BP OIL -- TOLEDO REFINERY

Document Type: Reference No.:

Practice Refinery Wide SAF 120

Effective Date: Revision No.: 0

February 15, 2016 Ventilation Guideline

Owner: Authorized By: Robert Myak Page 1 of 21

Matthew T. Grimes (signature on file)

This guideline applies to all BP-Husky employees, contract

SCOPE personnel, and visitors working in a confined space. Any time
a hazardous vapor or fume is present or produced, ventilation
and/or respiratory protection should be used to reduce the
concentration in the environment.

HEALTH The use of proper ventilation helps prevent employee

exposure to hazardous vapors and/or fumes.
Special PPE & Special Hazards

Standard Refinery PPE

SAFETY
Safe Work Procedure:
SAF 032: Confined Space Entry
REFERENCE
SAF 044: Hot Work and Hot Work Spark Potential,
DOCUMENTS and Vehicle Entry Procedure

Additional References
OSHA 29 CFR 1926.57: Ventilation
OSHA 29 CFR 1910.146: Permit-required Confined
Spaces
OSHA 29 CFR 1910.252: General Requirements
OSHA 29 CFR 1926.353: Ventilation and Protection in
Welding, Cutting, and Heating
OSHA 29 CFR 2910.1450: Occupational Exposure to
Hazardous Chemical in Laboratories
Field Guidelines for Temporary Ventilation of Confined
Spaces

SPECIAL MATERIALS & Ventilation equipment, fans, local exhaust systems

EQUIPMENT

QUALITY N/A

ENVIRONMENTAL N/A

PAPER COPIES ARE UNCONTROLLED. THIS COPY VALID ONLY AT THE TIME OF PRINTING.
 Reference No. SAF 120 Rev. No. 0

OVERVIEW

The purpose of this ventilation guideline is to eliminate or reduce harmful vapors and/or fumes in
the work environment. Welding operations often use inert gasses that can displace oxygen. The
goal of this guideline is to establish a guideline for hot work and lab operations, so that exposures to
vapors and/or fumes are kept below regulatory limits. This ventilation guideline includes:

Identifying when and how ventilation should be used.

Exchange rates for ventilation systems.

1.0 Definitions 1.1 Air Flow The volume of air flow for a specified time period, typically
expressed in terms of cubic feet per minute (CFM).
1.2 Air Velocity The speed of air flow, typically expressed in terms of feet
per minute (FPM).
1.3 Air Velocity Meter (Anemometer) A device used to measure air
velocity, typically expressed in units of feet per minute (FPM).
1.4 Full Welding Enclosure A temporary enclosure typically constructed of
a steel support structure (typically cube shaped) and draped with fire
retardant fabric (e.g. fire blankets) to contain sparks/slag and/or weather
protection. The enclosure has roof or ceiling, with at least 3 closed sides.
1.5 General Exhaust Ventilation A form of mechanical ventilation that
provides exhaust ventilation to a general area of contamination (e.g.
ventilation supplied to a room or confined space, but not directly at the
source of contaminant generation within the room or confined space).
1.6 Hazardous atmosphere - means an atmosphere that may expose
employees to the risk of death, incapacitation, impairment of ability to self-
rescue (that is, escape unaided from a permit space), injury, or acute
illness from one or more of the following causes:

1.6.1 Flammable gas, vapor, or mist in excess of 10 percent of its lower

flammable limit (LFL).

1.6.2 Airborne combustible dust at a concentration that meets or exceeds

its LFL.

1.6.3 Atmospheric oxygen concentration below 19.5 percent or above

23.5 percent.

1.6.4 Atmospheric concentration of any substance for which a dose or a

permissible exposure limit is published in Subpart G, Occupational
Health and Environmental Control, or in Subpart Z, Toxic and
Hazardous Substances, of this Part and which could result in
employee exposure in excess of its dose or permissible exposure
limit.

1.6.5 Any other atmospheric condition that is immediately dangerous to

life or health.

