Document N2qrqVqG6dwrqGdagOQpKRj7p

dv? 4r' -r ,' - ,'03'? :~.rr ' ^ MONSANTO COMPANY [' ' I I 1 1 1 ! ' I: j CHOCOLATE BAYOU PLANT r ' : 1 i 1 1 j; ! I ALVIN. TEXAS t;*vs-* / April, 1977 c 001472 CBY 3109597 Copy-No. SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP CHOCOLATE BAYOU PLANT ASSIGNMENT . Vfr This Safety Procedures Manual is assigned to and must remain in this location. This manual will not go with the individual filling the capacity noted above upon the individuals leaving the job. DO NOT TRANSFER THIS BOOK TO ANOTHER POSITION, LOCATION OR PERSON. Only upon General Superintendent or Manager of PTD approval, may an additional manual be issued. The manuals come in a set of three: General Procedures, Safety Procedures, and Emergency Action Procedures. ORIGINAL . /_ Ln ISSUE 4 /I /77 By REVISED / / REVIEWED / / By By C 001473 CBY 3109598 PAGE 1 OF 1 attachment SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP CHOCOLATE BAYOU PLANT TABLE OF CONTENTS SAFETY PROCEDURES Number SP-001 SP-002 SP-003 SP-004 SP-005 SP-006 SP-007 SP-008 SP-009 SP-010 SP-011 SP-012 SP-013 SP-014 SP-015 SP-016 SP-017 SP-018 SP-019 SP-020 Title Chocolate Bayou Plant Safety Program Fire and Spill Alarm Minor Injury Reporting and Investigation Treatment of Injury to Contract Personnel Investigating and Reporting of Significant Injuries, Near-Misses, Fires and Spills Equipment Inspection Electrical Ground Resistance Inspection and Testing Testing, Labeling, Handling and Disposing of Metal Sample Pressure Containers Bypassing and Testing Protective Devices Use and Control of Hoses In Plant Rail Car Moving Rail Car Loading and Unloading Solid and Hazardous Waste Disposal Use of Vacuum Trucks ' Fire Water Usage Isolation and Decontamination of Plant Equipment Removal of Equipment from Operating Units for Repair Machinery and Electrical Lockout Fire Permits and Vessel Entry/Fire Permits C 001474 Mobile Lifting Equipment Safety CBY 3109599 ORIGINAL ISSUE A h REVISED 5/6/82Byj.w.Koneable PAGE 1 OF 2 By W.W-KI emme REVIEWED / / By ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY _ _ _ _ _ _ _ _ _ _ SP- CHOCOLATE BAYOU PLANT SP-021 SP-022 SP-023 SP-024 SP-025 SP-026 SP-027 SP-028 SP-029 SP-030 SP-031 SP-032 SP-033 SP-034 SP-039 Scaffold Safety Rules and Practices Mobile Lifting Equipment & Insulated Bucket Truck Work Near High Voltage Lines Plumbers Plugs Guidelines for Work on Energized Electrical Circuits Plant Wide Gas Cylinder, Regulator and Manifold Safety Procurement and Handling of Radioactive Materials and X-Ray Producing Equipment Scrap Material Disposition Static Grounding and Bonding of Hydroblasting Equipment and Other Portable Equipment Hydrocleaning Testing and Operating of Fume Hoods Corrosion-Inspection of Process Equipment and Tankage Respiratory Protection Program ORIGINAL ISSUE _4 C 001475 CBY 3109600 REVISED 5 /6 >62 by j.w.Koneable PAGE 2 OF 2 BvW.W, Klemme REVIEWED / / By ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- CHOCOLATE BAYOU PLANT SAFETY PROCEDURES This page is issued quarterly - check reviewed/revised dates against those in the manual to be sure latest copy is in the manual. PROCEDURE NUMBER TITLE DATE LAST REVIEWED ' SP - 001 SP - 002 / Chocolate Bayou Plant Safety Program Fire & Spill Alarm 4/1/77 ^SP - 003 r Minor Injury Reporting and Investiga tion . SP - 004 * Treatment of Injury to Contract Personnel SP - 005 VSP - 006 Investigating and Reporting of Significant Injuries,N-M, Fires & Spi .Is Equipment Inspection . SP - 007 * SP - 008 Electrical Ground Resistance Inspect! 5n and Testing Testing, Labeling, Handling & Disposi ig of Metal'Sample Pressure Containers SP - 009 4 SP - 010 Bypassing and Testing Protective Devices Use and Control of Hoses 8/13/81 SP - Oil In-Plant Rail Car Moving SP - 012 Rail Car Loading & Unloading ' SP - 013 SP - 014 SP - 015 < Solid and Hazardous Waste Disposal Use of Vacuum Trucks Fire Water Usage 3lC 9601 DATE LAST REVISED 3/3/81 8/5/81 8/5/81 3/20/80 5/5/82 8/1/81 8/30/80 12/15/80 8/27/81 8/27/81 11/30/81 12/17/81 9/4/81 < SP - 016 Isolation and Decontamination of Plant Equipment 7/27/81 C 00147( original , A. ISSUE _ A77 ByW.W. Klemme REVISED 5/ 6/82By J.W.Kongable REVIEWED / / By PAGE 1 OF ATTACHMENT 2 SAFETY PROCEDURE MANUALSP- -- mini 1 'iHMirjin irqwij '-'"t'-i f"---- MONSANTO COMPANY i --MaMMaBBoi---- CHOCOLATE BAYOU PLANT PROCEDURE NUMBER SP - 017 iSP - 018 rSP - 019 SP - 020 TITLE DATE LAST REVIEWED >at last REVISED Removal of Equipment from Operating Units for Repair Machinery and Electrical Lockout Fire Permits and Vessel Entry/Fire Permits Mobile Lifting Equipment Safety 8/7/81 8/20/81 12/1/81 7/1/81 SP - 021 SP - 022 SP - 023 'SP - 024 SP - 025 SP - 026 SP - 027 SP - 028 Scaffold Safety Rules and Practices Mobile Lifting Equipment & Insulated Bucket Truck Work Near High Voltage ines Plumbers Plugs 6/3/81 Guidelines for Work on Energized Electrical Circuits Plant Wide Cylinder, Regulator and Manifold Safety 10/12/81 Procurement & Handling of Radioactiv< i Materials and X-Ray Producing Equip. 11/11/81 8/11/81 12/3/81 5/1/81 SP - 029 ~SP - 030 'SP - 031 SP - 032 SP - 033 SP - 034 SP - 039 Scrap Materials Disposition 9/1/81 Static Grounding and Bonding of Hydroblasting Equipment and Other Portable Equipment 6/22/81 Hydrocleaning Testing and Operating of Fume Hoods 6/23/81 8/14/81 Corrosion-Inspection of Process Equipment and Tankage tk k i P/tit IdspEosnctj Respiratory Protection Program CBY 3109602 11/19/80 3/2/81 c 001477 ORIGINAL . / L_ REVISED 5 /6/82 ByJ.W.Koneable PAGE 2 OF 2 issiiF 4/1/77 BvW.W.Kelmme REVIEWED / / By ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP CHOCOLATE BAYOU PLANT TABLE OF CONTENTS - SAFETY PROCEDURES TITLE;_______________________________________________________________________________ -A- Alarm, Fire & Spill 002 NUMBER -CCorrosion-Inspection of Process Equipment & Tankage Cylinder Gas, Regulator and Manifold Safety 034 025 -DDecontamination and Isolation of Plant Equipment 016 -E'Energized Electrical Circuits, Guidelines for Work on Equipment Inspection Equipment, Mobile Lifting & Insulated Bucket Truck Work Near High Voltage Lines Equipment, Mobile Lifting Safety Equipment, Removal of from Operating Units for Repair 024 006 . 022 020 017 -F- Fire Permits, Vessel Entry/Fire Permits Fire Water Usage -G- Ground, Electrical Resistance Inspection andTesting 019 015 007 -H- Hoses, Use and Control of Hydrocleaning Procedure BY 3*09603 C 001478 010 031 ORIGINAL A /n/7* U U i REVISED 5 /6 /82 By J.W.Koneable k. I pmiila;-.___ _--'--m,----------- PAGE or SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- CHOCOLATE BAYOU PLANT - -I- Injury Reporting, Minor & Investigating 003 Injury.Treating of to Contract Personnel 004 * Isolation & Decontamination of Plant Equipment 016 - -L- Lockout Procedure, Machinery & Electrical 018 -M- Machinery and Electrical Lockout 018 Mobile Lifting Equipment and Insulated Bucket Truck Work Near 022 High Voltage Lines Mobile Lifting Equipment Safety 020 -P- Plumbers Plugs Protective Devices, Bypassing & Testing 023 009 -R- Radioactive Procurement & Handling of Materials and X-Ray Producing Equipment 026 Rail Car, In-Plant Moving Oil Raid Car, Loading and Unloading 012 Removal of Equipment from Operating Units for Repair 017 Respiratory Protection Program 039 -S- Safety Program, Chocolate Bayou Plant 001 Sample Containers, Testing, Labeling, Handling & Disposing of Metal Pressure 008 Scaffold Safety Rules & Practices CBY 3109604 021 Scrap Materials Disposition C 001479 Spills, Investigating and Reporting of Significant Injuries, Near-Misses, Fires & 029 005 ORIGINAL /, / 1 A7 W T.T irlsmma . By J W. Kongable j? rig i SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP CHOCOLATE BAYOU PLANT Static Grounding and Bonding of Hydroblasting Equipment & Other Portable Equipment -TTesting, Electrical Ground Resistance & Inspection Testing and Operating of Fume Hoods -VVacuum Trucks, Use of Vessel Entry/Fire Permits -WWaste Disposal, Solid andHazardous 030 007 032 014 019 013 / CBY 3109605 C 001480 ORIGINAL 4/1/77 W.W-Tnprnmp j REVISED5 /6/32 By J .W.Kongabj^'pIrr'g 3 nc 3 SAFETY PROCEDURE MANUAL M--i^--mbtimTM----M--Trgrjimym MONSANTO COMPANY SP-ooi CHOCOLATE BAYOU PLANT CHOCOLATE BAYOU PLANT SAFETY PROGRAM PURPOSE This procedure re-affirms the Monsanto safety policy, defines respon sibility for safety, and outlines the general safety program for the Chocolate Bayou Plant. POLICY It is the policy of Monsanto that every employee is entitled to a safe and healthful place in which to work. To this end, every rea sonable effort will be made in the interest of accident prevention, fire protection, and health preservation. It is also acknowledged that all efforts in Monsanto are directed toward a favorable position in our free-competition economy. Monsanto management and, in particular, those who direct the Chocolate Bayou operation avow that the safety and welfare of all employees must be maintained in order to achieve this purpose. In order to produce quality products at optimum quantities and minimum cost, reasonable procedures and regulations have been es tablished. These together with continual safety educational ef forts, and firm, fair administration will necessarily result in a safe plant. .Vis-tHl*?- * RESPONSIBILITIES All employees share in the responsibility for the continual safe operation of the Chocolate Bayou Plant. This responsibility is distributed as follows: A. Line Organizations 1. The Individual Employee by virtue of his employment assumes a definite responsibility for his personal safety as well as for the safety of his co-workers. He is charged with observing all accident prevention regulations as a direct job responsibility. It is recognized that the formal safety efforts of plant management will be ineffective without the personal acceptance by all of safety as "a way of life". Conformity to safety procedures and the development of safe working habits together with concern for the "other fellow" are the greatest contributions an employee can make in furthering C 001481 CBY 3109606 REVISED / / By ORIGINAL ISSUE -/2/6 2 Bv D. K. Stephen REVIEWED 4/ l/77 By F.H.Duore PAGE 1 OF 6 ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- ooi CHOCOLATE BAYOU PLANT CHOCOLATE BAYOU PLANT SAFETY PROGRAM 4. The plant manager is charged with the responsibility for the overall safety of the Chocolate Bayou Plant. B. Staff Organizations 1. The Safety Department as a staff group assists the line organization in establishing and maintaining a safe operation. In this capacity they will re commend, advise, and assist line personnel. Ulti mate recourse in the event of conflicting opinions will follow the line organization to the plant manager. The Safety Department, however, is di~ rectly responsible for the following safety items: a. Safety orientation of new employees. b. Inspecting and maintaining all fire protection equipment. c. Training emergency personnel. d. Directing fire fighting and emergency personnel. e. Providing adequate medical treatment to injured employees. f. Performing atmospheric tests for fire-entry permits. g. Evaluating and appraising management of plant safety performance and informing management of problem areas. 2. Other staff departments in safety as well as other phases of work, are intended to assist the line. The responsi bility for correcting an unsafe condition and for performing a particular series of tests, for example, is still a line function although,staff personnel may be required to do the work. The responsibility for safety cannot be delegated. PROCEDURE The following procedures and methods are to be included in the Chocolate Bayou Safety Program. These will be supplemented as new methods are found suitable. A. General 1. Employee Safety Indoctrination and Subsequent Safety Training. 2. Committees - Permanent and Special 3. Establishment and Updating of Plant and Departmental Safety Rules. CBY 3109608 ORIGINAL // REVISED / / By______________ ISSUE _LlL2A2_ByD .K. Stephens ~jjyIEWED 4/1/P By F.H.Dupre PAGE 3 OF 6 ATTACHMENT c 001483 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-ooi CHOCOLATE BAYOU PLANT CHOCOLATE BAYOU PLANT SAFETY PROGRAM 4. Periodic Inspections of Departments 5. Accident Investigations and Reports a. Minor Injuries b. Fires c. Near Misses, Serious Injuries 6. Fire-Entry Permits 7. Lock-Out System 8. Control of Smoking and Matches 9. Personal Protective Equipment 10. Plant Manager's Inspection 11. Toxicity - Flammability Knowledge 12. Plantwide Publicity Efforts 13. Written Departmental Safety Rules 14. Process Hazard Audits 15. Setting Specific Safety Goals with Attendant Publicity and Program 16. Off-the-Job Safety Education and Publicity B. Plant Safety Organization 1. Plant Manager's Accident Prevention Council will meet monthly. The council is composed of the plant mana ger's immediate staff and a representative from Process Technology with the safety director serving as secre tary. This council will assist in directing the plant manager's overall safety program and will expedite performance down through their respective organizations. Typical activities of these meetings will include: a. The selection of safety programs and the assignment of program committees. b. A review of plant accident experience and corrective action. c. Assignment of special hazard committees. d. Establishment of plantwide safety regulations. 2. Special Committees will be chosen -fry rrrnTiAiln tr perform a specific one-time assignment. All employees are eli gible for these committees. The committees may serve the following functions. .7*.,: ` I**"*-* CBY 3109609 C 001484 ORIGINAL // REVISED / / By ISSUE IV 2/62 ByD.K.Stephens REVIEWED 4/1/77 By F.H.Dupre PAGE 4 OF 6 ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP.QOl CHOCOLATE BAYOU PLANT CHOCOLATE BAYOU PLANT SAFETY PROGRAM our safety effort. This contribution is evidenced by employees who continually use the required protective and safety equipment, routinely follow specific pro cedures, participate in safety programs, submit sug gestions to their supervisors, and actively strive for correction of plant hazards. o Each employee has the authority and the RESPONSIBILITY to initiate corrective action for unsafe practices and conditions of which he is aware. This will normally involve notification of his supervisor or the concerned supervisor. In cases where an immediate injury or equip ment damage is eminent, he must act immediately and then refer the problem and the action taken to his supervisor or the responsible supervisor. 2. Supervisory employees are directly responsible for the safety of operations under their control and for the personal safety of every employee under their super vision. This responsbility cannot be shared with any staff organiztion nor shifted laterally in any manner. 3. A supervisor is specifically responsible for: a. Developing safety procedures and regulations specific to his area of responsibility. b. Securing conformity to these as well as to all plantwide safety procedures. This job is made easier by: 1. Setting a good example to all his employees. 2. Establishing firm, equitable standards of performance. 3. Listening to employees' suggestions and answering them promptly. 4. Preparing effective departmental safety training and educational programs. 5. Investigating all injuries, thereby evidencing sincerity. 6. Maintaining departmental safety check lists and inspection records of safety equipment. 7. Seeking the assistance of staff personnel in aiding their departmental safety program. c* 'l09613 /uORIGINAL REVISED / / By______________ ISSUE 11 2-.nL2_BM3_.iw Stephens REVIEWED 4/1/77 By F. H. Dupre C 001485 PAGE 2 OF 6 ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-ooi CHOCOLATE BAYOU PLANT CHOCOLATE BAYOU PLANT SAFETY PROGRAM > 3. Office employees will attend a safety meeting every four months conducted by a program committee selected by the Accident Prevention Council. D. Inspections Inspections will include, but not be limited to, the following: 1. Quarterly inspections of the plant by a team of three general superintendents. The safety director and a fire/safety inspector will assist the quarterly inspec tion teams. 2. An annual inspection of the entire plant by the plant manager. The safety director and a fire/safety in spector will assist as necessary. 3. Operating departments will schedule and conduct formal inspections. Suggested schedule: weekly formal inspec tion by foreman using checklist; monthly inspection by operating supervisor and superintendent. 4. Inspection of safety equipment other than fire protection equipment and air masks is a departmental responsibility. (Including blankets, safety showers, eye baths, protective equipment). CBY 3109611 ORIGINAL / / REVISED / / By ISSUE _13: 2/ 6*y D.K.Stephe^REVlEWED 4/1/77 By F.H.Dupre PAGE 6 OF 6 Attachment C 001487 /I SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- ooi CHOCOLATE BAYOU PLANT CHOCOLATE BAYOU PLANT SAFETY PROGRAM 4. The plant manager is charged with the responsibility for the overall safety of the Chocolate Bayou Plant. B. Staff Organizations 1. The Safety Department as a staff group assists the line organization in establishing and maintaining a safe operation. In this capacity they will re commend, advise, and assist line personnel. Ulti mate recourse in the event of conflicting opinions will follow the line organization to the plant manager. The Safety Department, however, is di rectly responsible for the following safety items: a. Safety orientation of new employees. b. Inspecting and maintaining all fire protection equipment. c. Training emergency personnel.. d. Directing fire fighting and emergency personnel.