Document 6R0yBB2K6NxbEemrJqx1kD9ed

`-:i of Eouioment I for Maintenance -. y,~v-: "- - -- - or IM IS* Vtf;y. f tPUSTPaSI1^' m j- mmMm&ws-, & >* . | Carbide' and Carbon 5 j Ij Cheniicals Company -%^;Xr::^MTeiii'Cit7.Te t AUGUST 2. 1936 peeeGeeee<>eQe0&x>^^ ;. ;;*s?.p~r: -:% - --v;~ -r: SC 008372 LA A/1009583 PLANT PROCEDURE NO. 7 SUBJECT: PREPARATION FOR MAINTENANCE OR INSPECTION ON EQUIPMENT AND LINES Reference: Plant letter No. 174, "Hazardous Work Permit" Plant Letter No. 175, "Shutdown Requests" Plant Memorandum, "Lockout Procedure" Plant Letter No. 203 All consolidated and superseded by this issue. When physical entry is to be made into equip ment or when work is to be performed on or in lines or equipment, mobile or stationary. Plant Procedure No. 7 of this date entitled, "Preparation of Equipment for Maintenance or Entry", which supersedes all previous memo Jr randa noted above on the same or related sub jects, is to be followed. The head of the department where the work is to be done is responsible for correct prepara tion, as described in the above-mentioned Plant Procedure, including permits and, where neces sary, shutdown requests. The department head may delegate these duties to his assistants, but is in no way relieved of responsibilities by such delegation. l sc 008373 LAM009584 Work requiring a "Hazardous Work Permit", "Shutdown Request", or "CO Permit" may be done only with the proper permit signed by a person authorized to sign "Hazardous Work Permits", as given in the most current plant list or subsequent letter of authorization on the subject, which also denotes the hazardous areas in the plant. The maintenance foreman assigned to the job has the responsibility of obtaining the proper permits, of checking the precautions taken to insure the safety of the men under his direc tion, and assuring himself that the person who gives permission to proceed is authorized to do so. When only one craft is involved, the maintenance foreman may delegate these duties to a leadman or, under conditions outlined in the above-mentioned Plant Procedure, to a craftsman, but is in no way relieved of respon sibility by such delegation. A deviation from this Plant Procedure is per missible only by letter from the appropriate assistant plant superintendent, who should send copies to the operating department head requesting exception, to the maintenance area foreman involved, and to the safety department. Deviations already approved under similar pro visions of Plant Letter 203 remain valid and need not be reapproved. T. A. Wilker Plant Superintendent 2 TABLE OF CONTENTS I. PREPARATION OF EQUIPMENT Page AND LINES ________________________ ,__________9 A. VESSELS AND LINES____9 1. Procedures 9 a. Emptying 9 b. Venting 10 c. Purging 10-11-12-13 d. Blinding 13-14-15 e. Treatment for Acetylides _____ 15-16 f. Washing16 g. Steaming 16 h. Cooling ____________ 16-17 i. Ventilation17 j. Testing18 k. Opening and Entry 18-19 2. Responsibilities of the Operating Department 19 3. Repsonsibilities of the Maintenance Department19-2 0 B. MACHINERY AND PRIME MOVERS__ 20 1. Procedures 20-21 a. Electric Motors21 b. Steam Engines, Turbines, and Pumps21 c. Gas Engines21-22 d. Gasoline Engines---------------------------22 2. Responsibilities of the Operating Department ------------ 22-23 3. Responsibilities of the Maintenance Department_____ 23-24 3 sc 08374 LAM009585 Table of Contents--Cont'd. C. ELECTRICAL CIRCUITS AND SWITCHGEAR24 Page 1. Identification24 a. Control Rooms24 b. Substations________________________ 24 2. Procedures24-25 a. Control Rooms25 b. Substations 25-26 3. Responsibilities;--u_26 a. Operating Department 26 1) Area Foremen--------------------------- 26 2) Utilities Foremen 2 6 b. Maintenance Department 27 II. PERMITS 28 A. HAZARDOUS WORK PERMIT 28 1. Procedures28 a. Purpose______________________ ______ 2 8 b. Origin28 c. Limitations-------------------- 1----------------28 d. Execution28 1) Unit or Department ------------ 28-29 2) Pipe Racks--------------------------------- 30 3) Adjacent Areas------------------------- 30 e. Use30 1) General30-31 2) Evening and Midnight Shifts31-32 sc 008375 Table of Contents--Cont'd, Page 2. Responsibilities 3 2 a. Operating Department------------------ 32 1) General 32 2) Departmental Supervisors ----- 33 3) Operating Foremen------------------3 3 a) General Shift Foremen_33-34 b) Area Shift Foremen __,,34-35 b. Maintenance Department _____ 35-36 c. Construction Department or Contractors 3 7 B. CO PERMIT 37 1. Procedures 37 2. Responsibilities 37 a. Operating Department ------------------ 37 1) Department Head or Area Supervisor _______________37 2) Operating Area Foremen_____ 38 C. SHUTDOWN REQUESTS ________________3 8 1. Intra-Area 3 8 a. Procedures 38 b. Responsibilities 39 2. Inter-Area _________________ a. Procedures 39 1) Purpose 39 2) Origin and Preparation39 3) Use 40 39 5 LAM009586 Table of Contents--Cont'd. b. Responsibilities _- Page 40 1) Operating Department a) Departmental Supervisors ................ .. 40 .40-41 b) Operating Area and Utilities Foremen _____.41-42 c) General Foremen---------- ____42 Appendix I. Danger Tags --------- 43-44--45-46 Appendix II. Slip Blind Standard for 150# Flanges ------------- .47-48 6 PLANT PROCEDURE NO. 7 SUBJECT: PREPARATION OF EQUIPMENT FOR MAINTENANCE OR ENTRY This Plant Procedure deals with the respon sibilities and procedures for preparation of equipment (including vessels, mobile stock, electrical gear, engines, compressors, and lines) for maintenance or entry. Only those persons listed to sign "Hazardous Work Permits", in the most current plant me morandum or subsequent letter of authorization on the subject, may authorize hazardous work, entry, or inter-area shutdown work in the areas designated. Such authorization is valid only when in the form of a signature on a properly filled out permit. "Entry" in the sense used above includes not only physical entry of a person but also, for purposes of maintenance, the breaking of any flange on equipment up to and including the first shutoff valve. "Hazardous Work" is defined as work in volving any source of ignition, such as open flame, sparks or source of sparks, hot material, or copper acetylide or a potential source of toxic gas. The areas designated as "hazardous" are those given in the most current plant memo randum listing personnel authorized to sign a "Hazardous Work Permit". 