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PAPER COPIES ARE UNCONTROLLED. THIS COPY VALID ONLY AT THE TIME OF PRINTING.
 Practice No. SAF 120 Rev. No. 0

1.7 Laboratory-type hood - means a device located in a laboratory,

enclosure on five sides with a moveable sash or fixed partial enclosed on
the remaining side; constructed and maintained to draw air from the
laboratory and to prevent or minimize the escape of air contaminants into
the laboratory; and allows chemical manipulations to be conducted in the
enclosure without insertion of any portion of the employee's body other
than hands and arms.

1.8 Local Exhaust Ventilation A form of mechanical ventilation, that

provides exhaust ventilation at the source of contaminant generation
(e.g. directly in the welding zone, etc.). Contaminants are not allowed
to escape beyond the point of generation.

1.9 Mechanical Ventilation Ventilation provided by a mechanical force,

such as a radial fan blade or other mechanical system (e.g. venturi air
horn, etc.).

1.10 Natural Ventilation Ventilation provided by natural wind convection

or natural up draft (e.g. such as a heater furnace/draft stack
configuration).

1.11 Powered Air- Purifying Respirator (PAPR) - Air-purifying respirator

with a hood or helmet, breathing tube, canister, cartridge, filter, and a
blower that passes ambient air through the purifying element. The
blower can be stationary or portable. It can also be designed and
equipped with a full face piece, in which case it is referred to as a full
face piece powered air-purifying respirator (FFPAPR).

2.0 Responsibilities 2.1 Industrial Hygienist

2.1.1 Maintain a ventilation guideline.

2.1.2 When determined necessary, conduct or coordinate sampling

of the atmosphere where work is being done.

2.1.3 Determine if added ventilation is necessary.

2.1.4 Recommend engineering controls to increase ventilation in

work areas

2.1.5 Write ventilation plans for BP personnel confined space entry

as requested.

2.1.6 Serve as a resource for reviewing contractor confined space

ventilation plans during turnaround work.

2.1.7 Ensure that BP local exhaust hoods and booths are annually
tested for functionality and flow rate.

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 Practice No. SAF 120 Rev. No. 0
2.2 Technical Engineering Department

2.2.1 Recommend engineering controls to increase ventilation in

work areas.

2.2.2 Consider ventilation in vessel design recommendations.

2.3 Maintenance Supervisors

2.3.1 Maintain an inventory of fixed and portable exhaust systems

as well as general air moving equipment.

2.3.2 Ensure ventilation equipment is properly installed per the

ventilation plan.

2.3.3 Remove equipment that is not functioning properly from

service.

2.3.4 Shall perform annual tests on ventilation equipment to ensure

flow rates and functionality are maintained as specified in
this document.

2.4 Maintenance Planner

2.4.1 Notify Industrial Hygienist to develop a written ventilation plan

or document that one is not required for work in a confined
space.

2.4.2 Inform the Industrial Hygienist of the chemicals involved with

the process.

2.4.2 Provide vessel drawings, vessel dimensions, metallurgy, and

work tasks to the Industrial Hygienist.

2.5 BP employees

2.5.1 Enforce the use of respirators when necessary.

2.5.2 Communicate additional hazards and equipment maintenance

needs to your supervisor.

2.5.3 Do not proceed to work in harmful atmospheres without

proper controls.

2.5.4 Follow requirements as specified in the ventilation plan.

2.6 Contractors

2.6.1 Maintain a ventilation guideline that complies with OSHA

1910.146, 1910.252, 1910.134, and 1926.353.

2.6.2 Ensure that employees use local exhaust devices correctly.

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 Practice No. SAF 120 Rev. No. 0
2.6.3 Ensure that local exhaust hoods and booths are annually
tested for functionality and flow rate.

2.6.4 Develop a written ventilation plan or document that one is not

required for work in a confined space.

2.6.5 Use proper ventilation techniques or respiratory protection

when necessary.

2.6.6 Communicate additional hazards and equipment maintenance

needs to your supervisor.

2.6.7 Follow requirements as specified in the ventilation plan.

2.6.8 Sampling should be conducted to determine contaminate

levels as determined by the industrial hygienist.