-' e. Providing adequate medical treatment to injured employees. f. Performing atmospheric tests for fire-entry permits. g. Evaluating and appraising management of plant safety, performance and informing management of problem areas. 2. Other staff departments in safety as well as other phases of work, are intended to assist the line. The responsi bility for correcting an unsafe condition and for performing a particular series of tests, for example, is still a line function although staff personnel may be required to do the work. The responsibility for safety cannot be delegated. PROCEDURE The following procedures and methods are to be included in the Chocolate Bayou Safety Program. These will be supplemented as new methods are found suitable. A. General 1. Employee Safety Indoctrination and Subsequent Safety Training. 2. Committees - Permanent and Special 3. Establishment and Updating of Plant and Departmental Safety Rules. C 001489 CBY 3109614 ORIGINAL n/2/^2 ByP.K.Stephens REVISED / / By ISSUE REVIEWED 4/l//7 By F.H.Dupre PAGE 3 OF ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY ( ==-- SP-ooi CHOCOLATE BAYOU PLANT CHOCOLATE BAYOU PLANT SAFETY PROGRAM 4. Periodic Inspections of Departments 5. Accident Investigations and Reports a. Minor Injuries b. Fires c. Near Misses, Serious Injuries 6. Fire-Entry Permits 7. Lock-Out System 8. Control of Smoking and Matches 9. Personal Protective Equipment 10. Plant Manager's Inspection 11. Toxicity - Flammability Knowledge 12. Plantwide Publicity Efforts 13. Written Departmental Safety Rules 14. Process Hazard Audits 15. Setting Specific Safety Goals with Attendant Publicity and Program 16. Off-the-Job Safety Education and Publicity B. Plant Safety Organization ( 1. Plant Manager's Accident Prevention Council will meet monthly. The council is composed of the plant mana ger's immediate staff and a representative from Process Technology with the safety director serving as secre tary. This council will assist in directing the plant manager's overall safety program and will expedite performance down through their respective organizations. Typical activities of these meetings will include: a. The selection of safety programs and the assignment of program committees. b. A review of plant accident experience and corrective action. c. Assignment of special hazard committees. d. Establishment of plantwide safety regulations. 2. Special Committees will be chosen by council to perform a specific one-time assignment. All employees are eli gible for these committees. The committees may serve the following functions. ~-v . r' ( C 001490 CBY 3109615 ORIGINAL ISSUE REVISED / / By I]/2/662: .ByD.K.Stephens REVIEWED 4/1/77 By F.H.Dupre PAGE 4 OF 6 ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-ooi CHOCOLATE BAYOU PLANT CHOCOLATE BAYOU PLANT SAFETY PROGRAM a. To conduct plantwide safety programs with attending publicity and safety meetings. The subjects of these programs will be selected by the Accident Prevention Council. (Examples: Fire Protection, Eye Protection, Vacation Safety, Housekeeping, Achievement of Safety Goals). b. To conduct plantwide hazard surveys. (Example: Ladder Survey or Hose Survey following indidents resulting from same). c. To conduct safety efforts outside the plant. (Example: Safety displays for employee functions). No committee can assume the line responsibility for safety but rather is intended to supplement line efforts. 3. Process Safety Audit Committee will be appointed by the plant manager and members will generally have a technical background. This committee will review new projects and expansions or revisions to existing units for hazards which could result in a disaster. It will not concern itself with minor personnel hazards which are a normal line super vision responsibility. (See GP-053JL).. C. Safety Training In addition to the day-to-day job safety training, formal safety training for hourly employees and special non-exempt groups (Example: lab analysts) will include: 1. Either a weekly 10-minute group or individual safety " contact by the line supervisor covering a specific planned safety topic, OR a monthly departmental safety meeting. 2. A plantwide safety program every three months on gene ral safety subjects. This program will be planned, prepared, and conducted by a committee selected by the Accident Prevention Council. CBY 3109616 ORIGINAL 13/2 /62byP.K . Stephens] REVISED ISSUE ----------------------------- . REVIEWED y 3/77 By F.H. Dupre rnvau vr ATTACHMENT C 001491 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 002 CHOCOLATE BAYOU PLANT FIRE AND SPILL ALARM SCOPE This attachment defines the responsibilities of personnel when a fire or spill occurs and the procedure to be followed in case of an alarm. % :- POLICY When a fire or spill occurs the individual observing the emergency should immediately turn in a fire/spill alarm. If in the judgement of the individuals involved corrective action can be taken without-'.'-, jeopardizing their safety, they should do so. RESPONSIBILITIES 1. To Sound a Fire and Spill Alarm The fire/spill alarm is activated by the telephone system, dial "77" and the proper area code. As the last number of the code is dialed the alarm will start sounding, also the security officer at the main gate will be able to talk to you and get some information as to the problem. In this manner should the alarm be false the security officer can relay to the Safety Department that it was false and avoid alot of confusion. The proper code for a particular area can be found on: a. The front of each telephone within its area. b. The fire and spill alarm code card. c. The map in front of the poant telephone book. EXAMPLE: To sound the alarm for the #1 Barge Dock Dial "77-1-1-1" 2. Failure of the Automatic System After turning in an alarm the code should start sounding immediately, in the event that this does not happen try once more to be sure you dialed correctly. If the alarm does not sound then dial the emergency number 4222 and explain to the security officer what has happened. Tell him the code and he will manually sound the alarm with the auxiliary horn. CBY 3109618 Jjfft /ORIGINAL . h /6Z. R r MrNoo' *EVISED 3/3/81ByC.A. Coburn PAGE 1 OF 3 issue 11/^ / " v R* G. McNee. Reveiweo / ATTACHMENT # 1 C 001133 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 002 CHOCOLATE BAYOU PLANT FIRE AND SPILL ALARM 3. When the Fire and Spill Alarm Sounds In the event of an alarm all traffic will move to the side of the street, stop and turn off the motor. The only exception to this rule is the emergency vehicles responding to the scene. Distribution, Utilities, Environmental Control and I & E vehicles will also be allowed to operate but need permission from either the Safety Department or Night Supervisor. If the diesel switch engine is in the plant it will be the responsibility of the Distribution Department to insure it is shutdown. All open flame and spark producing work and machinery must be stopped. Smoking must be stopped in all areas (offices included). All entries into the plant during alarm must be cleared through the Emergency Coordinator at the Main Gate, extension Depending upon the seriousness of the problem other precautions^ may have to be taken. Wind direction will be a determing facto! as to what must be done if there is a major spill or toxic vapo| release. It may be necessary to shutdown open flame heaters which would effect the operation of the unit or entire plant. ____ Immediate notification by the unit to exposed personnel in nearby operating areas or shops should be made by either radio or telephone. All information as to the emergency action or "|piirl:r evacuation should be reported to the Safety Superintendent or Night Supervisor at the Main Gate by using the emergency telephone 4222. The Fire Safety Inspector in charge of the emergency will be involved in the decision for whatever action^ is necessary for control of the problem. The Fire Safety Inspector is the main link of communication with the Safety Supervisor, ... Safety Superintendent or Night Supervisor. All personnel who are not members of the emergency response ? team or operating personnel of the areas involved must stay away, and if in the area must get out and remain at a safe distance. If in a unit with sign in tags and you are unable to leave through the Control Room, you or your supervisor should contact the unit or main gate so you can be accounted for. Work in an area may be resumed as soon as it has been determined it is safe and not affected by the fire or spill. The Safety Superintendent or Night Supervisor should be contacted at the main gate, extension 4301 to assist in this decision. It will be necessary for the operating personnel to resign the permits. Smoking may also be resumed in areas not affected. CBY 3109619 ORIGINAL u/2 /62^ R.G.McNeely REVISED ^ /3/ 81By C.A.Cobum REVEIWED / / By fPAGE 2 OF ATTACHMENT # C 001^94 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SF- 002 CHOCOLATE BAYOU PLANT FIRE AND SPILL ALARM 4. Back-up Fire Crew "Thl?: Should additional help be needed in an emergency, the next on-coming shift emergency response team will be called out. The need for additional help will be decided by the Safety Department. The contacts will be made by telephone. During off-hours the Fire Safety Inspector.,will instruct the security officer to make the calls, units should be notified what members, from their unit has been called out. An up-do-date list of emergency response team members on each shift will be mantained by the Safety Department. The security officers will have a copy of this list. 5. End of Emergency When the emergency is over, the member of the Safety Department coordinating the emergency in the field will check with operating supervision for the affected area. If agreed that all is safe, the Safety Department representative will radio the security officers and request that the "ALL CLEAR" be blown. The security officer will then sound the "ALL CLEAR" signal which is ONE 15 SECOND BLAST on the code horns. This will indicate that all parties concerned should resume normal operations. 6. Testing the Fire and Spill Alarm System The fire and spill alarm system will be tested every Monday at 1:00 P.M. The Safety Department is responsible for the maintenance of the fire and spill alarm system. &* AUTHOR: APPROVED BY: C. A. Coburn APPROVED BY: CBY 3109620 G. E. Davenport ORIGINAL n/2/62ByR.G.McNeely REVISED 3/3/ 8lBy r. A P.nhnm PAGE 3 OF 3 REVEIWED / / By ATTACHMENT #1 C 001495 The minor injury and accident investigation procedure is established' to provide a record of all industrial injuries and their causes for use in accident prevention work. POLICY ' Thorough analysis of the causes of accidents is essential to an effective accident prevention program. All injuries, no matter how small, must be reported immediately for treatment and investi gation. SCOPE This procedure applies to all employees at the Chocolate Bayou location. The procedure does not apply to injuries occurring to contractor or employees nor to off-the-job injuries occurring to our own employees. RESPONSIBILITY 1 The injured is responsible for reporting to the dispensary for treatment of his injury as soon as possible. The supervisor of the injured is responsible for the investigation of the events relating to the injury, taking corrective action if necessary, and completing the injury report form the Safety Department is responsible for the preparation and distribution of reports compiled from the injury report. PROCEDURE The Injury and Accident Report form is used for reporting the investi gation of a minor injury. See Attachemnt #1. This report_is initiated by the plant nurse (or the fire safety inspector) on any injury requir ing treatment and given to the injured employee to take to his supervisor The accident should be investigated and the report completed immediately but in no case later than the next working day. The report should then be mailed to the Safety Department via line supervision of the injured employee. cay 3l0962i ORIGINAL 9 /4/63 ByW.W.Vamado ISSUE revised 8 /5/81I3VJ. C.-Usrev REVEUVEt^ /2J%1 By PAGE 1 OF ATTACHMENT c 001496 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP" 003 CHOCOLATE BAYOU PLANT MINOR INJURY REPORTING AND INVESTIGATION Monsanto *0*3*1*10 LOCATION NO. t . t htfrT" STctsTvCcTt sm# *t MONSANTO COMPANY *T. toms. MISSOURI U | MU* M*! , . . . moo**ir; *m w*r i'.i I 3 1 IUSCUANO AtJUHV RESORT fttro*ro L. DU Q NO I#* <9t1* MMt MtJUW4 Tft M ^ IrONJATTt./;NT) tiLM Cant evn<c'' " ** 4--iiiut)Cr-nw` ni i Ecnrazars! N.'.j*4- -v5`J Vji S CD AC I .OfiTQAitv tt.r REOCCURRENCE TRMRiRATVftC W %'*$ . ~rcV'n~~."J~, r`7: srTl1<e? ''cr "iT*r*> 5k/, & *: : **.! 1 O' *COrtt^rni-f , j "rr; fiu..r.T;r;.T*^7--------------- * *J .ai;' I3lm 3 SfCOfMMiy m Sim Column f* THm Smu Cow L-tsh SAi|ft *4&e<wttlC#umA LSm\> U^jCAlPTION OS INMAT HAPPENED.CONAitVlvl ACTION TA<tU -MO*MV JuATE NIPORT QY QNO If YES. EXPLAIN ------------------------------------ 1 Oh Tfi.'Uj* V , M ! cw*6Ci''*:vv:iC' *t-.*<** s p l~.~ W..-I5fc Lot? `..-v* 't>n ! ', !>*.-3r: V v: . .. * tn o#J. *.tv "Kurt **si'V n-t..-7 -3; ; TRUNK t ' ! JiOt*fc<******> Li -*JO 1 .*) U*ji IIOAIWI J *",t: cn ta^hcatiqoiit imflcATgt i wastcicowtimsutow U;.L>( f1.C~V.'l I T "'IHMSAr-PAcfsltC*B"nVif3l)*"-<5i--Hiif /*/Q AuffKHUy**^ jrjtfi ___________ ^ > InRi UW ri I* *-.< to Sfewff Saco ; ">iT*Cii"v,-Tix JISM* 'AlC'lf SW I lH NW TVSS OS fl^URY *r ;c Q"> ,-*v\ j. mvtt 71_ Lioi Atm' ?jq*TV: iCiiijn ItfS.17 '. ^iu.i.bi tm, , 1 Ml;**.*4 ! PERSONAL FACTOR !.()' ^2225!2i^i2!il2--- . y.TTa.n.f^fa qi Hmf ot mif r~40C.`jneniioo h *yrT*Ac ~3 Cwni i Emu- agiPY-jgyj ..wwgwmg,. . l)iM\ulivt\ittiiiwS.B 1 ORIGINAL ISSUE 7jT*3~ntf ' *** ILL*-;$ (St'-etJWl jt.'i4is4.:awF^3.>stri*r (At fm Oa f.vir& ci os*i* 2:**; *.! "k.m Ciffv* a' _0TV-W ____________ *"j(lfWII' (?*i J }_ Lt^'OliC^WYtH^-?. ,cC-?7iv3-"--1t LU* I1t m* -1 ---i ui <i >74) ' J-'P-^cwy Svvyr. ... i.e*Si*r> Dae *ti i *io :^it^ ivv" *5 .*> Mr, !<>'* Mirt Sum* ,tu-!*o3ei CCi* it PtvueS'" ^v^YfcTTITXTlMkNT---------------------------------- IJNSAfg ACTS _____ '4 E"rlU Couip. *1 CovkQ Ww*fi| ilwruqwfit him < iM>e. 1Lff^f -J*" L.T ^ L-iofi..o*. Tewing ; *C7'i^nN P*umig : 30 'tr^TL' ** v tuwicwffi y ] j Mwcn u* a LiffIt Mtwor i lrr-.Omr A>xi> *euMvi 1 MOjNunf ' 1 ' *>> j 2:-i*wnf Uf 1 3?\~l~r^mTTaV;n01 SfliwB i .iafgff*,ttjayM^>gLQwV^BtNLTXTATUS_ _ J ! *o7i?Yr.rvs?T^5i~--~ ClAGNOill ANO TNfeA 7M(N T r TREATED Y VHTNCmS ftini fludflflui t'i i jT.y*ot xi T> I__`.W'll OKMXAMM'llul tivvr j , i"V' * <iT xmti.vfr "" V 4'wa^rMi i I fASV>Tel. qiW^ "TL'c C.Vig ' 'l`lj 6<io i OHat(<>h i *; v m id i 1 O'.f V\* J, (1 iinhiitivn irjr`Vj,ii ^nnz ACCtDfWTTWf iQtf>`Sii***4 "*<>VA^xi^< * iM**. *'tro'jyixMfun . .tjo*I*:rcC4,>MC "______ 1 1 T--7<-a2-1*-ljcl-iW-"-ific^Ct. *5uv.U..c.rcA'*ixvmV'--<vf*'j Tx'xf` j Taii^fSci >* 2 <^7>f4iiiiwiw jprmcf __ "TTwii <Tu- Hi rri-jTn^i THIS PORM MOST se COMPLETED ANO fTtMNtO TO f*l SAStTY IRECTOA WtmN SOAYSASTIM Ol^iNSAAY TREATMENT ASSOCiATIO ACCNCV NO. PLANT SAFFTY CcF^. C 001498 IC <<M0 Oxo> It) CO o q /lk/b7t ^ W.W.Vamado REVISED 8 /5 /81 By j.c. Usrev * REVEIWEDfcA/8^ ByiyjUAJ^I PAGE 1 OF 1 ATTACHMENT #1 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 004 CHOCOLATE BAYOU PLANT TREATMENT OF INJURY TO CONTRACT PERSONNEL PURPOSE The purpose of this procedure is to establish a practical method for treatment of injury to contract personnel. SCOPE This procedure covers all personnel of contractors working at Monsanto Chocolate Bayou. PROCEDURE 1. Any injury to a contract employee shall be immediately reported to the Monsanto Safety Department where appropriate treatment can be secured. 2. Should further medical attention be recommended by the Monsanto Safety Department, the contractor will be responsible for making arrangements for the injured to get further medical treatment. 3. In the case of a serious injury that requires immediate physician attention, Monsanto will furnish transportation to one of the following medical facilities: Alvin Community Hospital Clear Lake Hospital Danbury Hospital Emergency care will be administered enroute. 4. Each contractor must report injuries immediately to both the Monsanto supervision responsible for the work area and the Monsanto supervision to which they report. In addition, work must be stopped following a serious injury and must not resume until the appropriate Monsanto supervisor has checked the job site. Note: A contractor may obtain permission from the Monsanto Safety Department to maintain first aid facilities at their job site for the treatment of minor injuries. This practice will be the exception and not the rule and will only be considered upon the contractor meeting the following criteria: The person(s) designated to administer first-aid.is qualified (minimum of a current Red Cross First Aid Card), C 0C1439 CBY 3109624 ORIGINAL 9 /l8/fe7By K.B.Owen ISSUE REVISED 8 75/ 81By J.C.Usrey REVElWED^y/fl, By QfjH PAGE 1 OF 2 ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY --- - J ------~-- ' ---- I - SP-* CHOCOLATE BAYOU PLANT --gg-l ^ I II--^--g. TREATMENT OF INJURY TO CONTRACT PERSONNEL CONTRACTOR INJURY & ACCIDENT REPORT DATE TIME NAME OF INJURED DAY OF WEEK COMPANY DEPT. WHERE INJURY OCCURRED FOREMAN TYPE OF INJURY INJURED PART EMPLOYEE'S STATEMENT OF INJURY AND ACCIDENT CAUSE: TREATMENT: TREATED BY / /ORIGINAL ISSUE By DATE TREATED CBY 3109626 REVISED 8 / 5/81 By J.C.Usrey REVElWEOt / V f, 2, By -- C 001501 PAGE 1 OF ATTACHMENT# SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-005 CHOCOLATE BAYOU PLANT INVESTIGATION AND REPORTING OF SIGNIFICANT INJURIES.'NEAR-MISSES, FIRES AND SPILLS e. The chairman may need to be familiar with technology of an incident when the preliminary indicators show that technology is important to the cause and/or solution. Refer to Attachment #3 for suggested instructions to the chairman of investigation committees. 