7 SC 008376 LAM009587 sc 008377 In those areas where CO (carbon monoxide) may be present, a "CO Permit", as described below, is required. Where shutdowns of material transfer lines or utilities services affecting more than one area are involved, a "Shutdown Request", as described below, is required. All maintenance work requires approval by authorized personnel, either by signed permit or verbal permission, as conditions require, be fore the work is begun. 8 PREPARATION OF EQUIPMENT AND LINES A. VESSELS AND LINES 1. Procedures Equipment (including tanks, tank cars, barg es, ship compartments, and the like, cylinders, etc.) or lines to be prepared for entry, or haz ardous work, must be emptied of any hazard ous liquid contents, vented, purged, blinded, washed, steamed, and cooled if necessary, venti lated, tested for hazardous gases, and checked for special requirements as noted on the "Haz ardous Work Permit", as described below. Whenever entry is to be made into equip ment anywhere in the plant, or a source of ig nition may be present in any area designated as hazardous, a "Hazardous Work Permit", described below, is required. Regardless of pre paration or test, the first person who goes into the equipment must use a safety belt and life line, and have an observer standing by at the manhole. The use of the safety belt, life line, and outside observer must be continued as long as considered necessary by the operating and maintenance supervisors concerned. Equipment or lines being prepared for entry or hazardous work require the following steps: a. Emptying All harmful liquid contents should be re moved from the equipment. 9 LAM009588 008378 b. Venting Special care should be used when venting flammables to the air to avoid contact with any source of ignition. Where possible, a permanent vent, equipped with a steam or carbon dioxide snuffer, should be used. Where a temporary vent must be used, it should be located away from sources of ignition and preferably high in the air. It is imperative that it be grounded to the vessel venting .(in the case of hose, it must have a ground wire), and that steam or carbon dioxide snuffing of sufficient capacity be provided at the outlet, or a shutoff valve that can be readily reached if the vent catches fire. -- In any event, the vent should be of suffi cient size to prevent overpressuring or the for mation of a vacuum if cooled rapidly, as when filling with water. c. Purging for Entry or Hazardous Work Where flammable or toxic materials are or have been present, the equipment should he purged with an inert gas or filled with water first. Water must be used where copper or cop per alloy equipment is concerned because of the possible presence of acetylides, unless an authorized person signifies in writing it isn't necessary. (See page 15) Water is usually advantageously used, ex cept where its use would damage equipment or 10 material or cause subsequent freeze-ups, be cause it is positive and cooling. Care must be taken, however, to see that all other liquid is drained, to avoid leaving a hazardous atmos phere when the water is drained. If polymers are present, a hazardous atmosphere may also develop after the water is drained. It should also be remembered that cold water can pull a considerable vacuum in a hot vessel. If water is not practical for purging, then nitrogen, carbon dioxide, steam, or some com bination of these may be used. When purging with gas, displacement is not as positive as with water. Ideally, if the purge gas is lighter than the gas to be purged, the purge should be made from the top down; if heavier, from the bottom up. The greater the difference in density between -the gas or vapor to be purged and the purge gas, the easier the displacement is. However, it should be borne in mind that flammable gases and vapors should be dis charged high in the air and not at ground level. If purging is done from the top down, a vent pipe from the bottom leading back up in the air becomes necessary. Because this is sometimes impractical, heavier vapors and gases may be swept out from the bottom up by a lighter purge gas, but a greater volume of purge gas is required to do the job. When displacement is normal, a minimum of three volumes should be used. If conditions ll LAM009589 sc 008379 are not normal (i. e., if you are purging from the bottom up with a light gas), at least five volumes should be used. In either case, tests for complete purging should be made, as noted below, with care taken to see that the tests are not falsified by layering of the gases. When flammables are involved, the purge pipe or hose and the vessel or line should be grounded together; furthermore, to prevent an influx of air, a vessel should not be opened at both top and bottom at the same time before it is purged of flammables. After the equipment or line has been purged with water (or air), a check should be made with a suitable explosimeter. (Note that a special explosimeter is required for acetylene and hydrogen to prevent hazard from the ex plosimeter itself.) If a person is to enter the equipment, special tests for toxic gases may also be required, as set forth in the "Hazardous Work Permit". Any reading on the explosimeter of any kind calls for recheck and repurge if substan tiated. When ventilation is necessary to maintain a nil reading on the explosimeter, this fact should be noted on the face of the permit and the appropriate switch or valve tagged open. If steam, carbon dioxide, or nitrogen is used as purge gas, a direct check with the ex plosimeter cannot be made. The purge gas in the vessel must be replaced with air first. 12 Therefore, it is necessary to use a great excess of purge gas to be sure there will be no harm when air enters. The following indications when using the purge gases are to be followed; 1) Steam Purge until at least 30 minutes after odor decreases to a nominal level. 