2.7 Lab Supervisor

2.7.1 Annually ensure that lab hoods meet the capture velocity specified
in this document.

3.0 Procedure
3.1 Ventilation for general welding and cutting

3.1.1 Local exhaust ventilation: Should be designed to prevent

dispersion of dusts, fumes, mists, vapors, and gases into the air
at concentrations that may cause harmful exposure. Exhaust
systems should be designed so that dusts, fumes, mists, vapors,
or gases are not drawn through the work area of employees.

3.1.2 Design and operation: Ventilation equipment should be

maintained and operated properly to ensure functionality.

3.1.3 Duration of operations:

o The exhaust system should be in operation continually during

all operations which it is designed to serve.

o The exhaust system should continue to be in operation until

the environment is no longer contaminated or respiratory
protection should be used.

3.1.4 Factors determining adequate ventilation include:

o Volume and configuration of the space.

o Number and type of the operations.

o Concentration of specific toxic contaminates.

o Natural air flow and atmosphere conditions.

o Relation of workers breathing zone to the contaminate.

3.1.5 Sampling should be conducted to determine contaminate levels

as determined by the industrial hygienist.

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 Practice No. SAF 120 Rev. No. 0

3.1.6 Fumes should be avoided by positioning the work, the head, or

by ventilation that captures or directs fume away from the face.

3.1.7 When natural ventilation is not enough, mechanical ventilation or

respiratory protection should be used.

3.1.8 Contaminates should not be blown to other work areas at levels

that are above allowable limits.

3.1.9 Air cleaners may be used if they reduce contaminates below

allowable limits.

3.1.10 When using Antimony, Arsenic, Barium, Beryllium, Cadmium,

Chromium, Cobalt, Copper, Lead, Manganese, Mercury, Nickel,
Ozone, Selenium, Silver, Vanadium special ventilation is needed:

o Local exhaust and when required respiratory protection.

Contact the BP Industrial Hygienist to disuss/determine
appropriate respiratory protection.

o All persons in the area of operation should be similarly

protected.

o When in confined spaces involving fluxes, coatings, or other

fluorine, zinc, and copper, compounds, local exhaust or
respiratory protection should be used.

3.1.11 Arc and Gas cutting.

o Oxygen cutting using either a chemical flux or iron powder,

gas-shielded arc cutting, or plasma cutting should be done
using local mechanical ventilation and supplied air protection.

3.1.12 Ventilation should consist of ventilation systems or local exhaust

systems and should be used when:
3
o A space is less than 10,000 cubic feet (284 m ) per welder.

o In a room having a ceiling height of less than 16 feet (5 m).

o In confined spaces or where cross ventilation is reduced from

partitions, balconies, or other structural barriers.

NOTE: See appendix 6 for a comprehensive list and photos of

ventilation equipment available at the TBU

3.1.13 Minimum rate:

o Ventilation should be at the minimum rate of 2,000 cubic feet

3
(57 m ) per minute per welder, except where local exhaust
hoods or airline respirators are used.

3.1.14 Exhaust ventilation systems.

o The air exhausted from blast-cleaning equipment should be

discharged through dust collecting equipment. Dust collectors

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 Practice No. SAF 120 Rev. No. 0
should be set up so that the accumulated dust can be emptied
and removed without contaminating other working areas.

3.1.15 Local exhaust hoods and booths.

o Local exhaust shall be annually tested for functionality and

flow rate.

o Mechanical local exhaust ventilation may be by means of

either of the following:

1. Freely movable hoods (dudt eaters) intended to be placed

by the welder as near as practicable to the work being
welded and provided with a rate of air-flow sufficient to
maintain a velocity in the direction of the hood of 100 linear
feet (30 m) per minute in the zone of welding when the
hood is at its most remote distance from the point of
welding. When brazing with cadmium bearing materials or
when cutting on such materials increased rates of
ventilation may be required.

2. Fixed enclosure with a top and more than two sides which
surround the welding or cutting operations and with a rate
of airflow sufficient to maintain a velocity away from the
welder of greater or equal to 100 linear feet (30 m) per
minute.