3. The investigation will be started by the committee within 24 hours of the time of the incident. The following guidelines should be used: a. Visit scene of accident to investigate physical facilities. Take photographs or make sketches and diagrams to record details of the physical environment. b. Interview witnesses and the injured employee if available. The plant nurse should be contacted to determine extent of injury or disability. Additional concerned personnel may be interviewed and should include the concerned line supervision > c. The committee will tentatively agree on the cause of the accident and recommendations and the chairman will prepare a rough draft following the format in Attachment #1. d. A report number will be assigned by the Safety Department. 4. Within three working days following the incident the investigation report will be reviewed and approved by the Department Superintendent or Supervisor involved. The Safety Superintendent may assist in this review. The entire committee may participate if requested by the chairman, Department Superintendent, or Safety Superintendent. 5. Within three working days the committee will also present the report in person jointly to the Superintendent or Manager involved for approva 6. The basic report, with appendix, will be published within ten working days following the incident. Copies will normally be distributed to all Superintendents, Managers, and the Safety Department tinless restricted by the Plant Manager.7 7. The distribution of the basic report, without appendix, will normally be to all plant supervision, but may be restricted by the Superintender Manager, or Plant Manager. cBy C 001502 REVISED!! ,16/^ By J.C. Usrey SSuENAL 1 /4/65Bv D-K.Stephens REVEIWED / / By PAGE 4 OF 5 attachment SAFETY PROCEDURE MANUAL MONSANTO COMPANY -- SP- oos CHOCOLATE BAYOU PI T INVESTIGATION AND REPORTING OF SIGNIFICANT INJURIES. NEAR-MISSES, FIRES AND SPILLS 2. A NEAR-MISS is any incident where significant injury or property damage could have resulted had circumstances been only a slightly different than actual or had the activity been continued. A near-miss will be judged significant by the concerned Superintendent or PT Manager with the recommendation of the Safety Department considered. 3. A FIRE or SPILL will be judged significant by the concerned Superintendent or PT Manager with the recommendation of the Safety Department considered. RESPONSIBILITIES 1. The GENERAL SUPERINTENDENT, CED SUPERINTENDENT, AND PT MANAGER are responsible for: a. Insuring that incidents which are covered in the definitions section are reported to him and the Safety Department. b. Initiating an investigation, appointing a committee, and briefing the chairman for incidents as follows: r' f 1. For Fires or Spills: The Superintendent of the area in ve } J which the incident occurs. i j 2. For Injuries: The Superintendent of the injured person. e I 3. For Near-Misses: The Superintendent of the employee or d the equipment exposed to the near-miss. c. Assigning responsibility for corrective action in his involved area. d. Reviewing investigation reports for incidents outside their areas, determining application of recommendations and assigning responsibilities. e. Reporting application and status of the recommendations pertaining to their areas. C 001504 CBY 3109628 ORIGINAL 1/4/65Bv D- K.Stephens REVISED 11/16^ 83 By C. Usrey ISSUE REVEIWED / / By___________ PAGE 2 OF 5 ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 005 CHOCOLATE BAYOU PLANT INVESTIGATION AND REPORTING OF SIGNIFICANT INJURIES, NEAR-MISSES, FIRES AND SPILLS 8. The following instructions are applicable to status reporting: a. Each Group Foreman will report response to the recommendations to the Unit Superintendent, and to the Safety Department. A copy of the recommendations sheet from the accident report can be used for reporting this response, retyping should not be necessary. b. Each Group Foreman should indicate those recommendations that are applicable to operations, the date the recommendation is completed, any comments, and the status of the recommendation. Status should continue to be reported monthly until action on recommendation is complete. :',%* CBy 3109631 REVISED 11 46/83 ByJ. C. Usrey ORIGINAL 1 / 4/65gyD.K.Stephens ISSUE REVEIWED / / By____________ PAGE 5 OF ATTACHMENT C 001506 SAFETY PROCEDURE MANUAL SP-005 MONSANTO COMPANY CHOCOLATE BAYOU PLANT INVESTIGATION AND REPORTING OF SIGNIFICANT INJURIES, NEAR-MISSES, FIRES AND SPILLS MONSANTO COMPANY CHOCOLATE BAYOU PLANT ALVIN, TEXAS ACCIDENT INVESTIGATION REPORT NO. NEAR-MISS INVESTIGATION REPORT NO. FIRE/SPILL INVESTIGATION REPORT NO. DATE:(APPROVED BY) TO: ALL SUPERVISION (Normally) SUBJECT: Investigation of Accident in Department and Unit DESCRIPTION OF ACCIDENT The opening paragraph should be a summary statement of the incident itself stating the extent of injuries and/or damage to equipment, who was injured if applicable (functional job descriptions, not names) and the where, when, what and how of the incident. This should be v followed by a brief chronological description of the events occurring-^ and conditions existing just prior to, during and following the accident that are related to the accident or that will assist in giving a clearer understanding of the nature of the occurrence. This : should be given in summary and limited to a statement of facts only; not conclusions drawn as a result of unsubstantiated theories. CAUSE The prime cause, as determined by the investigating committee, that was responsible for the accident should be covered in this section. Only those secondary causes, if any, that the committee feels wefe critically important should be listed and labeled "secondary causes". (The listing of secondary causes tends to dilute emphasis on the prime cause.) RECOMMENDATIONS These recommendations should be the result of the investigation by the committee making this report. Only measures to correct both the direct cause and contributing causes to the accident should be covered. If corrections are already made or underway, this should be reflected in the report. Completion dates and assignments of responsibility to Superintendents will be included in this section. Assigning of joint responsibility should be avoided for clarity. Recommendations should be specific and realistic and should avoid generalizations such as "be more careful", "pay attention", etc. When recommending "reviewing" of C 001507 CBY 3109632 ORIGINAL i ISSUE JL /A /s5^p...Stephens REVISED 3 /2(/ 80ByR.D.Jeffers REVEIWEDl/1^83 ^ J. C. Usrey PAGE 1 OF 3 ATTACHMENT #1 II D is t r ib u t io n o f S ta tu s R e p o rts ( U n it Supv >c A HO i Qi +IQ> OE Q CJ U0 e < * < Attachment #1 SP-005 ** ** * n <o- m eo o L is t 0ne\ A / I , F /S , N-M R e p o rt # S u b je c t; A p p lic a b le p c 1 p aua0o4 E4 Hp <u Pa & i c 001509 < SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-005 CHOCOLATE BAYOU PLANT INVESTIGATION AND REPORTING OF SIGNIFICANT INJURIES, NEAR-MISSES, FIRES AND SPILLS REPORT APPENDIX ACCIDENT INVESTIGATION REPORT NO. NEAR-MISS INVESTIGATION REPORT NOT" FIRE/SPILL INVESTIGATION REPORT NOT ACCIDENT CLASSIFICATION DATE:(Approved by Superintendent) This should be enumerated as follows (where applicable). > 1. Name (Optional) 2. Department 3. Occupation 4. Experience on the Job 5. Equipment Involved 6. Operation Being Performed 7. Type of Accident 8. Mechanical Cause 9. Human Cause 10. Type of Injury 11. Parts of Body Involved 12. Time and Date of Accident 13. Date Investigation Initiated ACCIDENT INVESTIGATION C 001510 This should cover all pertinent information gathered by the investigatingcommittee in sufficient detail. It should include statements of witnesses past history of the injured if it affects the accident, and any other pertinent information gathered during the course of the investigation. PERSONNEL INTERVIEWED AND WITNESSES Include in this section personnel interviewed' and CBY 3109635 O /} A\ORIGINAL - ISSUE 1 REVISED 3 /2(/ 80ByR.D. Jeffers 5By_D .K.StephenpREVElWElj-6/ 83 gy J. C. Usrey PAGE 1 OFl ATTACHMENT #2 SAFETY PROCEDURE MANUAL *----^--MBBBgHSMHit., MONSANTO COMPANY SP-005 CHOCOLATE BAYOU PLANT INVESTIGATION AND REPORTING OP SIGNIFICANT INJURIES. NEAR-MISSES, FIRES AND SPILLS INSTRUCTIONS OF THE CHAIRMAN OF INVESTIGATION COMMITTEES 1. Selected chairman will meet with the Superintendent or Manager immediately following the incident requiring investigation to receive a general outline of what is expected as committe chairman. 2. The chairman should read Safety Procedure SP-005. 3. The chairman should not edict his opinions or allow individuals - reviewing/approving the report to do so with the committee members. He should use his conference leadership techniques in guiding the committee in their activities. The interest is.in using group dynamics to determine cause and corrective action for specific incident. 4. It is important that the committee determine the true facts of "what happened" and what can be done to prevent similar or related incidents in the future. 5. Frequently, errors in judgement or failure of individuals to follow established procedures are involved in am incident. These occurrences should not be "whitewashed". They should be recognized by the committee and noted in the report. However, it is important to speak to "what" was done and not speak to "who" did it. 6. The key committee function is to identify the prime cause of the incident. This prime cause should be identified in the report. Any other secondary contributing factors which the committee feels critically important should also be listed, but they should be labeled as secondary factors and should be minimized. 7. The committee's "recommendations" should deal with the prime cause of the accident. Secondary contributing factors and any other safety lessons that have been identified may be listed if they are relevant and important. Recommendations should be as specific as possible. It should not be assumed that plant supervision knows what "standard procedures" or "safe working practices" are. Make reference to specific procedure numbers, plant safety guides, or any other known documents. Describe the actual "do's" and "don'ts" the committee has identified in the incident. Keep in mind that supervision across the plant will be reading these recommendations and trying to relate them to our overall safety program. Make the recommendations meaningful and applicable. CBY 3109636 issueNAL 1 A/^5 By D.K.Stephen REVISED 3 /20/80 ByR.p. Jeffers ^REVElWEfl-^46/83 By J.C.Usrey PAGE 1 Or.. J2 ATTACHMENT* 3 - c 001511 SAFETY PROCEDURE MANUAL MONSANTO COMPANY ronirmn mir~r itiin--^--iiiiiih, h, mu...... .... TESTING, LABELING, HANDLING. AND DISPOSING OF METAL SAMPLE PRESSURE CONTAINERS SP- 008 CHOCOLATE BAYOU PLAN* PURPOSE This procedure provides a means for testing, identifying, labeling, and disposing of all metal sample containers used to contain material under pressure or vacuum, whether they are for samples or standards. This procedure does not Include compressed gas cylinders purchased from an outside vendor, or 1, 2, or 5 gallon cans. POLICY All metal containers used In the plant for samples or standards that are under pressure or vacuum must adhere to specified ItC (Interstate Commerce Commission), DOT (Department of Transportation), or other specifications. They must be tested at periodic intervals, properly labeled or identified, properly handled, and properly disposed of when they do not meet specified criteria. -- SCOPE This procedure covers the responsibilities of the departments owning and using these containers, specifications, and requirements for safe use and handling of the containers. RESPONSIBILITY Everyone is responsible for proper handling of these containers. The Control Lab is responsible for testing. Identifying, and disposing of all containers used for catching samples by Manufacturing, Distribution, and PTD, and those used for standards by the Lab and I & E Maintenance Department. The I & E Maintenance Department is responsible for testing. Identifying, and as necessary, removing from service containers used in the field for standardizing process analyzers that differ from those prepared by the Lab. All other users of metal sample containers are responsible for testing, identifying, and as necessary, removing from service containers they use which do not fall in the categories listed above. ORIGINAL ISSUE is&ljl* 11 H.W.Klenroe Mist* ae/gTss REVEIWED / / CBy 3109638 C 001513 PAGE 1 OF ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY CHOCOLATE tAYOU PLANT TESTING, LABELING, HANDLING, AND DISPOSING OF METAL SAMPLE PRESSURE CONTAINERS B. 5.3 1 Cylinder 1. These cylinders are to be used as the gas standard cylinders throughout the plant. They must conform to the following standard: DOT 4B240ET. These cylinders are painted blue. 2. These cylinders will be labeled as to content 3. Cylinders showing any visual abnonnaltles will be decontaminated and properly disposed of Immediately. 4. These cylinders are to be used only for gas standards. No other foreign material will be added to the cylinder, such as aluminum foil for mixing purposes. 5. The maximum working pressure on these cylinders will be 160 pslg. 6. After 5 years use these cylinders will be decontaminated and discarded. New cylinders wlllbe used for replacement. C. 5 Gallon Butane Cylinders 1. These cylinders are generally used by the I&E Department for standards used In the field. 2. These cylinders must adhere to the following specifications: DOT or ICC 4BA 240. 3. Cylinders In gas use will not require a safety valve. Cylinders In liquid use must have safety valves. 4. These cylinders will be painted yellow and their serial numbers recorded by I&E. See section H for painting specifications. 5. I&E will tag the cylinders showing the analyzer they are for and the composition of the standard contained therein. 6. The Control Lab will prepare the standards for these cylinders as needed and analyze the standards. 7. The use of an outside vendor Is recommended for hydrostatic testing of these cylinders at 360 pslg since the Control Lab's equipment will not handle them. It will be the I&E Department's responsibility to have these cylinders tested at least once every five (5) years. ORIGINAL ISSUE .REVISE! REVEIWED / / by D.L.Heade OF ^ ATTACHMENT C 001515 SAFETY PROCEDURE MANUAL MONSANTO COMPANY $ SPtXB CHOCOLATE BAYOU PLANT TESTING, LABELING, HANDLING. AND DISPOSING OF METAL SAMPLE PRESSURE CONTAINERS 8. Wrenches and pliers must never be used to close valves on sample containers. 9. General department procedures must be followed when taking samples. Sample containers filled with liquid samples must be filled from the Inlet valve on the container; l.e., not the dip tube end. All containers used for liquid samples must contain a dip tube. 10. Sample containers containing samples must be kept away from abnormal sources of heat. 11. Sample containers requiring repairs must first be decontaminated by steam cleaning. 12. Sample containers must not be thrown off or on truck, racks, benches, * etc. ; 13. Any cylinders taken out of service for refilling or storage, shall be Inspected visually all over for mechanical damage, such as rust spots, cracked paint, pits in paint, or dents In cylinders. Any damages found shall be reported to supervision and further inspection made before I further use of such cylinders. In any case all cylinder* In use will be Inspected semi-annually with appropriate records kept. 14. Cylinders used In outside service must be placed on an open grate In order to reduce rusting of the bottom of the cylinders. F. Proper Disposal of Metal Containers 1. All sample containers to be disposed of will be sent to the Lab for proper disposal or proper Instructions for disposing of the container. G. Specifications to Coat and Paint Carbon Steel Sample Bombs 1. Sandblast to white metal in accordance with SSPC-SP5-63 (anchor pattern shall conform to a minimum of 1 mils). 2. Apply one coat of Matcote 1-830 epoxy promer to the sandblasted surfaces (dry film thickness 1.5 - 2 mils). 3. Apply one coat of Matcote Rust-Ban EX-6707 minimum yellow to the primed surfaces. 4. Apply one finish coat of Matcote Rust-Ban EX-6707 minimum yellow. 5. Total dry film thickness should be 10 mils. ^ 00151.7 CBY 3109642 ORIGINAL 11/o$/ 77^, W.W.Klemroe ISSUE REVISED OVWob By D.L.Meade REVEIWED / / ____________ um--m--H--M PAGE 5 OF 6 ATTACHMENT SAFETY PROCEDURE MANUAL tnE-si- MONSANTO COMPANY SP* 009 CHOCOLATE BAYOU PLANT BYPASSING AND TESTING PROTECTIVE DEVICES PURPOSE revised} Define the control measures to reduce losses due to bypassed or malfunctioning | protective devices. POLICY No protective devices will be intentionally bypassed or made Inoperative without providing adequate alternate protectiont continuing communication that the device is bypassed, and approval from authorized supervision. All protective devices will be routinely tested to assure operability. SCOPE This procedure applies to any department (operating unit, laboratory or facility) which must use protective devices to minimize loss or control conditions that affect the safety of personnel and equipment. Examples of protective devices are shutdown devices, interlocks, alarms, relief valves, vents, back-flow preventers, etc. > i- RESPONSIBILITY The responsibility for control of protective device bypassing and the routine testing of protective devices rests with the owning department at the level of manufacturing superintendent or FT group supervisors as the case may be. Authorization for bypassing protective devices will not be delegated to lower levels of supervision by the manufacturing superintendent or PT group supervisor. Each department will be responsible for providing the necessary internal procedure to implement the control of bypassing and testing protective devices along the guidelines established in the procedure. Records of bypassing and testing of protective devices will be maintained by the owning department of facility. PROCEDURE A. Bypassing Protective Devices revised In the event that a protective device must be taken out of service,, it will be the responsibility of authorized supervision to approve its removal from service. For purposes of this procedure temporarily altering a safety device setpoint (vibration switch, P.S.Y., safety Interlock, etc.) either above or below a previously specified valve or altering an.activation point controlled through a computer system (such as modicon or provox) will be classified as bypassing that safety device. C O/Vf CT Q CBY 310964A 1i ORIGINAL 4 /9 /68 ^ J.C.Edwards [ REVISED 6/TJsTbvTj. 