAR Contractor / Agency EHS and Procurement Table.
Contractor / Agency PICS Registration EHS Annual Review / Approval Procurement Requirements
Special Considerations
No licensed base of NO – PICS is currently not set NO - An acceptance of risk must be obtained Yes –All commercial requirements,
operations within the up to analyze and/or manage from SLT. including insurance, must be met by
geographical boundaries EHS PQF data generated contractor and approved by Procurement
or governing laws of the outside the United States and While on site all contractor personnel must be before contractor is allowed to perform
United States and Canada. accompanied by a BASF Representative at all services on site. Contact your site
Canada. times. purchasing rep. to obtain approval.
Small specialty services 1st Option – Assistance to help NOTE: PICS application, PQF review / Yes –All commercial requirements,
with limited resources contractor enroll and submit all verification process could take up to 4 weeks. including insurance, must be met by
and limited intended use required PICS information contractor and approved by Procurement
(one to two times a year) should strongly be considered. before contractor is allowed to perform
of on-site service. services on site. Contact your site
purchasing rep. to obtain approval.
2nd Option – If contractor N/A N/A
company chooses not to
register with PICS consider
other alternatives such as
finding a different service
provider.
3rd Option - If option #2 is not YES – The submitted PQF will be reviewed in- YES – All commercial requirements,
viable, contractor to submit house by EHS, same qualifying criteria as including insurance, must be met by
completed PQF form directly used in PICS approval must be followed. contractor and approved by Procurement
back to Port Arthur After verification and acceptance of EHS before contractor is allowed to perform
Procurement Rep. minimum criteria, submit approval request to services on site. Contact your site
Perry Guentzel or John Davis. purchasing rep. to obtain approval.
Revision 00
(3)-5.2 EHS Manual
7.3. EHS Performance of Contractor

Each Contractor company that participates in on-site maintenance activates during the
Turnaround will be evaluated daily through specific EHS performance indicators:
• TAR 2012 EHS objectives
• Accident and Incident Reports
• Contractor Supervision/Safety job site safe work requirement audits
• BASF EHS job site safe work requirement audits
• Participation in Daily EHS / Contractor Safety Meeting attendance
7.4. Contractors EHS Personnel

Each General Contractor Company and their Sub-contractors will provide on site Safety
Supervision at a 50:1 worker ratio. Specialty Contractor Companies will be evaluated for
job scope work hazard (High / Medium / Low) services to establish on site Safety
Supervision requirements.
Revision 00
(3)-5.2 EHS Manual
8. Port Arthur Site Environmental Health & Safety Procedures
8.1. Contractor Safety Manual

This manual contains the minimum rules and procedures for performance of work by
Contractor Companies, their employees and sub-contractors as required by the Port
Arthur Site of BASF Corporation. Topics include:
1. Responsibility for Safety 13. Electrical Work
2. Emergency Procedures 14. Barricades, Obstructions, Excavations,
3. First Aid/Injuries/Reports 15. Trenches and Blue/Yellow Flashing Lights
4. Individual Action 16. Hazardous Material and Chemical
Information
5. Personal Protection 17. Demolition or Modification
6. Fire Protection 18. Applicable Safety and Industrial Hygiene
Standards
7. Vehicles and Traffic 19. Rigging and Heavy Equipment Operation
8. Security 20. Hexavalent Chromium Cr(VI) Compliance
9. Machinery, Tools and 21. Metal Welding, Thermal Cutting and
Equipment Grinding
10. Ladders 22. Naturally Occurring Radioactive Material
(NORM)
11. Control of Hazardous Energy 23. Assembly-Evacuation Locations Map
Sources
12. Permits and Procedures 24. Electrical Work
BASF PA Contractor Safety Manual
8.2. Emergency Response Plan & Procedures