3.1.16 Cadmium
o When done outdoors a minimum half mask respirator or PAPR
should be used.

3.1.17 Asbestos
o Site asbestos competent person should be contacted for any
work involving asbestos.

4.2 Ventilation in Confined Spaces

4.2.1 Written ventilation plan shall be required for confined spaces

based on the scope of work. There may be a need for multiple
ventilation plans for each confined space based on the tasks that
are being performed.

4.2.2 The ventilation plan shall ensure controls are evaluated to

provide adequate protection of the workers such as respiratory
protection, local exhaust ventilation and continuous gas
monitoring. See Appendix 6 Ventillation Flow Charts.

4.2.3 The need for a ventilation plan by task shall be determined

during the risk assessment.

4.2.4 Ventilation plans shall be provided to the BP Industrial Hygiene

Department for review prior to the start of the confined space
entry.

4.2.5 Industrial Hygiene services, including creation of ventilation

plans and sampling, are the responsibility of the company
performing the work in the space.

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 Practice No. SAF 120 Rev. No. 0

4.2.6 Some areas may not need mechanical ventilation but the
Industrial Hygienist should make that decision.

4.2.7 The written ventilation plan or documentation that one is not

needed shall be document. See Appendix 1 for an example of a
ventilation plan.

4.2.8 A copy of the written ventilation plan or documentation stating

mechanical ventilation is not required shall be kept at the
confined space with the entry permit.

4.2.9 The atmosphere within the space should be periodically tested

as necessary to ensure that the continuous forced air ventilation
is preventing the accumulation of a hazardous atmosphere.

4.2.10 If a hazardous atmosphere is detected during entry:

o Each employee should leave the space immediately.

o The space should be evaluated to determine how the

hazardous atmosphere developed.

o Measures should be implemented to protect employees from

the hazardous atmosphere before any subsequent entry takes
place.

4.2.11 General ventilation air replacement.

o The minimum general ventilation rate required in a confined

space is 2,000 cubic feet per minute (CFM) from a clean
source, per welder. Adequate ventilation must be provided
even if welders are using air-purifying respirators.

o It is recommended that a complete air change occurs every

minute so that there are 60 air changes in an hour:

This corresponds to a complete air change of the space

volume once every minute to control potential build-up of
gases, vapors or other contaminants.

Certain equipment limitations (i.e. very large size) or job

limitations (i.e. interference with welding inert gas, etc.) may
not allow these optimal air changes.

o Air should not be blown into a confined space using plant

supplied air due to the possibility of nitrogen or hydrocarbon
contamination.

o Compressors and fans are acceptable means of blowing air

into a space.

o In order to maintain proper pressure in confined spaces there

should be an even number of manholes open so that make up
air is replaced in accordance with air removal.

o It is preferred that open manholes be located at lower levels

and exhaust fans be located at higher levels.

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 Practice No. SAF 120 Rev. No. 0

o Fans and blowers should be mounted firmly against flanges

and grounded.

4.2.12 Respiratory Protection.

o All persons in the confined space should use the same

respiratory protection required by the welders.

4.2.13 Oxygen for ventilation.

o Oxygen should never be used for ventilation.

4.2.14 Local ventilation.

o Local exhaust should provide an air velocity of 100 fpm at the

weld site.

o 100 fpm may not be adequate when other air drafts are
present.

o Usually requires the inlet to be within 12 inches of the

operation.

4.2.15 Local exhaust appropriate circumstances include.

o Vessels with single man ways or single open manway

o Confined spaces with dead spots.

o Confined spaces where air-moving devices are not feasible.

o See Table 1. for local exhaust guidelines.

NOTE: Local exhaust ventilation is only effective when it captures

fumes at the source.

4.2.16 Recommendations.

o Keep duct work short.

o Smooth duct work minimizes airflow loss.

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 Practice No. SAF 120 Rev. No. 0

o Flexible duct work is easily collapsible so they should be

straight and free of kinks.

o Instead of using many small ducts use one large duct with a
plenum to distribute air on the inside of a confined space.

o Some areas may not need mechanical ventilation but the

Industrial Hygienist should make that decision. Some areas
include:

1. Large-open roof tanks

2. On top of floating roof tanks

3. Open top excavations.

4. Large exchanger shells.

5. Fin fan enclosures.

4.2.17 Lead.

o In confined spaces or indoors, welding or cutting operations

involving metals containing lead, other than as an impurity, or
metals coated with lead-bearing materials, including paint,
should be done using local exhaust ventilation or airline
respirators. Such operations, when done outdoors, should be
done using respirators approved for this purpose. In all cases,
workers in the immediate vicinity of the cutting operation
should be protected by local exhaust ventilation or airline
respirators.