6. bsrey lBPVClWPn4/l / 77 n G.N. Peltier | ATTACHMENT 3 SAFETY PROCEDURE MANUAL MONSANTO COMPANY CHOCOLATE BAYOU PLANT BYPASSING AND TESTING PROTECTIVE DEVICES (Cont'd) B. Routine Checking off Protective Devices In order to minimize the loss potential resulting from inoperable protective devices, each department (operating unit, laboratory or facility) will define and implement programs for testing the oper ability of these devices. These tests may be either operational checks or based on preventive maintenance programs, depending upon individual circumstances, but should be sufficiently frequent to assure that the device will function when needed. Bach department having block valves located under relief valves will take the following precautions to insure relief valves are not inadvertently blocked out of service. These precautions will also be taken for block jit? valves located in vent lines when the vent line serves as relief protection for the equipment such as vessels normally operating at atmospheric pressure. j&iL 1. Maintain a current checklist showing location and status of block valves beneath relief valves, or in vent lines used for relief protection. Use the checklist on a regular basis (monthly is suggested) to physically verify block valve status. 2. Block valves will be car sealed in the open 'or normal position. 3. These block valves will be painted yellow for proper coding. AUTHOR: APPROVED BY APPROVED BY G. E. Davenport V C 001521 CBY 3109645 * ORIGINAL 4 /9 /68^3.0.Edwards REVISED 12/15/80 By C.C. Foots REVEIWED y2/83 By ^usrey PAGE 3 OF 3 ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-009 CHOCOLATE BAYOU PLANT CHECK BOARD EACH SHIFT FOR COMPLETIONS DEVICE DESCRIPTION/FUNCTION REASON FOR REMOVAL ALTERNATE PROTECTION REMOVED FROM SERVICE BY! PROCESSOR _TIME FOREMAN _ ... DATE ESTIMATED COMPLETION DATE/TIME SAFETY NOTIFIED (OUT OF SERVICE) BY! ____ __________________________________________ AUTHORIZATION: .......... MFG. SUPT. DATE_______________________________ SYSTEM RETIRED TO SERVICE & PHYSICALLY VERIFIED BY: PROCESSOR! .___________ TIME ^___ : FOREMAN: DATE______________________________ SAFETY NOTIFIED (iN SERVICE) by: _______________________________________________ RETURN TO MFG. SUPT. WHEN COMPLETE 3 ATTACHMENT #1 - SP-009 ORIGINAL ISSUE .By CM c 001522 REVISED 12/15/8O By C. C. Pouts REVEIWED 6/2 /83 By J. C. Usrey PAGE 1 OF 2 ATTACHMENT!?! SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-005 CHOCOLATE BAYOU PLANT INVESTIGATION.AND REPORTING OF SIGNIFICANT INJURIES, NEAR-MISSES, FIRES AND SPILLS INSTRUCTIONS OF THE CHAIRMAN OF INVESTIGATION COMMITTEES 1. Selected chairman will meet with the Superintendent or Manager immediately following the incident requiring investigation to receive a general outline of what is expected as committe chairman. 2. The chairman should read Safety Procedure SP-005. 3. The chairman should not edict his opinions or allow individuals reviewing/approving the report to do so with the committee members. He should use his conference leadership techniques in guiding the committee in their activities. The interest is.in * using group dynamics to determine cause and corrective action for specific incident; 4. It is important that the committee determine the true facts of "what happened" and what earn be done to prevent similar or related incidents in the future. 5. Frequently, errors in judgement or failure of individuals to follow established procedures are involved in an incident. These occurrences should not be "whitewashed". They should be recognized by the committee and noted in the report. However, it is important to speak to "what" was done and not speak to "who" did it. 6. The key committee function is to identify the prime cause of the incident. This prime cause should be identified in the report. Any other secondary contributing factors which the committee feels critically important should also be listed, but they should be labeled as secondary factors and should be minimized. 7. The committee's "recommendations" should deal with the prime cause of the accident. Secondary contributing factors and any other safety lessons that have been identified may be listed if they are relevant and important. Recommendations should be as specific as possible. It should not be assumed that plant supervision knows what "standard procedures" or "safe working practices* axe. Make reference to specific procedure numbers, plant safety guides, or any other known documents. Describe the actual "do's" and "don'ts" the committee has identified in the incident. Keep in mind that supervision across the plant will be reading these recommendations and trying to relate them to our overall safety program. Make the recommendations meaningful and applicable. CBY 3109636 C 001524 REVISED 3 /20/80 ByR.D. Jeffers By D.K.Stephen^y^gg^Q^Qg ^ j>c.Usrey PAGE 1 OF.. J- ATTACHMENT* 3 - SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-,TM CHOCOLATE *AYOU PLAN* TESTING, LABELING, HANDLING, AND DISPOSING OF METAL SAMPLE PRESSURE CONTAINERS PURPOSE This procedure provides a means for testing. Identifying, labeling, and disposing of all metal sample containers used to contain material under pressure or vacuum, whether they are for samples or standards. This procedure does not include compressed gas cylinders purchased from an outside vendor, or 1, 2, or S gallon cans. POLICY All metal containers used in the plant for samples or standards that are under tttpressure or vacuum must adhere to specified (Interstate Coainerce Commission), DOT (Department of Transportation), or other specifications. They must be tested at periodic intervals, properly labeled or identified, properly handled, and properly disposed of when they do not meet specified criteria. SCOPE This procedure covers the responsibilities of the departments owning and using these containers, specifications, and requirements for safe use and handling of the containers. RESPONSIBILITY Everyone Is responsible for proper handling of these containers. The Control Lab is responsible for testing, identifying, and disposing of all containers used for catching samples by Manufacturing, Distribution, and PTD, and those used for standards by the Lab and I & E Maintenance Department. The I & E Maintenance Department is responsible for testing, identifying, and as necessary, removing from service containers used In the field for standardizing process analyzers that differ from those prepared by the Lab. All other users of metal sample containers are responsible for testing, identifying, and as necessary, removing from service containers they use which do not fall in the categories listed above. C 00152S CBY 3109638 -llZofi/ORIGINAL ISSUE 77By W.W.Klemne jjVISED_ 06/;^B5 p.i.Head. RJEVEIWED/ / By PAGE 1 OF 6 ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY CHOCOLATE BAYOU PLANT B. 5.3 1 Cylinder TESTING, LABELING, HANDLING, AND DISPOSING OF METAL SAMPLE PRESSURE CONTAINERS 1. These cylinders are to be used as the gas standard cylinders throughout the plant. They must conform to the following standard: DOT 4B240ET. These cylinders are painted blue. 2. These cylinders will be labeled as to content 3. Cylinders showing any visual abnormalties will be decontaminated and properly disposed of iamediately. 4. These cylinders are to be used only for gas standards. No other foreign material will be added to the cylinder, such as aluminum foil for mixing purposes. 5. The maximum working pressure on these cylinders will be 160 pslg. 6. After 5 years use these cylinders will be decontaminated and discarded. New cylinders wlllbe used for replacement. C. 5 Gallon Butane Cylinders 1. These cylinders are generally used by the I&E Department for standards used in the field. 2. These cylinders must adhere to the following specifications: DOT or ICC 4BA 240. 3. Cylinders in gas use will not require a safety valye. Cylinders in liquid use must have safety valves. 4. These cylinders will be painted yellow and their serial numbers recorded by I&E. See section H for painting specifications. 5. I&E will tag the cylinders showing the analyzer they are for and the composition of the standard contained therein. 6. The Control Lab will prepare the standards for these cylinders as needed and analyze the standards. 7. The use of an outside vendor Is recommended for hydrostatic testing of these cylinders at 360 psig since the Control Lab's equipment will not handle them. It will be the l&E Department's responsibility to have these cylinders tested at least once every five (5) years. 8. The maximum working pressure on these cylinders will be 160 psig. The cylinders will be so labeled. CBY 3109640 C 001528 ORIGINAL ISSUE 11/ 09 77 >y W.W.Klewne "revised 06/Z5/& By b.L.Meade REVEIWED / /____ By PAGE 3 OF ^ ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY CHOCOLATE SAYOU PLANT TESTING, LABELING, HANDLING, AND DISPOSING OF HETAL SAMPLE PRESSURE CONTAINERS 8. Wrenches and pliers must never be used to close valves on sample containers. 9. General department procedures must be followed when taking samples. Sample containers filled with liquid samples must be filled from the Inlet valve on the container; l.e., not the dip tube end. All containers used for liquid samples must contain a dip tube. 10. Sample containers containing samples must be kept away from abnormal sources of heat. 11. Sample containers requiring repairs must first be decontaminated by steam cleaning. 12. Sample containers must not be thrown off or on truck, racks, benches, etc. 13. Any cylinders taken out of service for refilling or storage, shall be Inspected visually all over for mechanical damage, such as rust spots, cracked paint, pits In paint, or dents In cylinders. Any damages found shall be reported to supervision and further inspection made before further use of such cylinders. In any case all cylinders in use will be Inspected semi-annually with appropriate records kept. 14. Cylinders used In outside service must be placed on an open grate In order to reduce rusting of the bottom of the cylinders. F. Proper Disposal of Hetal Containers 1. All sample containers to be disposed of will be sent to the Lab for proper disposal or proper Instructions for disposing of the container. G. Specifications to Coat and Paint Carbon Steel Sample Bombs 1. Sandblast to white metal In accordance with SSPC-SP5-63 (anchor pattern shall conform to a minimum of 1 mils). 2. Apply one coat of Matcote 1-830 epoxy promer to the sandblasted surfaces (dry film thickness 1.5 - 2 mils). 3. Apply one coat of Matcote Rust-Ban EX-6707 minimum yellow to the primed surfaces. * 4. Apply one finish coat of Matcote Rust-Ban EX-6707 minimum yellow. 5. Total dry film thickness should be 10 mils. CBY 3109642 gjjyNAL 11/W77ftyW.W.Klemme C 001530 MEWbTWW# riT.'Hea'de REVEIWED / / By PAGE 5 OF ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 009 CHOCOLATE BAYOU PLANT BYPASSING AND TESTING PROTECTIVE DEVICES PURPOSE revisedf Define the control measures to reduce losses due to bypassed or malfunctioning { protective devices. POLICY No protective devices will be intentionally bypassed or made Inoperative without providing adequate alternate protection, continuing communication that the device is bypassed, and approval from authorized supervision. All protective devices will be routinely tested to assure operability. SCOPE fS jd.ft. This procedure .applies to any department (operating unit, laboratory or facility) which must use protective devices to minimize loss or control conditions that affect the safety of personnel and equipment. Examples of protective devices are shutdown devices. Interlocks, alarms, relief valves, vents, back-flow preventers, etc. RESPONSIBILITY The responsibility for control of protective device bypassing and the routine testing of protective devices rests with the owning department at the level of manufacturing superintendent or PT group supervisors as the case may be. Authorization for bypassing protective devices will not be delegated to lower levels of supervision by the manufacturing superintendent or PT group supervisor. Each department will be responsible for providing the necessary internal procedure to implement the control of bypassing and testing protective devices along the guidelines established in the procedure. Records of bypassing and testing of protective devices will be maintained by the owning department of facility. PROCEDURE A. Bypassing Protective Devices revised In the event that a protective device must be taken out of service,. it will be the responsibility of authorized supervision to approve its removal from service. For purposes of this procedure temporarily altering a safety device setpoint (vibration switch, P.S.V., safety Interlock, etc.) either above or below a previously specified valve or altering an.activation point controlled through a computer system (such as modicon or provox) will be classified as bypassing that safety device. C* 001532 CBY 3109644 J. c. Usrey jp^p i np"*T ORIGINAL 4 /9 /68 ^ J.C.Edwards IPPVPiwcn4A / 77 Rv G.N. Peltier | ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-009 CHOCOLATE BAYOU PLANT BYPASSING AND TESTING PROTECTIVE DEVICES (Cont'd) B. Routine Checking of Protective Devices In order to minimize the loss potential resulting from inoperable protective devices, each department (operating unit, laboratory or facility.) will define and implement programs for testing the oper ability of these devices. These tests may be either operational checks or based on preventive maintenance programs, depending upon individual circumstances, but should be sufficiently frequent to assure that the device will function when needed. Each department having block valves located tinder relief valves will take the following precautions to insure relief valves are not inadvertently blocked out of service. These precautions will also be taken for block valves located in vent lines when the vent line serves as relief protection for the equipment such as vessels normally operating at atmospheric pressure. . ' 1. Maintain a current checklist showing location and status of block valves beneath relief valves, or in vent lines used for relief protection. Use the checklist on a regular basis (monthly is suggested) to physically verify block valve status. 2. Block valves will be car sealed in the open'or normal position. 3. These block valves will be painted yellow for proper coding. c 001534 CBY 3109645 ORIGINAL ISSUE . 