Port Arthur Emergency Response Plan
Appendix D – Detailed Medical Response Procedure
PA-021MD-0002 Medical 1st Responder Quality Assurance/Quality
Improvement Program
PA-021-0006 BASF FINA Petrochemicals LP Facility (BASF-PA) Mutual Aid
Response Guidelines with Sabine Neches Chief’s Association
PA-021-0009 BASF Port Arthur Inter-Company Mutual Aid Response
Guidelines with TOTAL
Port Arthur 2012 BFLP & Sabina Turnaround - Additional On-Site Medical
Response Support
Revision 00
(3)-5.2 EHS Manual
8.3. Health and Safety Procedure Table

PA-020-0001A Control of Hazardous Energy
PA-020-0002 Hot Work
PA-020-0003 Safework Permits
PA-020-0004 Confined Space Entry
PA-020-0005 Line Breaking
PA-020-0008 Accident Incident Investigations
PA-020-0009 Compressed Gas Cylinders
PA-020-0010 Fall Protection
PA-020-0011 Hearing Conservation
PA-020-0012 Use of Seal Plugs (Sewer Plugs)
PA-020-0013 Portable Ladders
PA-020-0014 Hot Tap and Stopple
PA-020-0015 Scaffolds
PA-020-0016 Respiratory Protection
PA-020-0017 Personal Protective Equipment
PA-020-0019 Excavation, Drilling and Pile Driving
PA-020-0020 Contractor Selection, Safety and Oversight
PA-020-0021 Naturally Occurring Radioactive Material (NORM)
PA-020-0022 Hazard Communication
PA-020-0023 Hoisting, Rigging and Critical Lifts
PA-020-0025 Benzene Exposure
PA-020-0026 General Rules
PA-020-0027 Procedure Deviation
PA-020-0028 Pre Startup Safety Review
PA-020-0029 Management of Change
PA-020-0030 Contact Lens Usage
PA-020-0033 Radiation Safety
PA-020-0034 Facility Siting
PA-020-0036 Port Arthur Exposure Control Plan
PA-020-0037 Camera Policy
PA-020-0038 Hose Applications
Revision 00
(3)-5.2 EHS Manual
PA-020-0039 Grounding & Bonding

PA-020-0041 Benzene Compliance
PA-020-0042 1,3-Butadiene Exposure
PA-020-0043 1,3-Butadiene Compliance
PA-020-0047 Hydrocarbon Material Handling
PA-020-0048 Temporary Connections in Liquefied Gas Service
PA-020-0050 Piping Tie-ins
PA-020-0052 Inert Confined Space Entry
PA-020-0053 Material Safety Datasheets(MSDS)
PA-020-0054_Falling_Object_Prevention
PA-020-0057 Powered Industrial Trucks
PA-020-0058 Powered Mobile Platforms
PA-020-0059 Hexavalent Chromium Compliance
PA-020-0060 Metal Welding, Thermal Cutting, Grinding
PA-020-0061 Heat Stress Awareness
PA-020-0063 Mandatory Medical Surveillance
8.4. Environmental Procedure / Plan Table

PA-031-0005 Leak Detection and Repair
PA-031-0006 VOC Process Equipment Clearing, Cleaning and Routine
Maintenance
PA-033-0002 Source Reduction and Waste Minimization Plan
PA-033-0003 Site Recycling Program
PA-033-0005 Waste Management Plan
PA-033-0006 Hazardous Waste Training Plan
PA-033-0008 Management of Empty Containers
PA-033-0010_PA Salvaged Equipment and Materials
PA-033-0011_Universal Waste
BASF Port Arthur Spill Prevention Control and Countermeasures Plan
BASF Port Arthur Stormwater Pollution Prevention Plan
Revision 00
(3)-5.2 EHS Manual
8.5. Other BASF Port Arthur Procedure / Plan Table