2) Carbon dioxide Purge and check with Orsat for mini mum of 90 per cent CCk. 3) Nitrogen Thoroughly mix 25 cc of the effluent gas with 75 cc of air in an Orsat burette and check the resulting mixture with an explosimeter. Any reading calls for a recheck and repurge if substantiated. Plant air is sometimes contaminated. Therefore, an explosimeter test of the air should be made before it is used. You are referred to more detailed in formation on purging in Section 3 of the "Plant Manual of Equipment Safety and Fire Control Procedures". Where there may be conflict, this memorandum will prevail. d. Blinding Before purging is completed, all inlet and outlet lines, including instrument leads, must have been blinded or disconnected and blanked. Plant standard designs for blinds are at- 13 LAM009590 tached as Appendix II. Insofar as possible, only blinds meeting these standards should be used. Existing blinds may be used if they meet the standard for thickness and if they have handles. All new blinds must conform in entirety. Those units using soft metal blinds (cop per, Everdur, etc.) whose handles can be easily broken off may wish to modify the shape of the standard designs. This is permissible pro viding the thickness and diameters conform to the standards. The size, series, material, maximum temp erature, and maximum pressure must be stamped on the handles of all new blinds, re gardless of shape or material. Tags should be used to identify and ex plain the presence of blinds which have been inserted in unusual locations. Tags should also be used on valves closed preliminary to inser tion of a blind at a location not visible from the valve location. Tagged or locked valves, as well as double valves with vent or drain between, do not con stitute a safe block and are not to be used in place of a blind, except as noted below: Exceptions: 1) No blind is necessary if the repair in volves no more hazard than the insertion of the necessary blinds would. This might occur when changing a gasket, packing a pump, or chang ing a valve in a compressor. In such cases, the 14 valves should be at least properly tagged out as described in Appendix I. 2) Where practical, an inert purge should be used in these cases. The use of inert gas and adequate ventilation, for instance, can be universally applied for valve changes in compressors. 3) Any wider deviation from the rule of complete blinding or disconnect is allowable only by written permission of the appropriate assistant plant superintendent. e. Treatment for Acetylides As stated above, all vessels or lines of copper or copper alloy should be filled with water before entry. After the water has purged the vessel or line completely, but before drain ing, suitable connections just below or at water level may be removed and samples taken at these points by swabbing with a wet paper towel. These samples should be sent to the Works Laboratory, which will analyze the samples within 15 minutes after receipt, pro viding 3 0 minutes prior notice is given. If acetylides are absent, work may pro ceed in the normal manner. If acetylides are present, work may pro ceed by written permission of the department head, providing the equipment is kept cold and wet. Note that this latter condition precludes any work on the equipment, such as burning, that will dry it out or raise the temperature. 15 SC 008380 LAM009591 During this work the presence o the depart ment head or one o his assistants is required. If work of any kind must be done on a dry surface containing acetylide, the acetylide must first be destroyed by acid cleaning, according to Sections 3 to 7 of the "Plant Manual of Equipment Safety and Fire Control Proce dures". If a heavy grease or oil film is present, it must be removed first by pretreating (in an inert atmosphere) with hot caustic where film is heavy or by adding "Tergitol" to the acid if the oil coating is light. Considerable time will be saved if acetylides are removed first, before testing, where they are known to exist. After acid treatment, the equipment must be emptied of the acid solution, washed until neutral, and again tested for acetylides. f. Washing After blinding and treatment for acetylides, the equipment or lines should be washed with water, where possible without danger, to re move harmful materials and to cool. g. Steaming Polymers and heavy liquids will require steaming for removal. h. Cooling Any temperature above 120 F. (approx imately 50 C.) in vessel is too hot for safe working conditions. Therefore, the atmosphere 1G of all vessels should be cooled to or below this temperature by use of water or adequate air ventilation before any person goes into the vessel. i. Ventilation To provide the proper atmosphere for work and to insure against any possible accumulation of hazardous gases in either a piece of equip ment or a line, sufficient ventilation should be used to supply a complete change of air at least every five minutes. For tanks of greater than 100,000 gallons capacity, a slower general ventilating rate may be used with localized ventilation of the work area. Where available, a positive displacement blower is recommended. Its displacement at the discharge pressure prevailing should be known, and care should he taken to see that the intake is assured of good air. If a blower is not available, an air mover may be used. Again, what volume of air may be expected to be moved should be known. Air movers should always exhaust the air to avoid breathing plant air. Use of plant air through an air hose is a poor third, and is allowable only when it is not to be used for breathing. The volume avail able through the hose should be known. Fur thermore, the plant air should be checked with an explosimeter, as noted above. 17 SC 008381 LAM009592 j. Testing When all other preparations are complete, but before entry or hazardous work is begun, final checks should be made. For hazardous work without entry an explosimeter test is sufficient. For entry, tests for any toxic gases or for oxygen content, as required on the ``Hazardous Work Permit", should be made in addition to an explosimeter test. k. Opening anil Entry When performing work on equipment and lines that have been cleared but are' known to have contained such materials as hot chem icals, hot water, sulphuric acid, acetic acid, nitric acid, hydrochloric acid, acetic anhydride, crotonaldehyde, caustic soda, and ethylene amines: The workman making the initial opening shall wear protective equipment consisting of rubber rain gear, rubber gloves, goggles, and acid hood or face cape. Ready means of access to and frotn the actual work must be available before the work starts. If such work is in the pipe rack or well above ground level, and if deemed necessary by the supervisor, the em ployee performing the job shall be provided with a life line attached to his body. The life line is to be placed over suitable support and manned at ground level. A plentiful supply of water shall be made available at the job site 18 before the work starts. The area shift foreman, maintenance foreman, or technical supervisor will be present to direct the work. In addition to use of the foregoing safety equipment, rub ber boots are to be worn by personnel perform ing work on such jobs at ground level. As described on page 9, the first person who goes into a piece of equipment must wear a safety belt and life line and be observed from outside. 