4 A / 68Bv J. C.Edwards REVISED 12/15/80 By C.C. Fouts REVEIWED 6/2/B3 By j.C.Usrey PAGE 3 OF 3 ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY CONTROL TAG (FRONT) $P-009 irrmni--mm------wa---- CHOCOLATE BAYOU PLANT CHECK BOARD EACH SHIFT FOR COMPLETIONS DEVICE DESCRIPTION/FUNCTION REASON FOR REMOVAL ALTERNATE PROTECTION REMOVED FROM SERVICE BY; PROCESSOR____________________ FOREMAN TIME DATE ZM X --t? I i ESTIMATED COMPLETION DATE/TIME ................. ^ SAFETY NOTIFIED (OUT OF SERVICE) BY: _________________________________________________ AUTHORIZATION: .......... MFG. SIFT, DATE________________________________ SYSTEM RETURNED TO SERVICE & PHYSICALLY VERIFIED BY: PROCESSOR:--__________ TIME _ FOREMAN: 'DATE___________________________ SAFETY NOTIFIED (iN SERVICE) BY: ____________________________ _____________ RETURN TO MFG. SUPT. WHEN COMPLETE ATTACHMENT #1 - SP-009 ORIGINAL ISSUE // / / Bv CBY 3109646 C 001535 REVISED 12/15/80 By c. C. Fonts REVEIWED 6/2/83 By J. C. Usrey PAGE 1 OF 2 ATTACHMENT# 1 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 019 CHOCOLATE BAYOU PLANT FIRE PERMITS AND VESSEL ENTRY/FIRE PERMITS PURPOSE The purpose of this procedure is to define work requiring a Fire Permit or Vessel Entry/Fire Permit and to define the requirements and procedure for issuing such permits. SCOPE This procedure applies to work performed in the fenced plant and the cross-country pipelines which might provide a source of ignition and/or require entry into a vessel. POLICY Work requiring Fire Permits or Vessel Entry/Fire Permit should be done only if no alternate, safer means of accomplishing the same end result is available. Each request for a permit should be ex amined critically to determine if the same work can be done without the use of ignition sources, vehicles or without having personnel enter the vessel. Only if no other method exists, or the alternate method is totally impractical, should a permit be issued. PROCEDURE The permits covered by this procedure are Fire Permits and Vessel Entry/Fire Permits. Either of these two permits may or may not be a "special" permit. The requirements for the types of permits are described below: 1. A Fire Permit (see Attachment #2) is required for all ignition producing operations that are not a part of a vessel Entry/Fire Permit in the following locations: a. All hazardous areas described as Division I or Division II as shown on Drawing No. 340EE1 (Attachment #1) except control buildings and except the Distribution tank truck loading rack where it is impractical to issue a permit to each truck. b. Any non-harardous area as shown on Drawing 340EE1, any approved open area, or any other undesignated area where ignition producing operations are being done on a closed vessel or pipe, contaminated equipment, or near flammable liquids or gases. This does not include natural gas lines or acetylene bottles in maintenance shops. c ooisarr CBY 3109648 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 019 CHOCOLATE BAYOU PLANT FIRE PERMITS AND VESSEL ENTRY/FIRE PERMITS Fire permit work on the inside of a vessel. d. Open flame work to be done onthe outside shell of a vessel. Entry of vessels which cannot be done without Baking exceptions of certain precautions as stated in the section entitled "Comments" later in this procedure.' f. Entry of a vessel by a group not doing Special Permit work where another group is doing Special Permit work. Work on or. in close proximity to energized circuits, 480 volts (277 volts phase to ground) and higher. i h. Open flame work, or use of internal combustion engines/ vehicles in "pump alleys" handling flammable materials. The "pump alleys" or other areas requiring Special Permits will be identified by the Manufacturing Department. Use inside a vessel* of equipment requiring greater than 32 volt electrical supply. j. Operation of lifting equipment near high voltage lines. (Procedure SP-022 applies.) Exceptions (Ordinary Fire Permit Required) a. Steam, water,* or steam condensate piping 2" or less in diameter where length from the last closed block valve to the open end of the pipe does not exceed 6' and the stain header on the other side of the block valve is pressured. Steam tracing with block valves closed from sources of .pressure, provided the tracing is a minimum of 8" from any process or utility line and depressured. Sandblasting of process piping not containing cumene hydroperoxide, chlorine, hydrogen cyanide, oxygen, and acetylenic compounds. Hot bolting (removing every other flange bolt) with an impact wrench which may be done on a regular Fire Permit if the line or equipment has been depressured. C 00i53 CBY 3109650 ORIGINAL ll/5o/63ByW.W.Varnado REVISED 12 / l/81ByC.R.Murrell PaGe 3 OF 9 REVEIWED4/6 /83 ByJ.C. Usrey ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 019 .CHOCOLATE BAYOU PLANT FIRE PERMITS AND VESSEL ENTRY/FIRE PERMITS 6. Welding may require two permits - one at the machine and one at the work. The same idea applies for other internal combustion engines. Locating the welding machine or engines out of a classified area (see Attachment #1) will eliminate the need for one permit. The Shift Foreman will specify the location of welding machines, engines or similar machines which must be located in a classified area. One permit will be sufficient for machines grouped together in a classified area. Machines should be shutdown when work is discontinued for personnel breaks, etc. 7. Operating personnel are required to issue permits to themselves as well as to maintenance and other personnel. 8. All permits throughout the plant are automatically cancelled when a fire alarm sounds. Prior to the all-clear in areas outside the emergency area, and after the Shift Foreman has determined that work can be resumed safely. Processors may re-issue permit by signing them. In the emergency area itself, this authority cannot be delegated before the all-clear has sounded. After the all-clear, permits may be re-issued by Processor signature. COMMENTS ' No procedures can be written which would cover all precautions necessary to make a job safe, but the following paragraphs are intended as a list of items to be considered when issuing permits. 1. Sewers are a constant fire hazard. Therefore, sewer openings in the vicinty (within 35 feet) of open flame work must be tightly covered and protected against slag and sparks. This can be accomplished by: sealing sewer openings with plastic sheeting and sand; sealing with plastic sheeting and water; or purging with a generous flow of steam. 2. Suitable protection should be considered for each job requiring a permit. Such protection includes, but is not limited tO: fire protection equipment, fire containment blankets, a fire watch, etc. The permit should state these precautions. 3 All piping vessels which have contained flammables or which might have become hazardous through contamination with flammables must be isolated and decontaminated before a permit is issued; otherwise a Special Permit is required. ^ C 001541 a. "Isolation" of a line or vessel means blinding (with a gasket inserted on the side of the blind away from the line or vessel being worked on and the flanges tightened again), or disconnecting and removing from the area the line or vessel (refer to SP-016 for Isolation Methods). Blinds must have REVISED 12/ 1/ 81By C.R.Murrell issufNAL ll/zo/S3bv W.W.Varnado REVEIWED 4/ 6/83 By J. C . Usrey PAGE 5 OF ATTACHMENT 9 CBY 3 1 0 9 6 5 2 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 019 CHOCOLATE BAYOU PLANT FIRE PERMITS AND VESSEL ENTRY/FIRE PERMITS 5. When spark-producing work is to be done (cutting torch, welding, etc.) special consideration must be given to containing the sparks to as small an area as possible. Consideration of proxi mity to possible fuel sources, amount of sparks produced and worker safety should all be taken into account. 6. Decontamination does not necessarily eliminate the need for special protective equipment, such as air masks, respirators goggles, lift lines, or other equipment which is considered necessary for the safety of the job by the operating foreman. Safety harnesses and/or wristlets with lift lines attached should be worn when entering a vessel. Wristlets only should be used if the vessel opening is too small to permit removal of a man with a safety harness. Safety harnesses and wristlets are not practical in certain situations such as where the vessel internals will not allow pulling a man out or in the case of bottom entry with the man working on a scaffold inside the vessel. 7. Before any tank, tower or other vessel containing flammable material is pumped out by means of portable equipment: a. The portable equipment must be electrically grounded and bonded to the vessel. Strong consideration should be given to the use of hard piping in making the connection between the vessel.and portable equipment. In the event that the use of hard piping is impractical, SP-010 must be followed in select ing, testing and using a hose system, r P 0~5^> .8 'Hot Taps" are permissible only as a last risort in case of emergency or when the expense of isolation and decontamination is unreasonable, and then only with a Special Permit. The metal thickness and condition of the .equipment to be "hot tapped" must be checked by the Materials Technology Section prior to perform ing the work. All "hot taps" on lines must be approved by the General Superintendent in charge of the line. Lines which should not be "hot tapped" are compressed air, cumene hydropero xide, chlorine, ethylene over 450 psi find 155F., hydrogen cyanide, oxygen, hydrogen, caustic, butadiene, acetylenic compounds. Mo welding is to be done on any carbon steel or low alloy lines where the operating temperature is below 70F. with out prior consultation with the Materials Technology Department. Work on or in close proximity to energized circuits of 480 volts (277 volts to ground) will be done only as a last resort, in an emergency, or when no other practical method exists, and then only under a "Special Permit". C 001543 CBY 3109654 ORIGINAL n/20/6 3gy w. w. Vamado REVISED 12/1/81 By C.R.Murrell PAGE 7 OF REVEIWED4/6/83 By J.C. Usrey ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 019 CHOCOLATE BAYOU PLANT FIRE PERMITS AND VESSEL ENTRY/FIRE PERMITS 14. Driving or extracting piling using a crane causes unusually high stress to be placed on the crane boom and associated equipment. For this reason special consideration should be given to such things as type of equipment used, placement of equipment and personnel while doing this type of work. Also, special consideration should be given to the possibility of underground piping, wiring, etc. being in the way of the piles being driven. (Underground drawings may not be complete.) In most cases a special job safety analysis should be conducted before doing this type work. 15. For work covered by a vessel entry permit a ground fault inter ruption device must be used with any equipment requiring greater than 32 volt power source. SITUATIONS NOT COVERED Situations not covered by this procedure must be approved by the concerned general superintendent. RESPONSIBILITIES See Attachment #4. ORIGINAL AUTHOR: W. W. Varnado REVISED: APPROVED BY: APPROVED BY: fit**!(u/ti C. R. Murrell (]J. W. Kong^ple G. E. Davenport " C 001545 CBY 3109656 ORIGINAL / / REVISED 12/1/81 By C. R. Murre] ^AGE 9 QF ISSUE ll/2(y 63Bv W.W.Varnado REVEIWED4 /6 / 8 3 By J C. Usreyl ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 019 CHOCOLATE BAYOU PLANT FIRE PERMITS AND VESSEL ENTRY/FIRE PERMITS personnel inside vessel, account, for personnel inside vessel, direct evacuation of work crew? remain alert for changes in surrounding area that could affect work inside vessel; perform special duties as defined on the permit form. Normally the Safety Back-up will be from the group performing the work. Carrying out the above responsibilities is signified by the signatures required on the various types of permits according to the following table: - Vessel Fire Entry/Fire Special Permit Permit Permit .1. Shift Foreman 2 Processor Yes Yes 3. Day Foreman or Operations Planner * 4. Monsanto Maintenance Technician Yes .5. Monsanto Maintenance Foreman ## 6 Contractor Foreman (Maint. & Yes Yes CED) *** Contractor Hourly Personnel ** Yes Yes Yes Yes Yes Yes ** Yes Yes Yes Yes Yes Yes . (Maintenance and CED) 8 Monsanto CED Supervisor .9. Anyone 10 Fire/Safety Inspector Yes Yes r Yes Yes Yes Yes (Required when vapor tests ^ 11. Manufacturing Superintendent are performed by him) ' ^ No- No Oral Approval 12. I&E Maintenance Super intendent ### No No Only ;< Oral Approval 13. Superintendent, Manufacturing 14. Superintendent, Maintenance ### 15. Night Supervisor No No No No # Oral Approved. Only Oral Approval *- * ** *** f ## ### Required for any ignition producing work on process or utility . lines or vessels. Not required except for contractor hourly personnel work individ ually such as TMI technicians and truck drivers. Contractor Foreman (Maint. and CED) signature not required for vehicle or electrical test equipment, May sign for any supervision absent from the plant and may act for any superintendents absent from the plant on all permits except special permits. Monsanto Maintenance Foreman signature not required for vehicle, electrical test equipment, nor "in-plant" contractor work. Only for 480 volts (277 volts phase to ground). 3109667 CBY c 001547 3 ORIGINAL n^o/63^w.W.Varnado REVISED 12/1 /81 By C.R.Murrell PAGE 6 OF REVEIWED4/6/33 ByJ.C. Usrey ATTACHMENT #4 SAFETY PROCEDURE MANUAL MONSANTO COMPANY m FIRE PERMITS AMD VESSEL ENTRY/FIRE PERMITS SP- 019 CHOCOLATE BAYOU PLAN ) 10. The Plant Engineering Department la responsible for classifying instruments and types of work on instruments which are intrinsically safe and do not require * fire permit for Division I and Division II areas. Also, they have the -v responsibility to evaluate and tag portable electtical equipment and tools which do not require fire permits for use in classified areas. Equipment not identified and tagged will require a fire permit for use in classified areas. 11. The Safety Department will provide a Fire/Safety Inspector who, upon request by operating or maintenance supervision, will make initial vapor tests, except at the pipeline metering stations, and subsequent vapor tests as requested. The inspector will indicate on the permit the type of tests made, the time and results of such test, and affix his signature. Interpretation of the test results and hazards Involved, if any, will be discussed with the superviso requesting the test. When vapor testing is necessary, a test should be don immediately prior to commencement of work. If there is to be a time delay between vapor testing and the start of work, precautions should be taken ` to prevent contamination of the equipment. If there is any doubt, the vapo test should be re-done before beginning work. {For vessel entry the Fire/Safety Inspector will perform vapor tests for Oxygen content and for vessels with Radioactive sources use a gqlger counter to assur the complete isolation of the source prior to Issuance of the permit. All test results will be entered on the permit form by the Fire/Safety- Inspector. On jobs where vapor tests for flammable vapors should be made during the progress of the work or when requested, the Fire/Safety Inspector will, at the request of the Shift Foreman, leave an instrument with operations after making the initial check. All subsequent test shall be recorded and initialed on the face of permit by the person making the tests. ',, 12. The Manufacturing Superintendent has specific responsibility only on "special" permits. His oral approval signifies that the work is necessary, the method : is practical, and the prescribed precautions, when taken, are adequate. He determines the need for and approves a contingency plan when needed. Be is responsible for staking frequent unannounced work sampling visits to operating areas to monitor work practices and procedure compliance. 13. The I&E Maintenance Superintendent has specific responsibility only on "special" permits to be issued for work on or in close proximity to energized circuits of 480 volts (277 volts to ground) and higher. His oral approval signifies that the work is necessary, the method is practical, and th<e prescribed precautions, when taken are adequate. He determines the need for and approves a contingency plan when needed. ORIGINAL11 _ V.W.Varnado CBY 3109665 C 001549 PAGE 4 OF 6 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 019 CHOCOLATE BAYOU PLANT FIRE PERMITS AND VESSEL ENTRY/FIRE PERMITS ) a) proper work site b) how equipment was decontaminated c) what service the equipment was in d) what the hazards are in the area e) how complete decontamination was verified f) how to be reached if any problems are encountered 9) .location of nearest safety equipment, safety showers. He is responsible for stopping work in his area being done by others if, in his opinion, conditions change making further unsafe. If this occurs, he will notify the Shift Foreman immediately after stopping such work. He may make subsequent vapor tests or request that a vapor tester be left at the work site. The Safety Department will issue and maintain these vapor testers. 0 3. The Day Foreman (or Operation Planner) is responsible and must 4^ sign the permit for any work requiring ignition producing equip-^'* ment on or in process or utility equipment. He must also sign all vessel entry permits. , The Monsanto Maintenance Technician performing the actual "hot", work or entering a vessel will sign ALL permits, indicating that he understands and will follow the precautions and! special 1 instructions prescribed. He is responsible for verifying the ' job situation to be safe, in his opinion, prior to starting work. He will stop the work if, in his opinion, conditions change making further work unsafe. If this occurs, he will notify the Shift Foreman or area Processor immediately after stopping such work. He returns the bottom sheet of the permit to the Shift Foreman when the work is completed. He may make subsequent vapor tests or request that a vapor tester be left at the work site. The Monsanto Maintenance Foreman is responsible for the personnel performing the work including contractors which do not routinely in the plant (non-"in-plantM contractors). He has the responsibility for implementing any special precautions specified by the permit. 