2012 TAR 2011 Hurricane Plan
2012 TAR Execution EHS Meeting Schedule
2012 TAR Industrial Hygiene Monitoring Schedule
2012 TAR Operations SW / HW / CSE Work Permit Approvers
2012 TAR Severe Weather Plan
PA-010-0012 Personal Vehicle Usage in the Plant
PA-010-0020 Notification of Absence and Tardiness
PA-P-EI-602 Elect Room Safe Work Permits
PA-P-ME-401 Pressure Tests for Integrity after Construction or Leaks after
Maintenance
PA-TAR12-0002 Managing System Isolation Devices (PSV’s and Valves) that
Must be Removed During TAR for Equipment Project Upgrades
PA-TAR12-0003 Management and Handling of 2012 TAR Incidental Wastes
Sabina C4 BD Tower Repack Hazard Assessment
C2 Splitter Re-tray Hazard Assessment
8.6. TAR EHS Forms Table

Daily Contractor Safety Meeting Agenda & Attendance Form
Daily Safety Field Audit Form
Daily EHS Summary Report Form

BFLP & Sabina Petrochemicals 2012 Turnaround EHS Manual

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

BFLP & Sabina Petrochemicals 2012 Turnaround EHS Manual

Încărcat de

Drepturi de autor:

Formate disponibile

BFLP & Sabina Petrochemicals

Preparer: Approver: Approver:

Document Revision Change Table

2. Risk Management Process

8. Port Arthur Environmental Health & Safety Procedures

During normal operation and prior to shutdown:

During the Shutdown the following activities will be carried out:

Expected number of personnel that will be involved in the Turnaround;

The Site’s approach to implementing these principles is as follows:

Juergen Fuchs John Lycan Brad Hopper Archie Myers

1. Organization, Coordination and Responsibility

EHS Turnaround Coordination

Port Arthur Site EHS Personnel

Safety, Environmental, and Emergency Response Coverage

Port Arthur EHS 2012 TAR Organization

TAR Director NTU

Site EHS Manager

TAR EHS Training

General Contractor On-site Leadership and EHS Personnel

JV Industrial Companies (JVIC)

Turner Industrial Group (TIG)

BASF Port Arthur On-site EHS & Contractor Contact List

1.2. EHS Communication, Jour Fix

1.3. EHS Documentation

1.4. Incident and Accident Analysis and Reporting

A designated TAR Accident/Incident Investigation Coordinator will be assigned per shift to

1.5. Personnel Tracking & Security

Contractor Badge Request

Requirements for BASF FINA & Sabina Petrochemicals:

To request ISTC Safety Training or Security Clearance waiver for emergency/special

Contractor Vehicle Entry Request

Personal and Vehicle Security Checks

1.6. EHS Budget and cost management

1.7. Recruiting EHS personnel

Turnaround Safety Experience

1.8. Evaluation and Lessons Learned

A review of defined TAR EHS process/programs will be conducted following the

2. Risk Management Process

2.1. Collection of Impacting Items for the Risk Evaluation

Confined Space Entry into an Inert Atmosphere

Confined Space Entry – Welding, Thermal Cutting, Grinding

Congested Work Area

Hot Taps / Stopples

Initial Line Breaking

NOX (Also called blue ice)

Pedestrian and Bicycle Traffic

Radiation Sources in Confined Spaces

C4 Columns Upgrade (USE-303119)

Charge Gas & Flare Header Clearing

Heater 100 – 900 Entry

High Pressure Water Cleaning (HPWC)

Pyrophoric Areas of Concern

Equipment with the potential of containing pyrophoric materials include:

2.3. PPE Concepts

Minimum PPE for Plant Process Entry

2.4. Management of Interaction Risks

Management of Change (MOC) #PA-020-0029

Pre-Startup Safety Review (PSSR) #PA-020-0028

2.5. Perform Job Safety Analysis

2.6. Discovery Work and Additional Work

2.7. Risk Evaluation for Temporary Facilities

3.1. TAR Permit System:

Sabina C4 Areas and Four (4) Permitting Stations