2. Responsibilities of the Operating Department In preparing equipment and lines for main tenance, the department head is responsible for correct preparation of the lines and equipment; for determination of wThat permits, if any, are required; and for correct execution of the neces sary permits. Detailed responsibilities imposed in execution of the various permits are given below under "Hazardous Work Permits", "CO Permits", and "Shutdown Requests". Except for signature on permits, which can be authorized only by letter, the department head may delegate execution of any or all of these duties to his assistants but is not relieved of his responsibility by so doing. 3. Responsibilities of the Maintenance Department It is the responsibility of the Maintenance area foreman to see that proper authorization, whether by permit or otherwise, is obtained 13 sc 008382 LAM009593 before work is begun. It is also his responsibility to check the equipment for safe working con ditions, as set forth in this procedure and as further prescribed on any permit required, both before work is begun and during its progress. Detailed responsibilities in connection with the various permits are given below under "Haz ardous Work Permits", "CO Permits", and "Shutdown Requests". The maintenance area foreman may delegate any or all of these duties to his assistants, but is not relieved of responsibility by so doing. When only one craft is involved on a job, these duties may be further delegated to the leadman, if desired, but again the responsibility remains with the foreman. In instances where a craftsman's immediate work is not ordinarily supervised by a leadman, as in the case of a rigger assigned to a winch truck, the craftsman himself may be delegated to obtain the permit. Where there is no crafts man aboard a truck, however, the foreman who calls the truck is responsible for obtaining the permit, a duty which may be delegated to a leadman. B. MACHINERY AND PRIME MOVERS 1. Procedures Before maintenance work can be done on machinery or prime movers, in addition to the preparation described above under "Equipment 20 and Lines", the prime mover must be positively immobilized as described below. In addition, all necessary precautions should be taken so that the machine member normally driven does not cause the driver to turn. a. Electric Motors In the case of 44 0 volt equipment, the starter box must be locked out. In the case of 2300 volt equipment, the isolator bar or cubicle door must be locked out, if possible, after the circuit has been properly deenergized and the isolator opened or the breaker rolled down. If lock-out is not possible, the isolator bar or cubicle door should be tagged out in accord ance with the procedure of Appendix I. In the case of synchronous motors, the motor-generator will also be locked out in ad dition to the lock-out or tag-out of the 23 00 volt equipment. Proper procedures for this are described below in "Electrical Circuits and Switchgear", pages 11 and 12. b. Steam Engines, Turbines, and Pumps The inlet steam line and the exhaust line, if connected to a header, must be blanked or disconnected. (See exceptions on page 14.) c. Gas Engines The starting air line must be blanked or disconnected and the ignition disconnected or 21 SC 008383 LAM009594 SC 008384 grounded. Flywheels should be pinned and locked (or equivalent) when a person enters the crankcase, a cylinder, or when working through a valve port in a cylinder. d. Gasoline Engines The battery must be disconnected or the magneto grounded. When work is to be done on a prime mover itself or to any compressor or pump attached to a prime mover, the regular preparation pro cedure should be followed after immobilization, as described above under "Equipment". When minor repairs are to be made, such as the re placement of a valve or valves, that involve no greater hazard than the installation of blinds, the latter are not required, but constant purge of inert gas should be used, as noted previously. 2. Responsibility of the Operating Department It is the responsibility of the operating area foreman or department head to see that the correct procedures are followed in readying the equipment and in placing the locks. Tags may be used for identification and ex planation only. The operating area foreman or department head may delegate the execution of these duties to a chief operator or assistant, respectively, but is in no way relieved of the responsibility by so doing. 22 If there is a change of shift, the operating area foreman or chief should make notation in the chief's logbook, giving the status of the equipment and listing who has the key for the lock. Master keys for the lockout locks are kept in the general foremen's office and should be used by the general foremen only in event the individual key is lost or misplaced and only after a complete check to determine that it is safe to remove the lock. 3. Responsibility of the Maintenance Department It is the responsibility of the maintenance foreman to see that the locks are in the proper place and that the key is in his possession be fore work is begun. When only one craft is involved, the execu tion of this responsibility may be turned over to the leadman, if the foreman desires; or, in instances where a craftsman's immediate work is not ordinarily supervised by a leadman, as in the case of a machinist packing a pump, these duties may be delegated to the craftsman himself. These delegations of duty in no way relieve the foreman of responsibility. It is the further responsibility of the mainte nance foreman to be certain all personnel is clear before returning the key to the operating area forman or his designated representative for release of the equipment. 23 LAM009595 If there is a change of maintenance foreman or leadman, the key should be given to the foreman or leadman coming on. C. ELECTRICAL CIRCUITS AND SWITCHGEAR 1. Identification a. Control Rooms (440 volt Rowan con trollers, motor, plug, light circuits). All starter boxes shall be identified with the motor number and name, or the circuit name, as the case may be. b. Substations A sign will be placed in front of each sub station breaker panel, indicating whether the utilities foreman or an operating area foreman shall be responsible for the operation of that particular breaker. Identification signs will be placed on the tiebar of each set of isolators, designating which circuit the isolators are for. An arrow will also be placed on this bar pointing to the handle for that particular isolator. 