1 He signs ALL permits except those for vehicles, C 001551CBY 3109663 ^REVISED 12 /1 / 81 By C. R .Murrell PAGE 2 of * ATTACHMENT #4 SAFETY PROCEDURE MANUAL MONSANTO COMPANY VESSEL ENTRY/FIRE PERMIT SP- 019 CHOCOLATE BAYOU PLANT FI-RE AND ENTRY PERMIT PROCEDURE Refer to the Fire ana Entry permit procedure for further clarification. No procedure, especially a condensation such as this, can foe written to cover ail cases. The proper use of this permit depends on the judgment of the people.signing the permit and per forming the work. ...... This permit shall be securely fastened to the piece of equipment being worked on, or if this is impractical, at a point immediately adjacent and shall be clearly visible at all times while the work is in progress. DEFINITIONS: ' : Fire Permits are required for ALL welding or flame operations and any other spark ing operations within operating and distribution battery limits. Exceptions include inside area maintenance shops, the instrument shop, laboratory and fire training group. These exceptions do not apply to work on a closed vessel, pipe, or contaminated equipment. See map accompanying the Fire and Eiitry.Permit Procedure fos areas v.heie non-flame sparking work is permitted without permit. Entry Permits are required before any person may enter a dosed vessel or an open . vessel deeper than five feet (fire wall enclosures and pipe ways excepted).' , J Special Permits are required for especially hazardous work such as fire j^formit work O on or in closed vessels, or on piping which has not been decontaminated.'depressured or isolated with blinds or disconnections. (See exceptions in Fire and Entry Permit Procedure.) ` I '' Responsibilities: Department foreman is directly responsible for the safe condition of work: he approves the permit. Processor is responsible for executing the precautions and preparations to make thejob safe. Maintenance foreman is responsible' for the safety of the men performing the work, their instructions and precautions. Fire Safe ly inspector is responsible for making gas tests. Manufacturing Superintendents and Superintendents of Manufacturing must orally approve Special Permits. Night'Super? visors, wiio represent all supervision when that supervision is absent from the plant, may act in the capacity of all supervision, during off-hours. Superintendents are re quired to approve all Special Permits. Limitations: All permits are automatically cancelled when the fire or spill alarm sounds and can be re-issued by counter-signature of dcpartment.foreman and process or Permits are valid for a 24 hpur period with the proper signatures. Vapor test must be renewed on a minimum frequency of 12 hours. Please return the permit to the operating foreman or processor when job is complete. CBY 3109661 i C 001553 ORIGINAL REVISED 12/1/81 By C.R.Murrell PAGE 2 .'of 2 ISSUE 11/2Or i63By_W W.Varaadoj j.C. Usrey ATTACHMENT #3 ii'BMimii,aiiOTii a SAFETY PROCEDURE MANUAL MONSANTO COMPANY $P- 019 CHOCOLATE BAYOU PLANT ) FIRE PERMIT FIRE AND ENTRY PERMIT PROCEDURE ' -?i I, Refer 10 the Fire and Entry permit procedure for further clarification. No procedure, especially a condensation such as this, can be written to cover all cases. The proper use of this permit depends on the judgment of the people siting the permit and per forming the work. * This permit shall be securely fastened to the piece of equipment being worleMl on, or if this is impractical, at a point immediately adjacent and shall be clearly visible at all times while the work is in progress, : DEFINITIONS: Fire Permits arc required for ALL welding or flame operations and any other spark ing operations within operating and distribution battery limits! Exceptions include inside area maintenance shops, the instrument shop, laboratory and fire training group. These exceptions do not apply to work on a closed vessel, pipe, or contaminated equipment. See map accompanying die Fire and Entry Permit Procedure for areas where non-flame sparking work is permitted without permit. Entry Permits are required before any person may enter a closed vessel or an open vessel deeper than five feet (fire wall enclosures and pipe ways excepted). C6 W Special Permits arc required for especially hazardous work such as fire permit work o n on or in closed vessels, or on piping which has not been decontaminated, depressured or isolated with blinds or disconnections. (See exceptions in Fire ancT Entry Permit a Procedure.) Responsibilities: Department foreman is directly responsible for the safe condition of work: he approves the permit. Processor is responsible for executing the precautions and preparations to make the job safe. Maintenance foreman is responsible for the safety of the men performing the work, their instructions and precautions. Fire Safe ty inspector is responsible for making gas tests. Manufacturing Superintendents and Superintendents of Manufacturing must orally approve Special Permits. Night Super visors, who represent all supervision when that supervision is absent from the plant, may. act in the capacity of all supervision, during off-hours. Superintendents are re quired to approve all Special Permits. ............. - - Limitations: All -permits are automatically cancelled when the fire or spill alarm sounds and can be reissued by counter-signature of department foreman and process or Permits are valid for a 24. hour period with the proper signatures. Vapor test must be renewed on a minimum frequency of 12 hours. ........................ Please return the permit to the operating foreman Or processor when job is complete. CBY 3109659 '0 001555 ORIGINAL .... " IREVISEdTI/I >81 By C.R.Murrell PAGE 2 OF 2 * ISSUE 11/2Or 63ey W.W.Varnado REVElWEDl / 6/83 By J.C. Usrey ATTACHMENT <2 ST \ MONSANTO PROCEDURE MANUAL DISTRIBUTION Plant Manager (Jonas) Project Director,Mfg. (Frizzell) General Superintendent (Bagood) Employee Relations Supv. (Malfitano) Employee Relations Representative (Matkins) Benefits Rspresentative (Sebesta) TlSifetjr fi loss Superintendent (Wilbeck) (3y i "safety Supervizor (Satsky) Plant Security (Captain) Industrial Hygienist (Katy Lindberg) Plant Accounting Superintendent (Mall) Area Accounting Prop.S Maint. (Clemons) Data Processing Manager (Attra) Accounts Payable Supervisor (Kelly) Manager of PT (Yeretsky) PT Group Supervisor (Grahan) PT Group Supervisor (Saunders) General Superintendent (Gray) MTS Superintendent (Ingersoll) Pit.Engineering Superintendent (Fisher) Projects Group Supervisor (Isadora) Projects Group Supervisor (Pickett) Engineering Services Supervisor (Birch) Central Files (Knight) (2) General Maintenance Superintendent (Osbura) General Maintenance Group Foreman (3) Stores Superintendent (Ingersoll) Stores Supervisor (Loving) Maintenance Shop 4 (2) Maintenance Shop 5 Maintenance Shop 6 Maintenance Shop 7 -XGE Superintendent (Stultz) XfiE Group Foreman XfiE Specialist (Williams) (SPM) Contract Group Foreman Shop *1 (SAP fi SP Only) Shop tl-XGE (SAP fi SP Only) MTA/XDA Superintendent (Sheridan) MTA/XDA Group Foreman (Purdoat) MTA/XDA Tech.Superintendent (Silver) MIA/IDA TSD Supervisor (Turner) Resin/Formalin/DPO Superintendent (Lovivet) Fozmalin/DPO Group Foreman Formalin/DPO Shift Foreman Production Coord.Superintendent (Ogens) Manager,Env.Affairs ~fi Tech (Guilliams) Env.Affairs fi Tech.Superintendent (McCurley) Superintendent Mfg.fi Services (Ceyanes) Purchasing Buyer (Reed) Utilities Superintendent (Atkins) Utilities Group Foreman (Goza) Utilities Shift Foreman Energy,Util.fiSite Dev. Superintendent(Blake) Dist.Operations Superintendent (Harlan) Distribution Group Foreman (Menard) Distribution Shift Foreman (2) Distribution Production Spec. (Jolly) Might Supervisors AN & E.C. Mfg. Superintendent (Silva) AM Group Foreman AN Shift Foreman Control Lab Superintendent (Meade) Lab Group Foreman (Faulkner)(2) Env.Control Group Foreman (Strickland) Env.Control Shift Foreman Manager,Mfg.Guest Companies (Murrell) SAB Superintendent (Hamilton) SAB Group Foreman (Mathews) SAB Production Planner (SpM} Technical Superintendent (Fouts) Sorbic Superintendent (Steinhauser) Sorbic Group Foreman (Bass) Sorbic Shift Foreman MR/Projects Manager (Seals) MHBA MFG.Superintendent (Ochsner) MHBA Group Foreman (King) MHBA Shift Foreman MHBA Process Specialist CED Superintendent (Ganschinietz) c 015S7 Rev. 1/24/86 CBY 3109668 / V Monsanto Colton Isadora - Chocolate Bayou Plant - Ext.4537 . February 28,1986 < PROCEDURE MANUAL REVISIONS TO Attached Distribution Attached are updates for your SAFETf PROCEDURE MANUAL: SP-010 has been revised. Please remove the old copies from your manual and insert the revised copies. SP-010 USE AND CONTROL OF HOSES Pages 1-14 of 14 Attachment #1 Attachment f2 Attachment #3 Cl/sk Attachments Colton Isadore IN . IO (REV. m/77} CBY 3109669 c 001558 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-mo CHOCOLATE BAYOU PLANT USE AMD CQBTEOL OF BOSES PP1POSE Dm of hoMi In chemical process applications Is undesirable relative to fined piping. The objective oust be to eliminate the uaa of hoses whenever practical. This procedure provides a systematic means of controlling use of flexible hoses when they are found necessary. The control approach ..used Includes specifying hose testing methods, testing frequency and record keeping. POLICY The control system set forth In this procedure provides guidelines based on very minimum needs. Individual department requirements may call for more stringent or more frequent testing and Inspection. The very nature of hose systems dictates the need for over-control rather than under-control, and approaches In this direction are encouraged. Hose uses must be reviewed In departmental biennial safety audits and uses eliminated wherever practical. SCOPE Under this procedure hoses have been classified Into three groups: Group I Includes all hoses In chemical or oil (process) service. Group II Includes all hoses In air. water, nitrogen or steam service. Group III Includes specialized hoses such as those used in automobiles or In a laboratory. Group I hoses generally result In the most severe or hazardous consequences If a failure occurs. Flexible connections In permanent piping systems (expansion joints, "chicsan"(flexible elbow type) joints, bellows, etc.) are covered in piping specifications and not in this procedure. Boses used and provided by contractors performing specific services (i.e., vacuum trucks, hoses supplied by tank truck carriers, contractor add washing, etc.) are covered by this procedure. In the areas where full compliance Is not currently practical or controllable, the owning department and/or Maintenance is expected to develop approaches which will result in eventual compliance. The best practical alternate approaches (Monsanto ownerships, rigid pipe, on-site testing and _ _^ C 001.559 Inspection, etc.) should be used in the interim. The Monsanto CBY 3109670 REVISED 8 /i y5!> gy i.I.Satsky" BvJ.H.Bordelon BEVEIWED8/K)/ 85 By G.J.WtUamck PACE 1 OF 14 ATTACHMENT I SAFETY PROCEDURE MANUAL --m--tmsmwwi. i --e--wwi eaa MONSANTO COMPANY SP-0I0 CHOCOLATE AYOU PLANT TOE AM) CONTROL OF HOSES 5. Boms that have been tested should bs so narked by ths Mslntsnsnec Department. C. MTS, Maintenance Engineering, Project Engineering Will review snd approve new boss sppllcstlons and ssslst ths owning dspsrtasnt In sslsetion of boss or altsmsts astsrisls. Approval will bs by asao. Ths hots ssrvics will thsn bs addsd to ths approvsd ssrvlcss list in ths Local Standards List and B.A.E.D. HOSE SAPETT Undsr alaost all circuastancss bosss and hoss systsas will not have the physical Integrity of rigid pips systsas. This fact In itself indicates a need for extra precautions In handling hoses. The following general guidelines are provided as a help In avoiding daaage to hose systsas: A. Avoid sharp bends by Beans of suitable supports or hose routing; especially avoid kinking any kind of hose. The fabric or aetal braid will frequently break or deteriorate when subjected to low radius bends. (Bote: A ainlaua bend radius Is published for aany hoses in hose catalogs.) B. Avoid exterior daaage to hoses such as cuts, bruises, abrasions, chaffing, or chemical attack. C. Hever use a hose In any service other than that specifically stated for the hose. Chemical attack can occur in aany forns and rcaain undetected until failure. 0. Avoid use of hoses where a hose aerely nakes for easier piping connections. In general, no hose will 100Z substitute for rigid piping. E. The difference in hazards between suction hoses, open ended discharge hoses and pressure hoses Is an important consideration in hose selection. PROCEDURE A. Definitions CBY 3109672 Due to the large number of hoses at Chocolate Bayou the hoses have been classified into three groups for a more workable program. All abbreviations and definitions contained herein c 001561 .KEVISEP 8 /1/85 By" E.I.SatskT 12 X^/^4gyJ.H.BOD3alcn KEVEIWEP y3y 85 PyG.J.Wilbeck PAGE 3 OP 14 ATTACHMENT I SAFETY PROCEDURE MANUAL --row .n.jguuni-juiMm MONSANTO COMPANY SPmo CHOCOLATE BAYOU PLANT USE AMD CONTROL OF HOSES f. Group II Hosts Include: o Utility Hoses (water, sir t yellow nitrogen) (UT) Stesa Hoses (ST) Low Pressure, Oxygen-Acetylene Welding Hoses (W) 3. nitrogen Hose - Tellow To protect sgslnst inadvertent use of nitrogen, the following requirenente ere set forth controlling use of nitrogen hoses: a. nitrogen hose ststion will he equipped with (national Feaale Head with 3/4 Brass-B-BFF12. a b. nitrogen hoses will be a yellow 3/4 x 50F long B.F. Goodrich d nitrogen hose to be coupled national Braes-B-BFH12 on end d and national B-BME12LN other end. Both ends to be attached e with Dixon A-9 Cleans. Hose will be stenciled "Monsanto d nitrogen" every 24 inches. Crow's Feet will not be sttached to nitrogen Stations under any circuastances. In applica tlons where nitrogen ie regularly used, permanent piping properly equipped with back flow protection should be 1 installed. a c. nitrogen hose stations will be clearly labeled with high d visibility (yellow) permanent identificationsigns. d ** e d. In new installation, nitrogen Hose Station will be d separated froa utility hose connections by at least 10 feet where possible. Separation of nitrogen station* fron other utility stations is also to be considered where practical in existing application. C e. Stores will stock National male and female fittings necessary for connecting hoses to equipment. A MC Stock # will be assigned and made available to all units. 4. Croup III Hoses CBY 3109674 Include specialised type hoses such ss automotive or vehicular hoaes and very small (1/4") hoses that are used in the laboratory or on gas cylinders. However, if the hoses are used in a high pressure or hasardous service, even small hoses should be classified as Group I hoses. Group III hoses should be visually inspected annually. The judgement of the individual department supervisor sust be carefully exercised to determine if a hose falls-- into a Group III or Group Z category. C 001563 ORIGINAL ISSUE JL2 /ti/'74jyJ.H.Brtn*1nn lEVtsio 8 /I ^85 By' E.l.Satsky REVEIWED y3y 85 y G.J.Wilbnck 1 PAGE 5 OF 14 1 ATTACHMENT SAFETY PROCEDURE MANUAL rrfwrm.wA.il u juji uam MONSANTO COMPANY SP-010 CHOCOLATE BAYOU PUNT PSE ASP COWTROL OP HOSES b. Hom Data Records - Tha followins boat data will be aalntalnsd by tha owning department on each hose (sea Attachment #1): 1. Boss identification nuaber 2. Monsanto hose specification nuaber or hose description. 3. Bose pressure data: (a) Bose working pressure (b) Hose burst pressure (c) Bose test pressure c. Bose Identification Tag - A hose identification tag mist be affixed to each with the information outlined below: 1. Bose nuaber 2. Service 3. Date of manufacture or purchase 4. Working pressure 5. Burst pressure Purchase orders should specify that hoses be tagged by aanufacturer reflecting the above information. Stores should verify upon receipt. If a hose is not branded with aanufacturer's naae hose nuaber and tube material, this information must be included on the hose identification tag. Boae owners should have tags prepared and attached as needed to existing hoses. - d. Bose Inspection end Test Certification Sheet Fora (Attachment #2) - "Hose Inspection and Test Certification" sheet will be filled out each tine a hose is tested. The fora will be filled out by Maintenance and will be filed by the owning department. e. Bose Test Tag - A "Hose Test Tag" will be affixed to each hose by Maintenance indicating date of test. The hose test teg may be any of the following: C CBY 3109676 001565 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-OM CHOCOLATE BAYOU PLANT USE AND CONTROL OP HOSES iru is loose or the rainforceaant Is exposed). Kinks - for evidence of week spot or kink, pick op hose every 2 feet. A week spot will 1st the hose pertlelly collapse when picked up in this wanner. Bul(es. Soft Spots - Check for soft spots by pressing with the thuab the eres adjacent to the end connection for about two feet. End connection daaaged, internal liner, gaskets end "0" Kings. Metal Hoses - aetal hoses construction usually consists of a corrugated aetal tube (auch like a bellows) and a aetal braid covering. They are extreaely susceptible to daaage by overstressing in tension, excessive bending, crushing and broken aetal braid. The hose should be lsyed out full length and exaained for the following defects which are all causes for hose rejection: Metal braid broken. Kinks or permanent deformation. Overstressing damage - aetal braid pattern is elongated or corrugations of tube have expanded. End connection damaged - strands broken or braid loose at end connections. 2. Hydrostatic Test Procedure - (Non-Metal & Metal Hoses) Lay the hose out full length and position on platform to permit easy movement under test pressure. The hose1s end connections Bust be secured so they cannot fly off. Fill hose with water and bleed all air by raising vent end of hose. (Chloride free water should be used for stainless steel hoses.) C 001567 CBY 3109678 PACE 9 OF 14 ATTACHMENT I SAFETY WOCEWRE MANUAL MONSANTO COMPANY ^I--mil Ml 111111111 --------WWUBI " HI I HHBJia.JiL ,'I[4JHIIMH SP'OID CHOCOLATE BAYOU PLANT USE AMD COimtOL OF BOSES C. Croup II Boses 1. Farchmt Purchase of all Group II hosts shall ha In accordance with the "L" Manual standards and shall be narked as outlined In Section C-2 of thie procedure. 2. Identification end Kecords Utility and stean hoses are not to he Identified by e hose nuaber and no records will be kept. Identification will be by hose color. Utility hoses are green, stean hoses are nozaally black, red Is to be used normally for chenlcal transfer hoses and nitrogen hoses will be yellow, (added) Important - Some utility and stean hoses in the plant nay not conform to the colors as outlined above. In those cases hoses should be verified for the type of service before being need, mo color exception will be Bade for nitrogen hose, and yellow hose will not be used in any other service. a. Hose Identification - hoses (except for welding gas hoses) are to be narked or tagged when purchased as follows: Utility Boses - Monsanto Utility Stean Hoses - Monsanto Stean Nitrogen Hoses - Monsanto Nitrogen b. Hose Inspection Teg - the Inspection verification teg will be a band of vinyl color tap (Scotch #190A or equivalent) on each end of the hose next to coupling. The color code listed below will be used. If a hose does not have current coded tape on It, this hose Is not to be used. The following colors will be applied upon completion of inspection. January - Even Tears - Brown July - Even Tears - White January - Odd Tears - Bed July - Odd Tears - Green c 001569 C8V 3109680 ORIGINAL 12/27/74 J.H.Bardelon ISSUE 7/ M REVISED S/1/85 * E.l.Setsky REVEIWED^/^85 % G.J.Mlfamck !