4.2.18 Cadmium.

o In confined spaces or indoors, welding or cutting operations

involving cadmium-bearing or cadmium-coated base metals
should be done using local exhaust ventilation or airline
respirators unless atmospheric tests shows concentrations are
within acceptable limits.

4.2.19 Hexavalent Chromium.

o When ventilation measures are not adequate at removing

contaminates respiratory protection should be used:

1. Cr VI exposures less than 5.0 g/m3 require no

respiratory protection.

2. Cr VI exposures of 5.0 to 50.0 g/m3 require a half mask

air purifying respirator with P-100/HEPA cartridges.

3. Also, loose fitting Powered Air Purifying Hoods (PAPR)

can be used for Cr VI exposures of 5.0 to 125.0 g/m3.

4. Cr VI exposures greater than 125.0 g/m3 require the use

of supplied air respirators.

4.2.20 Cleaning compounds.

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 Practice No. SAF 120 Rev. No. 0

o In the use of cleaning materials, because of their possible

toxicity or flammability, appropriate precautions such as
manufacturers instructions should be followed.

4.2.21 Degreasing.

o Degreasing and other cleaning operations involving chlorinated

hydrocarbons should be located so that vapors from these
operations will not be released into the surrounding
atmosphere.

4.2.22 Cutting of stainless steels.

o Oxygen cutting, using either a chemical flux or iron powder or

gas-shielded arc cutting of stainless steel, should be done
using mechanical ventilation adequate to remove the fumes
generated.

4.3 Laboratory

4.3.1 The TBU should perform initial and periodic monitoring if there is
reason to believe that exposures for any regulated substance
exceeds action levels.

4.3.2 Lab hoods must be checked annually to determine flow rate and
functionality.

4.3.3 Flow rates shall be maintained between 80 and 100 fpm.

4.3.4 Chemical exchanges and handling should be conducted in lab hoods.

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 Practice No. SAF 120 Rev. No. 0
5.0 Appendices

Appendix 1: TBU Example Ventilation Plan

Ventilation plan for Stripper Reflux Drum

PR 1666
*** Valid for listed work tasks only ***

Work Task
Grinding on carbon steel
Wet Mag Testing

Discovery Work
Changing conditions requiring additional personnel, welders, or work tasks requires this ventilation plan to be re-evaluated by the
site Industrial Hygienist.

Entrants
BP Inspection
BP Heavy Craft
BP Process Engineer

Calculations
Enclosure Height: 6 ft.
Enclosure Radius: 1.5 ft.
3

Enclosure Volume: 42.41 ft

Calculated Air Changes per hour: 2405.09 ACH

Ventilation Equipment
1 3HP air horn (1700 CFM @ 80psi) will be placed at the 2 vent labelled V (see attached drawing). Air horn must be
oriented to pull air from the space as an eductor (suction end in the space).
The man ways must remain open and unobstructed (see attached drawing).

Monitoring
All confined space work areas will require continuous gas monitoring. Inside the confined space BP employees will have a four gas
monitor. This will monitor for 02, H2S, LEL, and CO. Additional Industrial Hygiene monitoring may be required.

Personal Protective Equipment Requirements

A minimum of half-mask respirator with NIOSH approved purple P100 HEPA filter cartridge or welding PAPR will be used during
carbon arc cutting, carbon steel grinding, and stainless steel welding activities. Normal Refinery PPE as well as PPE identified by
the L2RA shall be worn. No respiratory protection is required for carbon steel welding while ventilation equipment is in place.

Rescue
Contact C&W for any confined space rescue emergencies on 16A. See rescue plan for additional requirements.

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 Practice No. SAF 120 Rev. No. 0

Air horn must be

connected to the 2
vent (V) as an eductor.