2. Procedures Before maintenance is done on or in connec tion with any electrical circuit, the preceding switch, isolator bar, or cubicle door shall be locked, where possible, or tagged in accordance with the procedure of Appendix I where there is no provision for locking after the circuit 24 has been deenergized and disconnected as des cribed below. A "Shutdown Request" will be required for the disconnect of any switch affecting more than one area. For proper coordination, intra area requests should be made through the op erating area foreman. a. Control Rooms For circuits from individual control rooms, the appropriate controller or switch is to be locked, and the key is to be in possession of the designated maintenance department representa tive before work is begun. b. Substations For circuits from substations, the appropri ate switchgear will be deenergized and tagged by the designated foreman, who will then auth orize the electrical maintenance department to roll down the breaker in the case of metal-clad switchgear, or open the isolators in the case of open switchgear. On shift, the area foreman will lower, or direct the lowering of, the breaker or opening of the isolator, providing the work to be done does not involve the electrical maintenance de partment. Lockout and tagout procedures should be followed, the operating foreman retaining any lockout keys himself. The cubicle door of metal-clad switchgear or the handle of the isolator bar shall be locked out, where possible, and the key is to be in 25 sc 008385 LAM009596 possession of the designated Maintenance de partment representative before work is begun. If locking is not possible, the tagout procedure of Appendix I should be followed. 3. Responsibilities a. Operating Department The operating department is responsible for the correct preparation of electrical gear for maintenance, as described above under "Pro cedures". 1) Area Foremen The operating area foreman is respon sible for the operation of the switchgear in the unit control rooms under his jurisdiction, as described in "Procedures" above. He is also responsible for the operation of individual 2300 volt motor switchgear, as described above, and for notification of the utilities foreman when any other substation circuit is to be removed from service. These duties may be delegated to a chief operator, if desired, but such delegation does not relieve the foreman of responsibility. 2) Utilities Foremen The utilities foreman is responsible for removal of substation circuits from service, other than individual motor starters, on request of the operating area foreman. 26 b. Maintenance Department The maintenance foreman is responsible for seeing that the right switch is correctly locked or tagged out and for possession of the key, if there is a lock, before work is begun. Where only one craft is involved, he may delegate these duties to a leadman, but is in no way relieved of responsibility by such dele gation. In instances where the craftsman's im mediate work is not ordinarily supervised by a leadman, as in the case of the evening shift electrician, the foreman may delegate these duties to the craftsman. 27 008386 LAM009597 sc 008387 II. PERMITS To be Taken" columns. Anyone acceptable to the signer of the permit may initial the "Prepa A. HAZARDOUS WORK PERMIT rations", "Tests" and "Precautions" -- "Com 1. Procedures pleted and Satisfactory" columns. a. Purpose Special preparation requirements, tests, or precautions should be completely and clearly To protect personnel and equipment, a stated on the face of the permit. properly executed "Hazardous Work Permit" (Form CT-14 41) is required whenever work . If an open flame is involved, the area in a hazardous area involves spark, heat or shift foreman on duty is to be notified. flame, entry, copper equipment, or toxic gases. Samples and analyses for acetylide test- b. Origin t ing can be obtained as described under "Treat ment for Acetylides", page 15. In the case of The permit, for work designated as hazard night work, arrangements should be made to ous, is requested by the maintenance depart call out the appropriate laboratory personnel. ment and executed by the operating depart ment, with responsibilities outlined below. When the permit is completely filled out, it is to be signed by a member of the operating c. Limitations department authorized by letter to sign permits for that unit or area. After checking the equip A separate permit is required for each job, ment against the requirements of this proce but one may cover several crafts. If revision is dure and those given on the face of the permit, necessary, both the person who signed the per the appropriate maintenance foreman is to sign mit and the maintenance man who checked * where more than one craft is involved. If only should initial the change. one craft is involved, the leadman designated A new permit is required each morning at by the foreman may sign. Under special cir- 7:30 o'clock, even though the job is continuing. , cumstances, the foreman may delegate these d. Execution 1) Unit or Department The permit is to he completely filled out. duties directly to the craftsman (see page 20.) In all cases, the person who signs the permit or his designated representative will be present at the start of the work. A person authorized to sign the permit is to initial the "Preparations to be Made", the "Tests--To Be Made", and the "Precautions-- 2S 23 LAM009598 2) Pipe Racks "Hazardous Work Permits" authorizing open flames on pipe racks, trenches, or roads adjacent to restricted operating units must be initialed by the area shift foreman and depart ment head or assistant of such units involved before signature by the general foreman or authorized utilities department personnel. Permits signed by acid plant technical supervisors or general foremen are required for non-operating personnel to enter pipe racks containing cast iron acid lines. Prior to issuing these permits, the flow of acid should be stopped and the pressure relieved on the cast iron acid line. 3) Adjacent Areas In all cases, thought should be given to areas other than those normally covered by the person signing the permit. If there is a possi bility that the operation may be hazardous to an adjacent area, that area should be notified of the condition, and, preferably, an authorized person from the area should initial the permit. e. Use 1) General The original of the properly executed permit is to be posted at the job site. Where there are to be open flames, pro vision is to be made for continuous observation by a salaried operating supervisor. 