*mil (riiur""`*`wiw>Mii---- PAGE 11 OF 14 ATTACHMENT SAFETY PROCEDURE MAHUAl MONSANTO COMPANY SP-qiq CHOCOLATE BAYOU PLANT USE AMD COHTKOL OF HOSES Boim with damaged nd connections can b repaired but bat hoses wist be hydrostatically tested to 375 pslg after repair. Stesa hoses fall under the Group II Boses* and only require hydrostatic test of 250 pslg after repairing. BOTE: If a hose is to be used open ended only* the fitting connection on one end wist be removed. b. All hosas wist have a current hose inspection tag or tape affixed prior to putting Into service. c. It Is not required that hoses be automatically replaced at a specific age. The owning department nay* however, chose to Institute a regular replacement procedure (i.e. MHBA unloading hoses are replaced every 6 months). D. Group III Hoses Testing, inspection and record keeping for these hoses is not required. Group III hoses Include those In automobile service and hoses in non-critlcal* low pressure laboratory applications. However* good conmon sense and safe practices anA visual Inspection should still be applied to these hoses. The Items covered under "Hose Safety" apply to all hoses. CBY 3109681 ORIGINAL ISSUE ,t 12 2/74 By J.H.Bordelon (REVISED 8 /1/85 * H "Oatsky {gEvEiwgp 6/3^65 ' G.J.Kllback C 00X571 PAGE 13 OF 14 ATTACHMENT DATE ATTACHMENT #1 STEAM HOSE HYDROTEST HOSE LOCATIONS __________________________________ NUMBER OF BOSES TO TEST* _____________ _______ % KEY FOR TEST RESULTS: A PASS HYDROTEST AS TESTED B PASS HYDROTEST AFTER TIGHTENING COUPLING BOLTS X REJECTED DUE TO COUPLING LEAK Y RUPTURED (NOTE LOCATION IN COMMENT) Z VISUAL REJECTION (NOTE IF LEAKS OR BULGES) NOTE: HOSES PASSING ARE TO BE TAPED WITH ORANGE TAPE MARKED EITHER ODD/EVEN YEAR. NO. PASS FAIL COMMENT i i! | C 001573 m STEAM HOSE HYDROTEST PAGE 2 ATTACHMENT #2 NO. PASS FAIL COMMENT TOTAL TEST: NO. HOSES PASSING NO. HOSES FAILING C 001574 C 001575 YEARLY HOSE TESTING REPORT I FHONSEEEDNEOD.) HOSE DESCRIPTION 4 eigf1 <o o> o n > oeo ATTACHMENT #3 HOSE SERVICE LOC. TEST PRESSURE WORKING PRESSURE TEST DATE SAFETY PROCEDURE MANUAL MONSANTO COMPANY IN PLANT RAIL CAR MOVING SP- on CHOCOLATE BAYOU PLANT PURPOSE The purpose of this procedure is to define the responsibilities for moving rail cars within the Chocolate Bayou Plant. SCOPE This procedure applies to all rail car moving done within the Choco late Bayou Plant excluding NTA Hopper Cars, that are moved with a special Cable System, and handjacking cars a few feet. The methods discussed within this procedure are: 1. Normal moves by railway switch engine 2. Special moves by railway switch engine 3. Other special .moves PROCEDURES AND RESPONSIBILITIES I. Normal Move by Railway Switch Engine Rail cars are routinely moved within the plant during the graveyard shift C2400-0800) Monday through Saturday. To get a car. moved during this time, the following must be done: 1. Notify the Traffic Department of the need to move the car. 2. The Traffic Clerk will add the car to the switch list and -the car will be moved by the railway switch engine. NOTE: Notice must be given to the Traffic Department no later than 1200 hours for cars that require moving on the next graveyard shift. . II. Special Moves by the Railway Switch Engine I. Notify the Distribution Loading Foreman of the need to move a car outside the regular switching time. This notice must be given at least 24 hours prior to the time the move is required'. 2. The Distribution Department will notify the Traffic Department. c 001576 3. The Traffic Department will make the request to the railway company. cBy J10,686 ORIGINAL i/gAsby L*C* Peeler REVISED 8/27/ 81By J.M. Talbert PAGE OF SSUE REVEIWED6 /l!j/ 83 ByJ.M. Talbert ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- on CHOCOLATE BAYOU PLANT IN PLANT RAIL CAR MOVING (Cont'd) It is entirely up to the railway company whether or not they can make the move. In the event the railway company cannot make the move, a special move made by .the Maintenance Depart ment can be evaluated. III. Other Special Switches In the event that neither of the above methods can be used for moving a car, the following method can be used. This method will only be used where there is a high potential for signifi cant. business interruption, personnel or property loss if the car is not moved. 1. The department requiring the rail car to be moved will make the request to the Distribution Department-Loading Foreman. Information that must be supplied at the time of the request will include: a. The situation requiring the need for a special move b. The chemical to be handled c. Deadline before which the move must be made .2 The Distribution Department will review the request and determine its feasibility. 3. If the move is feasible, the Distribution Department will issue' a work order to the Maintenance Department. 4. The Distribution Department will then initiate a job plan based oh the Maintenance Standard Safety Procedure SIQ , Emergency Spotting of Rail Cars, and. a special vehicle permit to accomplish the move. The special permit must be signed by supervision up through the General Superintendent, Manufacturing/Maintenance of the requesting department, Distribution and Maintenance. The Maintenance Department will perform the job as outlined in the Maintenance Standard Safety Procedure s IQ / Emergency Spotting of Rail Cars, and the Distribution Department will supply a flagman/brakeman. Under no circumstances will anyone be on the rail car while it is moving. C 001577 CBY 3109687 ) ORIGINAL JSSUE /g/75 By REVISED 8 /57/8lBy.T-M. PAGE 2 OF L.C. Peele;'REVIEWED? /Is/r^ Bv.t.m. Talhorl- ATTACHMENT 3 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- on CHOCOLATE BAYOU PLANT IN PLANT RAIL CAR MOVING (Cont'd) 6. A member of supervision from the Distribution and Main-, tenance Departments will be present during the job. ORIGINAL AUTHOR: L. C. PEELER Car 3109688 c 001578 ORIGINAL ISSUE --------ccro-- r-- iA/sbvL.c Peeler REVISED 8/&7/8lByj.M. Talbert REVEIWED6/15'' 83 ByJ.M. Talbert PAGE 3 OF ATTACHMENT 3 - SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-012 CHOCOLATE BAYOU PLANT ivwmumfl----IM^^--IMHUTlJWMMIIlHIBIJmiWl--------MMBB RAIL CAR LOADING/UNLOADING PURPOSE The purpose of this procedure is to define legal and safety require ments for protecting railway cars from movement during loading/unloading operation. SCOPE This procedure applies to all railway cars loaded or unloaded at the Chocolate Bayou Plant. PROCEDURE AND RESPONSIBILITIES It will be the responsibility of the department connecting the. rail car to process piping to do the following prior to the connection being made: 1. Confirm the hand brake has been set by the railway company. 2. Place a derail at least 50 feet in front of the tank car being connected, to prevent another car from being pushed in from the main line. 3. Place "chocks" on the rail against the wheels of the car in such a fashion as to prevent accidental movement of the car in either direction. 4. Raise the blue flag that is installed on the track. This is a warning device for the railway company personnel to tell them a car is connected. The reverse of the above procedure will be done when the car has been disconnected from process piping. The department responsible for connecting the rail car will also be responsible for disconnection of the car and removal of the precautions taken in steps 1 thru 4. ORIGINAL AUTHOR: L. C. PEELER C 001579 CBY 3109689 gSr* 3 /17/7%vL.C. Peeler REVISED 8 /2 7/ 81 By J.M. Talbert PAGE 1 OF 1 REVEIWED6/iy 83 ByJ.M. Talbert ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-012 CHOCOLATE BAYOU PLANT RAIL CAR LOADING/UNLOADING PURPOSE The purpose of this procedure is to define legal and safety require ments for protecting railway cars from movement during loading/unloading operation. SCOPE This procedure applies to all railway cars loaded or unloaded at the Chocolate Bayou Plant. PROCEDURE AND RESPONSIBILITIES It will be the responsibility of the department connecting the rail car to process piping to do the following prior to the connection being made: 1. Confirm the hand brake has been set by the railway company. 2. Place a derail at least 50 feet in front of the tank car being connected, to prevent another car from being pushed in from the main line. 3. Place "chocks" on the rail against the wheels of the car in such a fashion as to prevent accidental movement of the car in either direction. 4. Raise the blue flag that is installed on the track. This is a warning device for the railway company personnel to tell them a car is connected. The reverse of the above procedure will be done when the car has been disconnected from process piping. The department responsible for connecting the rail car will also be responsible for disconnection of the car and removal of the precautions taken in steps 1 thru 4. ORIGINAL AUTHOR: L. C. PEELER ORIGINAL ISSUE c 001580 3109690 L.C. Peeler REVISED 8 /2t/81 By J.M. Talbert PAGE 1 OF 1 REVEIWED / / By ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 013 CHOCOLATE BAYOU PLANT 3109691 ORIGINAL REVISED 10/10/74By S. Chamberli // By ISSUE Reviewed 4/ 1/77 bvl . C 001581 PAGE I Of 1 ATTACHMENT 2 nwnfWM--i SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-015 CHOCOLATE BAYOU PLANT w SOLID WASTE DISPOSAL SITE - AREA PLAN CBY ,, c 001582 3109692 " 1/1/ 7^yjli,i ^amberl^-g^ A L By______ ^L.C. Peeler PAGE 1 OF 1 ATTACHMENT #1 SAFETY PROCEDURE _M_A_N_U_A_L_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ____ _ _ _ _ _ _ _ _ _ _ MONSANTO COMPANY * CHOCOLATE BAYOU PLANT SOLID AND HAZARDOUS WASTE DISPOSAL ATTACHMENT #1: EPA HAZARDOUS WASTE LISTS AND HAZARDOUS WASTE CODE. NUMBERS D. Designated EPA Hazardous Waste Materials: Discarded Commercial Chemical Products, Off-Specification Species,. Containers, and Spill Residues Thereof. The following materials are hazardous wastes if and when they are discarded or intend to be discarded: (a) Any commercial chemical product or chemical intermediate having the generic name listed in tables below, or (b) Any off-specification commercial chemical product or chemical intermediate which if it met specifications would have the generic name listed below, or (c) Any container or inner lining removed from a container used to hold any of the listed materials unless triple rinsed to remove all residues, or (d) Any residue or contaminated soil, water, or other debris resulting from the clean up of a spill of any of the materials listed below. Acute Hazardous Wastes CBY 3109693 HAZARDOUS WASTE EPA HAZARDOUS WASTE NUMBER HAZARDOUS WASTE EPA HAZARDOUS WASTE NUMBER fHWWI,Q. moro- Aratmat. Acaawua. 2Jmoro. Aoaae aod *uof. Kdu. aM 6pmo*loy)i., ra|i (Mr 3-tamna acaiunyMamnU I hrttmyujumann art ua 1 AcaiyU-PPxraa Aim MM aieonoi Akpnnun pnoaoooa P-(Ar -numi 1 aniirom 4 fcAmmopynana Ammomum pcfata (A) Ammon*** vanadate Anm, txtftyv Aanm *023 *002 *057 POM P001 P0Q2 P003 P070 P004 POOS POOS poor POOS POOS PITS P010 POT 2 P011 pon P0t2 POM P09S ahum eyance Banaenamme. *-oaor. Qanianamce. iwim (encremeeMV \2 awinwol, araanetncf Mrtryl qaonda Baryte** due lalcMoremamyO amar Bremoeoatone ruema CatCRim evanM Camonana. oettemoro. Camammcoaatanoc aod Careen beutfee Careen demfioa Careonyi emonoa CNomt cvanca Chcreacataioenyoe P-O*croan*r We^aoropnanvomcuraa 3-Oaorepreecncoaa CoenreyanoM CypnOM IKKutM qmi uni. iw P013 P024 P077 POM P042 P014 POM P01S PCtS P017 P01S P021 PT23 PT03 P022 P022 POM P033 P023 PC2 POM P027 POM POM CO CO m H w ffJfF'NAL 10/V* REVISED 11/3C/91 BvW.R.McCurlev pap.p7! of 10 S.ChamberlfiffeEVlEWED / / Bv ~ | ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 013 CHOCOLATE BAYOU PLANT SOLID AND HAZARDOUS WASTE DISPOSAL ATTACHMENT #1: EPA HAZARDOUS WASTE LISTS AND HAZARDOUS WASTE CODE NUMBERS Acute Hazardous Wastes (Cont.'d) HAZARDOUS WASTE EPA HAZARDOUS WASTE NUMBER HAZARDOUS WASTE EPA HAZARDOUS WASTE NUMBER Cynopan Cwflopw cmonda OOMcNdpmropftanyiarana O.O-CM--4 S-tt*4any<--o>e--} p wrownyi pnoapnaia 0.0 &a--4 0*pan)tf pftoaeftoro--dt Omanotia ((mawyianioCardonyO om* O.OOma--4 Oe*Mreonanyt phoaphom >ma--ilpnanariylciMia mol and idti 4.t*Owarfro<ycionaay<phancl Ocncaonomnada, aoiwmyt. OmoeyrophMpftonc aod. tmertyl aawr Endoauifan Epmapnnna Efwnimnt. 1.1 dma--Al'ahnwy* ENnmn, M-nt--ffcN rat6ii> E--teyanda E--Haomma FRaumomprear Pvkmnc aod. mercuryfW) MR <RT) Hawacmor 1A3.4.10.10HtMChioro47 apoay l.4.4glt?,>.M ocunypo Tdo^ 1,4;S.t*d*naftanonaiiniria<ain 1X3.4.10.10 iracwofo f.7-apoay. 1.4AJ oama--anm'oungitMnt 1JJLd IQ in M--rfIIIW A,AAm 4 a neMnyori.4 S.t who, ando otmm 1XX4.10.10 HaoacNnro l,4.4a.H4d h--atpidro l.4 fi,t ando aio aowiaiionapng--ana Ho>cwoiofai<fi)da<804op owtcnonapdinaiana Hydropaw cyarada Myowyo pnoapnca taocvaoc aod. mar* astar 3<2H) tioaaiotona. 5 pwawamyO* Marary. taoetaio-Oioftar*. MMaitrawrya.MemayocaaifaO(tOR'Td)* Mariana. mranar (P) MatnanaVKX dcnoip 4.7 Mpgiano iH^noana. 1.4,S.X7.14^aeiacmoro^4.4.7.7a laranyoro. Manor* mi POM PON POST rat rat rao ra3 pom ras P071 rat rat ra7 rat rat rao ras rat rat piot mo mi rat rao rat pioi mt rar mo POJ7 mt ras rat mi ra7 rao P004 POtO PO&2 PI It POtt P063 P063 POtt POM P007 P0t2 P065 POlt P112 Pill mt POM 2Ma--4wr--na Mar* hyoraana Ma--4 eocyiMi tM Mt** pflfMMfl' IpftO Napn**--our-- NcMt carOdr* NcMleynOt NcfcORff) C|fWMt NcMt twcarw* Ncoana and uM NcrcoMda p-Ndroanrina Noogantaida Mro-nOO ecdt NaroganflV) coda Noogycanna <B) M Mcotoanatiytanana N >aiiuomag*vt*an'wc Notomana2>danaffianet. 1.444.7.7* AtlMHOfD. cydc idtt OOuararra*jmaPo*hiymccnoapnorr,iad Ovnwffl ereudo 7*teocveC24.17ratana*24* ocareoiytc add Pan--cn PUP**. 2 cydoftaay* t,4n> Pftaool 2.4-omt^ Pnanot 2.o --a t man* ranot. l,a d--*o a (lmat*e*c--0* Pand, . ammora-- aai (P) Papt a--doava --anjxrwarounc aeaiaa* N Purr*--nraa Ptcrata --wapana Pnoacnot Prcacnonc aod. da--4 p*atwar* m7 rat Pott rat P071 0072 ton P074 P074 P073 pots rao PG77 rat rat rat poti po*2 pot4 pom pPo0a057 pot? rat PO rat rat ra7 po20 rat P036 potJ po3 pom pom ?o*6 rai --oapnoroO--oc aod. 0,0*mrff* ^ `mmar*amno>*24*auag*)aawr pnoMroodMcnc aod. oa(Hiawyia--4K Ptidaonore--ec acid, 0.0 6a** S* M**--o--*mm Phoapnon--co aod. OjOda--4 O-lpx* : pod. 0.0-a--4 O- pyvp* Phoapnon--oc aod. 0.0 oma--4 Uipnaarytanwio) aurtqrty<)pna*pO--lar --anoana. iaaaaii< Potaapum eyanca Potaaaum Mr eyanda PfoeanaL 2 w--* 24wa--4--oK O* lunarlynaMOWroonyOfloma Prooanara--a PPfrOoopaatnMaOo----aa.. 23---crftOorrooa*y*24wa--4* i4>Preoownot. mam (P) 2 Pfocanona. i^romo* 2 Piugaii id t Prooyn %*o CBY 3109694 P044 P0*3 P0S4 POtt P040 m7 PiiO POM POtt P070 P101 P027 POtt POil P017 PI 02 003 POOS m7 P1C2 POOt ORIGINAL ISSUE REVISED 11/30/81 PyW. R.McCurley PAGE 5 OF 10 74ByS .Chamberlin REVIEWED / / Bv___________________ ATTACHMENT #1 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 013 CHOCOLATE BAYOU PLANT SOLID AND HAZARDOUS WASTE DISPOSAL ATTACHMENT #1: EPA HAZARDOUS WASTE LISTS AND HAZARDOUS WASTE CODE NUMBERS Acute Hazardous Wastes (Cont.'d) HAZARDOUS WASTE EPA HAZARDOUS WASTE NUMBER Pynan*. (S^I-oMtiy^i^ynotdmyt)'. and -- Pyiopfto--ncne aod. Hiret--y> mm itunmn* Sfrar cyanoa Soduaaada S-- cyanda SmuMdM Stycf--itoia, and --s S--r--wiO-ooa. 23 d--pay Srvcfmna and aaMt SuNune aod. naHuryl) m* Tca--ywopyrophoacnaia Tag--ffryl Had T--r--ytpyropnoa-- T--rantrama-- (R) Twapnoaoddnc acid. ItdaMdty* daaar Thafte osov P075 Pill Pi03 Pi04 PI05 PI09 Pi07 PI09 P019 Pi09 P115 P109 Pi 10 Pill P112 P092 P113 HAZARDOUS WASTE Tfcataavmooada ThafcimO) aaianm Thaftumfl) autfaia Th--nca Th--cartwnc panada TThtaoHohaawioai taBd* Ttaawaa. B-emorecndnyf). Th--. i-nacnm-ayt D--m. phanyfc Teaaenana TncraoromathanagM Vanadc aod. ammonaim laJt Vanaduni pa--ada vanada--KV) -- wartam Znccyanda 2lnc pnoapnda (R.T) EPA HAZARDOUS WASTE NUMBER P113 Pi 14 P11S P04S P049 9014 Pi 19 PQ29 pan 9093 P'19 PI 1ft Pi 20 Pi 20 P001 P121 P122 Hazardous Wastes HAZARDOUS WASTE EPA HAZARDOUS WASTE NUMBER HAZARDOUS WASTE EPA HAZARDOUS WASTE NUMBER AoatHdahyda (I) 4c--awrryoa. flW Aowidt, N4*-a--oaypnAy<h Acatamoa. N~9H.fcjerww2`yi Ac--c cod. --fmm 0) Ac--c coo. mo --ft Ac--c tod. thatomfl) Ml Ac--on* (fl Ac--0--0.T) Ac--yi -- (CAT) Aon--mda ao-- -- <n Acr-- Aiam, Hp--frcN--o) --4-. t* A-- A-- 0.T) A--rJ'3.4)pyT*oo 3-alindOla l.7 --. tcimno A (--wwocaWaon/Q to m--rnjay i iwa--y<, 8--gCflaraan--ry--> 1.2-d-- ftargtcjaenftna 11 ffnrauuw* S-- --onM U001 U034 U197 uoos U112 0144 U214 0002 UOOS 0004 uoot uoot 0007 uoot uoot Uiso U011 U012 0014 U01S 0010 0157 0019 001* 0017 Nntfi]--mera 131--irrmrto-- 13 Banran----. 7.124--y4 ftamanamna (1T> ft--uan--mm, 4,4*^--ytMNA 4.4V , 2-m--4hydrocMonoi ft----c. 2 m--ny< 6 mro MUT) cnoropnanyl) ---- hyoroay. athjrf --tar 9amana, i crone pftanary 9amana. --ro Uto--ca--ryac cod --nda 13 Banlanadtecrpowyac cod. (test2--M. h--yi>3 mm 13 flagganarfirarocayAc cod, dfemv* --car 13^>--nana--rorwyto aod. dfOM a--ar 13 ParganaHcjrooiyfce aod. --y< 13 ftamar--rt--dg aod. Bamana. l3-dcn*cr> ftargana.)--ro--nvi). oOoOialt 00ft4 0012 U014 0049 0093 0159 0222 U181 0019 0039 uox 0037 0190 0029 0069 0089 U1C2 0107 0070 0071 0072 0017 0223 CBY 3109695 1/3 CO 1/3 H O O C Ao/iORIGINAL , ,, ISSUE REVISED 11 /^q/ 8lBv W. R.McCurlev, PAGE 6 OF 10 4 BvS.ChamberliijiR[rvipv/pn / / By ATTACHMENT #1 SAFETY PROCEDURE MANUAL MONSANTO COMPANY _ _ _ _ _ _ _ _ _ _ _ _ _ _ SP- 013 CHOCOLATE BAYOU PLANT SOLID AND HAZARDOUS WASTE DISPOSAL ATTACHMENT #1: EPA HAZARDOUS WASTE LISTS AND HAZARDOUS WASTE CODE NUMBERS Hazardous Wastes (Cont.