Man hole must remain

open and
unobstructed.

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 Practice No. SAF 120 Rev. No. 0

Appendix 2: Respiratory Protection requirements

Oxy/Acetylene Tig or Heli-
Grinding Stick MIG Arc Gouging
Torch Cutting Arc
No No No No No
No Respiratory
Carbon Respiratory Respiratory Respiratory Respiratory Respiratory
Protection
Protection Protection Protection Protection Protection
Open Space
No No No No No
without Local No Respiratory
Galvanized Respiratory Respiratory Respiratory Respiratory Respiratory
Ventilation Protection
Protection Protection Protection Protection Protection
Half Mask Half Mask or Half Mask or Half Mask Half Mask Half Mask
Stainless
or PAPR PAPR PAPR or PAPR or PAPR or PAPR
Half Mask Half Mask or Half Mask or Half Mask Half Mask Half Mask
Alloys
or PAPR PAPR PAPR or PAPR or PAPR or PAPR

Oxy/Acetylene TIG or Heli-

Grinding Stick MIG Arc Gouging FCAW Pac/W
Torch Cutting Arc
Half Mask Half Mask or Half Mask or Half Mask Half Mask Half Mask or Half Mask
Carbon SA or PAPR
or PAPR PAPR PAPR or PAPR or PAPR PAPR or PAPR
Confined Space Half Mask Half Mask or
Galvanized PAPR PAPR PAPR SA PAPR PAPR
with Ventilation or PAPR PAPR
Half Mask Half Mask or
Stainless PAPR PAPR PAPR SA PAPR PAPR
or PAPR PAPR
Half Mask Half Mask or
Alloys PAPR PAPR PAPR SA PAPR PAPR
or PAPR PAPR

Note: *PAPR Powered air-purifying respirator

*SA - Supplied air

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Appendix 3: Ventilation Equipment List

Ventilation Equipment
Heavy Craft Shop

Quantity Unit Model number Flow Rate

5 3" air horns short1 TX3AMS 1076 CFM

3 3" air horns 2 TX3AM 1308 CFM

4 6" air horns 3 TX6AM 3020 CFM

1 3" air horn4 MP-6AM 3347 CFM

Coppus Jectair 3" air

3 3-HP 1700 CFM
horns 5

1 6 TX- JF 20 up to 10,420
Coppus fan (20")

2 12" ducts 7

3 8
8" ducts

stationary unit with two

1 collectors and one vent NOT IN USE
9
duct

1 Lincoln x-tractor 1GC10 K652-1 55-115 CFM

5 Lincoln Portable units 11 LFA 4.1 MOB CPL 735 CFM

2 Dust Hogs 12 FPH2-3 1200 CFM

Instrument shop
Single arm operation = 700
Lincoln Statiflex 200-M CFM,
1 13 K654-2
Dual Arm Base Unit Double arm operation =550
CFM

Machine Shop
1 Lincoln Portable unit14 LFA 4.1 MOB CPL 735 CFM

NOTE: Superscripts are to be used to reference pictures in Appendix 4.

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 8 13
1 10 2 11/14 3
5 6 8
12
Practice No. SAF 120 Rev. No. 0

Appendix 4: Ventilation Equipment

10

11

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Appendix 5: Ventilation Techniques

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Appendix 6: Ventilation Flow Charts

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 Practice No. SAF 120 Rev. No. 0

Flow Chart for Open Atmosphere Ventilation

Start

YES Contact site

asbestos
Is asbestos
competent person
involved?
for any work with
asbestos.

No

Is welding, torch No
Mechanical
cutting, or
ventilation is not
brazing being
required.
performed?

YES

No
Is work being done on Mechanical
stainless steel or ventilation is not
alloys? required.

YES

Local exhaust
ventilation is required.

Note: See appendix 2 for respiratory protection in

open spaces without local exhaust ventilation.

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Revision History The following information documents at least the last 3 changes to this document,
with all the changes listed for the last 6 months.

Date Revised By Changes

February Matthew T. Implementation of this document. Initial Revision.

15, 2016 Grimes MOC # M2016445-001

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