30 In the event of work interruption, the equipment should be rechecked by a qualified person, as defined in the above paragraph, be fore work is resumed. 2) Evening and Midnight Shifts For permit work continuing into the evening or midnight shift, the following pro visions shall be made: Complete written instructions shall be left as to the necessary precautions. If an open flame is to be encountered in the course of the work, arrangements should be made for a qualified fire watcher (salaried operating sup ervisor). A copy of such a permit should be left on the desk of the operating area foreman. The foreman on duty when the work is finished or the permit expires should mail it to the pro cess safety department. The foreman should check such jobs as soon as practical after coming on duty, and make sure that all maintenance and operating personnel concerned are aware of the hazards present and the precautions to be followed. For jobs extending into the following day shift the permit should be renewed by an authorized departmental man before the pre vious permit expires at 7:30 a.m. For hazardous work scheduled to be gin on evening or midnight shifts, the auth orized person signing the permit may at his 31 SC 008388 LAM009599 SC 008389 discretion require on the permit the operating area foreman or other specified person to wit ness the start or progress of the work. Work may be continued without his presence, subject to the provisions above. Emergency work during the evening or midnight shift is taken care of by the shift foremen as noted below. 2. Responsibilities a. Operating Department 1) General The operating department has primary responsibility for designations of hazardous work. The person who signs the permit must be authorized to do so by letter, and is re sponsible for seeing that each permit is care fully filled out and that the required prepara tions and tests are complied with. He is further responsible for noting on the face of the permit what special procedures and precautions are to be taken, and' for seeing that they are under stood. (See ``Execution" beginning page 13.) Where there is any doubt as to the requiremmts for safe practices, the authorized person shall consult his supervisors. In all cases, the person who signs the permit or his designated representative will be present at the start of the work. 32 2) Departmental Supervisors The department head is responsible for designation of hazardous work and the correct execution and use of the "Hazardous Work Permit" in connection with it, as detailed above under "Procedures", except in cases of emer gency, when the general foreman assumes re sponsibility as outlined below. He may delegate these duties to his assistants, subject to the re quirements of authorized signature, but is not relieved of primary responsibility by so doing. In particular, the correct execution and use of the permit require, most importantly, that the permit be filled in completely; that special preparation requirements, tests, and pre cautions be clearly stated on the permit; that the permit be signed by an authorized person; that the signer or his designated representative be present when work is started; that the permit be posted at the job site. They further require that arrangements be made for a qualified observer when an open flame is present; that supplemental instruc tions be left for the area foreman when work continues into the evening or midnight shift; and that arrangements be made for renewal of any permits at 7:30 a.m. 3) Operating Foremen a) General Shift Foremen The general shift foreman is autho rized to sign "Hazardous Work Permits" for 33 LAM009600 any area in the plant where unscheduled work resulting from breakdown or emergencies occurs and when other authorized personnel are all absent from the plant. If the general shift fore man feels that he has inadequate information on which to authorize a ``Hazardous Work Per mit", he should call out the department head of the unit involved. All permits authorized by the general shift foreman should be initialed by the area shift foreman where the work is to be performed. By signature on the "Hazardous Work Permit", the general foreman assumes the re sponsibilities of the department head outlined above. A copy of any permit authorized by the general shift foreman will be passed on to the foreman relieving him if the work is in complete at the end of his shift. As noted above, continuous observa tion by a salaried operating supervisor should be supplied when an open flame is present. j I j j b. Area Shift Foremen When notified of an open flame, as re quired when a permit is issued, the area foreman is responsible for close supervision of the operations in the area around the source of ig nition, to minimize hazard from unexpected venting or spillage. For scheduled work continuing into the evening or midnight shift the area foreman 34 ' is responsible for continuance of all precau tions outlined in this procedure and on the face of the permit prepared by the departmental sup ervisors, in addition to that outlined above for open flame. The area foreman (subject to the re quirements of authorized signature) may sign permits for his area of the plant where un scheduled work resulting from breakdown or emergencies occurs during absence from the plant of the departmental supervisors. The gen eral foreman should be notified of all permits signed by the area foreman, and should be con sulted if there is any doubt as to the require ments for safe practices. By signature on the permit, the area foreman assumes the same responsibilities out lined above under "General Shift Foreman". b. Maintenance Department The foreman in charge of the work is re sponsible for requesting a "Hazardous Work Permit", as noted under "Origin of Permit" above. He has the further responsibility of checking the precautions taken to insure the safety of the men under his direction; of checking the condition of the equipment against requirements of the permit; and of assuring himself that the person who signs the permit is authorized to do so. Where only one craft is involved, he may delegate these duties to a leadman, but is in no way relieved of responsibility by such delegation. Under special circumstances, 35 Sc 008390 LAM009601 the foreman may delegate these duties to the craftsman. (See page 20.) Each maintenance foreman will see that all employees under his supervision understand that they must not use spark or flame-produc ing tools and must not enter equipment until they have obtained permission by a "Hazardous Work Permit" signed by authorized personnel. The maintenance foreman in charge of work involving contract work being done under the supervision of the maintenance department is responsible for seeing that the contractor and his employees understand that they cannot use spark or flame-producing tools in restricted areas without an authorized "Hazardous Work Permit". The maintenance foreman in charge of re pair work requiring a "Hazardous Work Per mit" will consult with the operating department head, if necessary, in order to obtain a clear understanding of all hazards involved. He will see that leadmen and maintenance personnel assigned to the work understand the restric tions imposed by the permit. The maintenance foreman in charge of re pair work requiring a "Hazardous Work Per mit" will be responsible for the use by main tenance personnel under his supervision of all normal safe practices in carrying out the re pair work in addition to any special require ments set forth in the permit. 36 c. Construction Department or Contractors All work performed by the construction department or contractors under the supervi sion of the construction department is subject to the same control by "Hazardous Work Per mits" as work performed under the supervision of the maintenance department. Personnel re sponsible for requesting "Hazardous Work Per mits" will be designated by the construction superintendent. B. "CO PERMIT" 1. Procedure This permit is issued to persons, other than members of the operating department, perform ing routine work in areas where carbon mon oxide could possibly accumulate. It is not intend ed for use in place of a "Hazardous Work Per mit" for entry into piping or equipment. Certain areas within some operating units are designated as requiring a "CO-Permit". No persons, other than members of the operating department on duty in those units, should go into these areas until they have secured a "CO Permit" (Form CT-1369 ). 2. Responsibilities a. Operating Department 1. Department Head or Area Supervisor Those persons authorized to sign "Haz ardous Work Permits" for these areas are also authorized to sign "CO Permits". 37 SC 08391 LAM009602 sc 008392 2. Operating Area Foremen The operating area foreman is also au thorized to sign these permits in the absence of other authorized persons. C. SHUTDOWN REQUESTS 1. Intra-Area a. Procedures Shutdowns of chemical or materialtransfer lines or utilities between units of the same area do not require a written form other than the "Hazardous Work Permit" or "CO Per.mits", where necessary. However, the other units af fected, and the operating area foreman should be notified. The actual shutdown is to be made only through the area foreman, to insure proper coordination between units. Electrical circuits shall be removed from service according to the procedure noted under "Electrical Circuits", page 24. If it is necessary to close the valve immediately adjacent to the main distribution header for water, fuel gas, plant air, or steam, this shall be done under the direction of the utilities fore man. Firewater lines shall be shut off only with the authorization of the Fire Protection Div ision. In all the above cases, the general shift foreman shall be notified. 38 . ; \ i j ] ' | ; I 1 i ! I } ! | ' ! b. Responsibilities The authorized person making the request for shutdown is responsible for notification of other departments and the operating area fore man. The area shift foreman is responsible for the coordination and execution of the job. 2. Inter-Area a. Procedures 1. Purpose of Written "Shutdown Re quest", Form CT-1162 In order to promote safety in planned shutdowns involving inter-area services, which include electric, fuel gas, water, steam, and fire systems, as well as many chemical and material transfer lines, the proper authorization for such shutdowns must be obtained on form CT-1162. This will assure proper notification of all units whose operations will be affected. 2. Origin and Preparation of Request Any department desiring inter-area work may initiate the "Shutdown Request". In preparing the request, all areas and departments in any way affected by the pro posed shutdown should be noted in the proper places on the "Request for Shutdown" form and checked by the general foreman, after which the form will be initialed by the department head or authorized personnel in his department, area supervisors, and operating area foremen of de partments and areas concerned. 39 LAM009603 3. Use of Permit For all tie-ins, revisions, or repairs to any inter-area service, a "Shutdown Request" properly filled out and signed must be in the possession of the maintenance foreman or leadman before work is started, together with a "Hazardous Work Permit" and/or a "CO Per mit", if either is required. Work shall not com mence until an authorized person in the depart ment initiating the request has signed the re quest below the signature of the general shift foreman, and the other permits necessary, if any, are on hand correctly signed. In case of emergency, the general shift foreman shall have jurisdiction as outlined un der "Hazardous Work Permits" above. b. Responsibilities 1. Operating Department a. Departmental Supervisors It is the responsibility of an authorized departmental supervisor to initiate a "Shutdown Request" whenever he desires to remove an in ter-area service from operation. It is also his responsibility to notify the area maintenance foreman or his assistant of any work request requiring such a shutdown by noting the fact on the face of the request. He should fill out the shutdown request as far as possible, designating the other departments to be notified. Each department affected will issue 40 ( f I the proper shutdown instructions for his portion of the system in question. These instructions are to be issued to the area shift foreman for co ordination with those of other departments or areas. The man initiating the request or one of his supervisors should satisfy himself that all preparations have been correctly carried out and then shall make final signature to authorize the maintenance department to proceed. b. Operating Area and Utilities Foremen The area foreman is responsible for carry ing out preparations for shutdown as outlined by the departmental supervisor for his own area in accordance with the preparation instructions above. For shutdowns involving chemical transfer lines between departments, he will see that all draining, blowing, flushing, blanking, and lock ing-out and tagging are done. For tie-ins, repairs, or revisions affecting utilities' service lines, the utilities foreman will be responsible for the operation of the header ^alve on the line affected, this being the valve immediately adjacent to the main distribution header and controlling the unit service line af fected. For electrical shutdowns, the Area, Utili ties, and Electrical Maintenance Departments share responsibility as outlined under "Electri cal Circuits", page 24. 41 008393 LAM009604 sc 008394 Firewater lines shall be shut off trnly with authorization of the Fire Protection division. The operating area foreman is respon- sible for coordination of his work v'.tz. all other ! , ] APPENDIX I. SUBJECT: DANGER TAGS areas affected for clearance of com own portions of the lines or services to avoid an/ injury and insure complete preparation. When he has finished, he shou.rt initial the form and notify his general foreman c. General Foremen Purpose "Danger" tags are for use on blinds, valves, switches, equipment out of service, equipment I unsafe for use, and the like. When equipment or lines are being prepared for maintenance, their use is limited, as described in Plant Pro cedure No. 7. The general foreman shall chee-t tie list of people to be notified and correct it r-e he feels necessary. When he has satisfied himself than the prepa rations required, as indicated in r.h* foregoing memorandum have been finished sa.r_sfactorily, he shall sign the "Shutdown Request" to indi cate this. The general shift foreman maz .satiate and make final signature on the "S'r. irvdown Reouest", in event of emergency wrier- other au thorized personnel are all absent from- the plant. In such cases, the operating area '.vrman af fected should initial the form. Procedure At the time of use, the tag is to be filled out with the name of the man placing the tag, his department, date, and the time, being certain that all necessary information is completed on both sides of the tag. Upon completion of the work, whatever its nature, all tags placed are to be removed only after all of the work indi cated in the blocks beneath the wording "Equip ment Ordered Off For" are filled in. In other words, if a piece of equipment is out of service for both mechanical and electrical repairs, the blocks opposite "Mechanical Repairs" and "Elec trical Repairs" should be checked. Upon comple tion of the work, the man who originally signed for the mechanical repairs (assuming it is fin ished first) will, under "Work Completed" check the block opposite "Mechanical Repairs"; place the date, time and initials on the lines provided alongside. The man who originally signed for the electrical repairs will check the block oppo- 42 43 LAM009605 site "Electrical Repairs"; mark the date, time and initials on the same tag. Thus, the last man to complete his work would advise the Operating Department of this fact and the Operating De partment would then remove the tag, noting the name and date of the person removing the tag and forward the completed tag to the Safety Division. No tag should be removed until sig natures are complete. For tags bearing the signature of a leadman, or craftsman, this same man must initial the "Work Completed" portion unless the area main tenance foreman, or the general shift foreman sign in his stead. Because of the nature of the shift organiza tion, it will often be necessary for one shift to remove another shift's tags. When this is neces sary, tags affecting units under jurisdiction of one chief operator may be signed and removed by the chief operator. Tags affecting units under more than one chief operator must be signed and removed by the area foreman or general forman. A new tag should be used on each and every job. The other side of the tag carrying the word ing: 1. DO NOT OPEN, 2. CLOSE, 3. is to be filled in as necessary, noting the exact reason for placing the tag. On this side should be stated whether the valve or switch should be opened, closed, or left alone, and the reason 4-i why it would not be safe to actuate or use the item or equipment on which the tag is placed. Responsibilities Operating Department The department head or area shift foreman is responsible for the correct use of the "Dan ger" tags as described above under "Procedure", including preparation, placement and removal of the tags, when applied to operating equip ment for whatever reason. The department head may delegate these duties to an assistant or the area shift foreman to a chief operator, but such delegation does not relieve the department head or foreman of re sponsibility. Placement of tags for such jobs does not in itself constitute permission to proceed with the job. The department head, area shift foreman, or designated representative, should notify the maintenance foreman or his representative to proceed with the work, as usual. If the tag is used for other purposes, the signer assumes responsibility for preparation and use of the tag. Maintenance Department When a "Danger" tag is used in connection with maintenance work, the Maintenance area foreman is responsible for his portion of the tag, both in preparation and removal, as de scribed above under "Procedure". In the inter- 45 00839S LAM009606 est of his men's safety, he is also responsible for checking the use and placement of the tags. These duties may be delegated to an assis tant, and, when only one craft is involved, fur ther delegated to a leadman or craftsman, but such delegation in no way relieves the foreman of responsibility. Placement of tags for such jobs does not in itself constitute permission to proceed with the job. Permission should he obtained from the department head, the area shift foreman, or one of their designated representatives, in the usual manner. APPENDIX II 46 L SC 008396 47 LAM009607 APPENDIX II .. '*< I* / I4** l 48 SC 008397 i. LAM009608 LAM009609