*d) HAZARDOUS WASTE EPA HAZARDOUS WASTE NUMBER HAZARDOUS WASTE EPA HAZARDOUS WASTE NUMBER Iwm. *ioi|t<l,1) IManmaM Mmini, hncMvo* mana. h--H|nnw (Q l.rgTM. hyurmy lam, mmr*r* antana. mm. l-wryt-tHma mm. U w--iiiimituiiirf^iumi)*. mm. (ImryiHiyt)-d) mm, nx>. #.7) l9Mtt. pmlMMOM* mmaaaaiac and cnaonda (C.B) ftmnaaumyy cNonoa |CR) mm 1.2.4J iaacniet atom. OicnKyomaBVHCATl amm Uiama (RT) vnooni 1 7 BiiwihwiijMi 1 unt. i.l^andi melalpytm i. 8wnap|iain P Banmniaxma araowama (C.RT) tf iorow 0.T) (t.r^nanyiM.d'-dwim n.l'-twulH.i'mia. X3T<Ma, (l.oi-y8-nany<Ht.4 mam. Umax- (t.1'*90hany<M.4'<*amffia. 3J* dfcfW>yt Ba(2<noiMB9iy) mMnt 6M<lCNoroMBQrep0 athar Hmxymccftamcjyi) aauwaa ai<ha()() pwmauM trpwwia cyawast |fqMQlgi*|) ^9fomop9anyi phmyl linf Ufcaaaana. t.l JJ..4-naueMofoMuwwim. wmyumtotcuanoc art. 4-(*a<J-cm*r>y<)anml ttww 1>9utonoi 0) lauunm n.n 2-SuiMon panada (W.T) 2iui>nrt item. t>4M J.T) n-8wpa aMPena) n ran^ac sod Casawm tfvomaw Cartsawm: aad. t*M Mr CartMwac aao. mMfyvwoacK *ry< aalar CaiPtam. Cmmojs ensonoa. dncvi)4> CarPorac art mawmai Carponocraaroc art maxyt aw (IT) Canon onAkoM (A.T) Canon laaacnsonoa Canonya hma (RT) OaofK Cmmaawuel Oaonana. lainmcat U239 UfOl 0127 0064 0194 U220 U10I uioe 0203 0141 uoeo U055 0199 0193 0195 U030. 0030 0207 0023 0234 0021 U202 0130 0022 0022 0197 UC23 U050 0095 0021 yon 0091 0095 0027 U22S 0030 0128 urn 0031 U1S9 0190 0053 0074 U031 U138 0032 0239 0179 0179 U21 0097 U21S 0154 0033 0211 0033 0034 U03S 0036 0029 0037 lHpOXotcttanayO-SmBioay-2- 21-CfRCr6N0oo1w)r>Ao2raiJ0nO*aI^wp3n>oOyat iO>99p9Ormo6c1^9a0 CNoroton* CMoronatu* maty atar Dasa-Sasannacnmasawi OaoromokiWna. hydreaaenaa O*omc art cafew tail Owyam Craoaoaa KnmM Craayteaad Cnnnaionnydf Cumana (0 Cyanooan bwnda 1,4<CyQiOAaKaO*na*ona CywAaam (I) Oyooftaianona I^Cyaoaanaaaana. orw> 1A3iWw CycsupnoyiaiT4ja 2.44-0. tan ans aatara Oaunomyan 000 DOT 0acacnsonoctaftyori4.*4wattwoa>^ cycaeeuuIe^lmMawwJma fiMMasa Owim (RT) DiamnoaoSuana Dfemtajilanavaem I.T^.ft^Viarginffiraiiana Ii7j-O*amoorm OmataJlpyrm i^OaiQAaO^Aaiutmaiit OouM pmnam $-<2>0rttoro*RyO a-OKWonoanana w Ocworoofuna l.*Ocwo2 amawa (UT) OioW9ooAiuo>owaAa>t 33-0t4on>*H1.1mmX|il 2 mD/ntf Okbkvq ocwvofniAi Ocwo ocnany* howmiubi 2.4-0cn*OfOpf>i4Mnor 2.ft-&eraoro0nMoi 2.4-Ocnionpftanoityacaac aod. mas ana U-Ocmorwoocr* t^QcfMoroorootrK Ul*-Onpoiywsni fl.T) l.4-0inytana aono* N,N-OMP>yifvji iu ># O.0 Chan* $ m^oy^caooftoaxia* O^ciyi onm*Mi OaotyStttbMffof 0**rOPOMfTM IT tVlWffXMySmiLBjtM 0041 00*2 00*4 00*6 0047 0049 0032 0050 U0S1 0052 U052 0053 0055 U24 0197 0056 0057 0130 0059 U240 0059 uoeo 0061 0142 U082 0133 0221 0063 0063 0064 0064 0096 0069 0062 0070 0071 0072 0073 0074 U07 0192 0060 0091 0074 0079 U025 ooai 0062 034C 0063 0064 0065 0106 0099 0097 0094 0099 0149 0090 0091 o<o 0* o m4 CO > a u ORIGINAL // | REV ISED 11/30/31BW. R, McCur ley PAGE 7 OF 10 ISSJE 10 AO/74 ByS.ChamberlinREV[EWED / / Bv ATTACHMENT #1 cr CD in h o o t? JfS SAFETY PROCEDURE MANUAL _ _ _ _ _ _ _ _ _ _ _ _ _ _ SP- QX3 MONSANTO COMPANY CHOCOLATE BAYOU PLANT ( SOLID AND HAZARDOUS WASTE DISPOSAL ATTACHMENT #1; EPA HAZARDOUS WASTE LISTS AND HAZARDOUS WASTE CODE NUMBERS Hazardous Wastes (Cont.'d) HAZARDOUS WASTE EPA HAZARDOUS WASTE NUMBER HAZARDOUS WASTE EPA HAZARDOUS WASTE NUMBER 7.ia-&nmnyMnUlim*nci i IT mr.iii u.Tr.iiui -_u OnwthyicflAaffi^ cNoRda Oimawjrf pnmmm Oamfiyl aetata 2.4-OmvmdMM 2>Owremuon 0Mveiyt imw I.i-Owmm 1.2-OwMniimimiBM OpBpymwn. (I) 0 N procyttwaaiwpi Enmi (i) Etiana, t2-- Etnaw. Udehur^ ' Emana. 17ocmoroT^'Efltanatfvnacardamodan--e aeta Emm. 1.1.l.Z2-Mucmon>- EMm. 1.tXnwn)MMM(oiyt)M2> tftfor EMmmm* (1. T) Emm.Um (1) EDiana. 1.r-oyem2<r>ky> EMa, pa--aeraor^ Emm. 1.1.l^.w>ewai EMm. i.tZincN. Effiana--tnaa Emm. t.tjenon. Emm. cmoio> EDiana. 2<Maoafnoxy Emm. i.i-Aonw Emm. MM-u-acneroEffwna. M.2L2*--ract*on> Emanci. 27Wfl*daowoitf Emanona. i-pnanyEianoii mono. (CRT) E*V MMM (1) Em* mn < E*v wimim (mm. EWy* 4.4'^tfNoroMnMa Fm*anao*io<noca<oanac a--0 Etyaa oa--ioa Etoyana doaonoa Eaaana o--M 0.T) Emyiana aaou-- EM* mr (1) EHjWOana gcraonoa EimvMMM EffV mamanaa^iowaia Fame aaitM AmMMM Fo--anyoa Forme OC (C.T) Cwan(l) 2*^uran--oanyda (1) UfinMm Pain, wwniniiu. (I) Ftanm (t) f**in (1) OKSiuesemnoM. VNeurwooh UON UOM UOM UOM uotr U0M UOM U101 U102 U1C3 U10S U1M U107 uios uios U110 Utn U001 U174 U007 ucra U077 U114 U1S1 UOM U003 utt7 UQ2S U104 U200 U209 4J2lt U227 U043 U042 U07t U07S U210 U173 U004 uooa U112 mis u2sa UOM U114 UQ07 uorr U11S U11S U117 U078 ui*s U*1 U1S9 U120 U122 U12S U124 U12S ISIS U12S U124 U20t 0>cgy<ioi^ Guanon* Hnroo-*nanyi.Wip. H--actaorobtfuana Haatctaomomafrant httmaorocyctoftai -- (gamma taomao Hataitaarocyooc--<afloa li--ae--mant MmacNorOCW iUMCWoreorpow Myaraant (.T) Hydraana. I ifnram, 1.1--natfiy* Hyomna. \2+rm*nyfc Mydram. \2<X***& HyOreAuone aotf (C.T) Hydrogao Muenda (C.T) Hydrogan wiM lKiyyijyro--oyadrworwxdtni.ylI--*maia9*ej4a-lonayiaii)4awyi (M> 1 HTwumFiri------------ Mm( l JL3-cc)pr*m laeeutyi aconoi (i.T) MOMlroM Moon* Uaeearpma Laad acatata Maro*y Mamacryiorataa (I.T) umm, on-- (IT) Matnarw. tforomagi--r Mamawa. wonA0 Mi--aaia (i.T) Mar*na. w--omo- MMM. Mmmae ago (CT) *7 Mtman--wan. t.2.4.S.*7.t.**oct* tfwyo-Sa.47.7a nwyaro Mamapyaa*a i Mawyajmart--ia fl) Maw* tfdonoa 0.11 ^ Ma*incwo--m 3 Matnyajuyanrrawa aZ.24- Maffn<anaod(2<iaooar--Ml Maq>j<an--a(X4.HncfliOfOO>^oH Matijiana oromda utaa U127 yi2t yigg ytso ytsi U132 yjaj u133 UON UOM uios U134 U134 U13S UOM UtM Uiif Ut37 U29 UTSS Ut40 U141 U142 U143 Ut44 UT45 U144 U12S U1*7 U140 Uit U'SO UTS1 U1&2 U092 U02f U04S UOM UOM uoao U075 Utss U11S 1*11 Ut21 UTSS U22S U121 U123 UOM UTS4 UU1'5545 U029 U1M UC4S UU2i2HC U1S7 U1SS U132 UOM rs * <0 Or O *-4 m v CO u I* oo ITS H O O J wgfe ORIGINAL // REVISED 11/30/ 81 Bv W. R. McCurleyl PAGE 8 OF 10 .ISSUE "- 10 AO/74 BvS.ChamberliliRFviFWFn / / Bv 1 1-- -- .in- . --a-- -^a............................ =s^Bsac (ATTACHMENT #1 ' n, 1 t-1 *.: SAFETY PROCEDURE MANUAL MONSANTO COMPANY _ _ _ _ _ _ _ _ _ _ _ _ SP- ob CHOCOLATE BAYOU PLANT SOLID AND HAZARDOUS WASTE DISPOSAL ATTACHMENT #1: EPA HAZARDOUS WASTE LISTS AND HAZARDOUS WASTE CODE NUMBERS Hazardous Wastes (Cont.fd) i n M i --fm HAZARDOUS WASTE EPA HAZARDOUS WASTE NUMBER MaWjrtana cMonta hm MaVtyi a*y Mm (LT) Maoy atn** tetona pm--aa (H.T) GOKjB Maa>)( ooouiyl aaaona (p Ma<y< mariaoryiaa (1.T) 4 Mwy( 2-p4ianona (i) C 5.12*Napf*ftaeaadwna. <S g 1 ao--y* l(K(3 amno 2J.I rowy >im L^fu> haaooyianoay4leTH-7.M.1CMiTaiyi> M.n.wH)aroy-maa>8yHiowniain waawtiaiana. 2<mer> 1 a fiTMVITlMWfrmi ^Waonmannanni wenc aod. SJ'-TOJ 4iaaa*Hi.l'-bchan)4Hk4'dvO)-b t.a.Naeranmwnona HPNrftipwiyMmi Oatt^aoneiyiamaM 2-Naanainanawa. RN M2-eMer PXfOOanii ia <t,T> 3 M^rooriapana (0 M yaaftaMi a raola^^i FMaoiodiii^iiim W4aaa>H-iriai>ajaa' M >ih>u<unvartrin< H4aaaaepynokOna UOaMm.U4taaN 2H-1JJ-Oaa2apMapnenna. 2-na(2- M anyOamno)M(an)o>. oada 2- Oxana 0.T) Oaaana. 2-KMoranaiyO3arttoanyd 3aacft*ofootfl*artt ^maeNorecOiant Pamarhmgpftanoi 1 J-Pamaoana (I) 3f>anMnn 3r>anei Ptmnot 2<ntoropnanoi. 4-cmoo^-maai)4PrwM. 2.4-^eryoroPnm. l&^KMoroPtwnoL tomnoi. 4-tmro- PfMneia panuenmanano. 2J.4*4aaacWow Pm Pm. uwtfttO' noamnc aod. Laad a* phoaonoroMe aod. 0M99iy4>( S- nwnrwoa' UOM U122 U1SI uiao U1M Ultl U1t2 uita U1C1 U1*4 U010 U059 uie U047 U1M U23C U16 U1C7 U1M UU7 ui UOM Uld? U170 U1?1 U172 U173 U174 urn U17 U177 um um UltO U1S1 U193 UOM um U041 Ult2 U123 U1M U15 U242 UtM U17 U1M uoa UOM uoei U02 U101 U170 U242 U212 U230 U231 U137 U1AS U0t7 ' / HAZARDOUS/ WASTE EPA HAZARDOUS WASTE NUMBER Wwnoum auffida (A) WaaiaH arnyowa !Ara Prananaua 1`Atgmnn (l.T) lAroparwnna, M-prap|4> (I) arooana, 1.24d*cin9-cMn niona.iau.xla ftotm, (i) ftooana. 2"oytn2-<rtoro- tjancm KAen* 1-nropano., 2>dArento>. phsaenaia (3:1) 1-nropanci. 7.3 apoay 1-Propane.. 2-ma*l)4- (l,T) 2-Prooanona (I) t4wwM Preoana. 1.3 Dirnicwj I4npm. l.l.23J.fta*aciaero- 2-Prepanan.taa 2-ProptnanBto. t-maSty*- (IT) 3-nrccancc aod P) 2-Prec*nac aod. Mtyi aawr (1) 2-nropanuc aod, 2-madita-. ndry* aaar 2-nrooanac aod, 2-mamyK marrryt aasar 0.T) Propone nod. 7-0.4.S-*ra*aupr lauuiy)- n PropyWrina p,T) Prooyrana denonda Pynona Pyndha. 2-tg-IOnePtylanano)^ manyM. nanol- Pyndoe. hexrrydro.4nnrep> PynOna. 2-.naffry.- 4(iM)^ynmidnont. 2J-04ryOu--iiia(l>yt. SSaacmcheann and Sival-Sarma, oazonoraaa faatar) 4.4'.SWbanadl. atoftaxpna'-Oaatyk Saasnmoon Soto iryonoa SuHine aod. Omaa^l now StMr pnoasnaa (B) soar aalanea <H.T) 2.4.S-T 12.4J-Taaaentouoaraana t.I.U-Taaaoaooainara 1.1 iJ-Taaacraoroamana Tatracrnoretinytana 2J.4.a-Tanacraoepnano< Tmnorainn P) Thanuram aeataia TfraHaawP) catoonaia Thaauwi) cnonde TPaaamq taraw THoaoatamoa TNamathano. P.T) TThhaoamm a Tckiana TohimMtenM Tobant ifcaocyanmi (*.T) uiw UilO U1*< U1*2 Uia* U11O UOM U14* U171 U027 Uit3 U235 U126 U140 U0C2 U007 UOM U243 UOCS U1S2 U000 U113. Ulli U1C2 U233 U14 U0t3 U1M UU! U17t Ultl U1M U10 U20Q U201 U202 U2C3 U204 U20* U20S U015 U233 UOM U206 LM35 Ut03 UM U205 U232 U207 U209 U20S U210 U221123 U21 U215 U21 U217 U2H CM 53 U219 U24 U220 U221 U223 O9s O9s O *n co u ORIGINAL ISSUE 10 /io/7 24 By REVISED 11 /3Q/ S .ChamberliaREviEWED / / 81BW. R. McCurlev Bv PAGE 9 OF 10 ATTACHMENT #1 C 001588 SAFETY PROCEDURE MANUAL MONSANTO COMPANY _ _ _ _ _ _ _ _ _ SP- 013 CHOCOLATE BAYOU PLANT SOLID AND HAZARDOUS WASTE DISPOSAL ATTACHMENT #1: EPA HAZARDOUS WASTE LISTS AND HAZARDOUS WASTE CODE NUMBERS Hazardous Wastes (Cont.*d) HAZARDOUS WASTE EPA HAZARDOUS WASTE NUMBER O-ToMdnai WyapcNanda 1H.1.2.4.THC013 rnmm 1,1,1-TncMoroaaiana 1.1.2-Tncraaroacnan* TneMoroctnan* TriCWflWlBWftlOWWllMM 24,5-Tncrtorecftand 24.S.Tmajuun'nM)ete add ynvTonrtrobcnztnt (ftT) 1J.5-Tno*ana. Tna8J4Bremcprepy1) pnoapnan Trypan BM Uraoi S[Brt<orom<rty*>T*a). liras iiuUA Vifjd dHondt' Xylm (1) Yohmunn-K-cmPotyie add. 11.174*. btraoyQOcyK mOTyt Mr. U222 UQ11 UZ2t U227 UZ2 U23I U121 U23Q uni U232 U234 U1S2 ims U23C U237 U237 U043 U239 U200 HAZARDOUS1" . WASTE EPA HAZARDOUS WASTE NUMBER SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 013 CHOCOLATE BAYOU PLANT SOLID WASTE DISPOSAL PURPOSE To define the responsibilities and procedures related to the disposal of the plant solid wastes. POLICY The disposal of the plant solid wastes will be done in accordance with the requirements set out by the Texas Water Quality Board and will be consistent with Monsanto policies regarding health, safety, and housekeeping. SCOPE Solid wastes are definied as those solid and semisolid materials that are not salvageable for reasons of a contaminated condition or com position and, therefore, must be disposed of. The waste will consist of catalyst, process sludge, miscellaneous containers, equipment, lumber, concrete, glass, etc. This procedure applies to solid wastes only and is intended to be used in conjunction with O&P Procedures No. GP-0304 and SP-029 relating to salvage and scrap materials respectively. RESPONSIBILITIES CBY 3109700 The Environmental Control Department is responsible for regulating the disposal of the plant solid wastes to assure compliance, with requirements of the Texas Water Quality Board regulations. The Environmental Control Department must maintain records on the quantity, character, classification, and disposal location of all Class I and Class II wastes (See Attachment #3). These records must be kept for three (3) years and be available for inspection by the Texas Water ..Quality Board. At the option of the TWQB, an annual report may be requested summarizing this information. The waste generator will be responsible for developing the data necessary for Environmental Control to obtain the waste classifica tion. Environmental Control will obtain a waste classification from the TWQB for wastes routinely sent out for off-site disposal. Environmental Control will insure that waste leaving the plant is disposed of in a site authorized, registered, or permitted by the Health Resources Department or the TWQB. ^ 001590 Solid waste disposal can be subdivided into off-site disposal and on site disposal ORIGINAL 10/1Q/ 74^. Charnberl irj REVISED /'*/ By PAGE 1 OF 3 REVIEWED ef 1/77 ByL.C.Peeler ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP" 013 CHOCOLATE BAYOU PLANT RESPONSIBILITIES (cont'd) On-Site Disposition of Solid Wastes 1. The waste must be segregated in the following manner before it can be accepted for disposal: Process Sludges Contaminated Solids Inert Uncontaminated Solids Asbestos Insulation (Greater (See Attachment explanation of than 1% asbestos) #3 for each category) 2. Prior approval for solid waste disposal must be obtained from Environmental Control Day Supervision during regular hours (0800-1630, Monday - Friday). The Night Supervisor will perform these responsibilities on off-shifts. However, every effort should be made for disposal on day shift. ' When large volumes (more than one dump truck load) of wastes are to be disposed of, three (3) working days notice will be necessary for site pre- , paration to receive the material. 3. ^ . A "Request for Solid Waste Disposal" form (Attachment #2) must be completed by the supervisor requesting disposal and the form must accompany the person disposing of the waste. The form will be turned over to the Environmental Control Board Processor. He will direct the person to the proper site (See Attachment #1) for disposal. Waste will not be sent to the disposal area without the completed "Request for Solid Waste Disposal" form. It is required that the description of the material (estimated weight, volume, or quantity) be indicated on the form. Blank copies of the "Request for Solid Waste Disposal" form are in Stores, stock MCB #272 (Revised 8/6/74). 4. Environmental Control will not accept solid waste while the plant is in area II or area III of the Hurricane Alert. t 5. In order to enter the disposal site area, the person must ' sign the admission register and obtain a key to the disposal site gate from the Environmental Control Board Processor. 6. When leaving the area, the gate must be closed and locked. The admission register, in the Environmental Control, control house must be signed, indicating your time in and out of the area. The key must be returned to the control house. ORIGINAL 10/iq/74bvS. Chamberlin REVISED / / By ISSUE REVIEWED-4/1 /77 ByL.C. Peeler PAGE 3 OF 3 ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 013 CHOCOLATE BAYOU PLANT CLASS III WASTE 2. Wood, insulation (excluding 1% asbestos insulation), etc. that is not con taminated should be placed in the dumpster at the Solid Waste Disposal area. * Only empty and decontaminated drums that have contained MEA, TEG, DMF, Ionol, TBC, Petromeen OS-8, Unicor, Dowtherm 1 & 2, VP-1, DPO, Crude DPO, Polyflow 100, lube oil, N-Propanol, Antifoam, and Sterox cleaning solvent will be accepted for disposal. Closed-top drums (bunghole) which have been de contaminated may be accepted by Environmental Control super vision with prior approval. The unit generating a drum that cannot be decontaminated will jointly work with Environmental Control towards ultimate disposal of the drum. All open-top decontaminated drums should be sent to Stores as described in SP-029. AUTHOR: APPROVED BY: APPROVED BY: c 001593 CBY 3109703 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-013 CHOCOLATE BAYOU PLANT WASTE SEGREGATION GUIDELINES In-plant solid waste will be disposed of concurrently at three (3). separate disposal sites within the designated Solid Waste Dispo sal Area. Class X, II and III sites are designated (See Attachment #2 for physical location) for disposal in accordance with the Texas Water Quality Board registration. The waste material must be segregated in the following manner: CLASS I WASTE All waste materials, not classified as Class II or III, normally including all industrial solid wastes in liquid form and all hazardous wastes. 1- Process Sludge - Various sludges and semi liquid waste, catalyst in a liquid or slurry state, 2. Contaminated Solids - Spent, dry solids catalyst of various types. Miscellaneous contaminated discards such as molecular sieves, silica gel, shell dirt, process piping, containers, drums*, pumps, valves, insulation materials, polyethylene, wood, gasket material. CLASS II WASTE CLASS III WASTE CBV 3109704 3. Asbestos Insulation - Insulation containing greater than 1% asbestos will be delivered to Environmental Control in sealed plastic bags for disposal. Only the asbestos insulation, not the tarpaper of metal wrapping, will be accepted for disposal. The handling of the asbestos insulation in the plant should follow OSHA and EPA standards. Organic and inorganic industrial solid waste that is readily decomposable in nature and contains no hazardous waste materials. This includes the plant trash. Essentially inert and essentially insoluble induatrial solid waste, usually including materials such as rock, brick, glass, dirt, certain plastics and rubber, etc. that are not readily decomposable. 11 Inert Uncontaminated Solids - Concrete, glass, brick, discarded road materials and other miscellaneous inert solids. OISRSUIGEINAL lIyr^lOi /f7n4a [ByS.Z. REVISED 1 X7/78 B>s.z. Chamberlair PAGE 1 OF Chantoer^aEV|EwEDl/2778 aft.C.Peeler ATTACHMENT 2#3 ? 001594 MONSANTO PROCEDURE MANUAL DISTRIBUTION Plant Manager (Jones) Project Director,Mfg. (Frizzell) General Superintendent (Hagood) Enployee Relations Supv. (Malfitano) Employee Realations Representative (Watkins) Benefits Representative (Sebesta) Loss Superintendent (Wilbeck) (3) SafetySupervisor (Satsky) Plant Security (Captain) Industrial Hygienist (Lindberg) Plant Accounting Superintendent (Wall) Area Accounting Prop.s Maint. (Clemons) Data Processing Manager (Attra) Accounts payable Supervisor (Kelly) Manager of PT (Yeretsky) PT Group Supervisor (Graham) PT Group Supervisor (Saunders) General Superintendent (Gray) MTS Superintendent (Ingersoll) Pit.Engineering Superintendent (Fisher) Projects Group Supervisor (Isadore) Projects Group Supervisor (Pickett) Central Files (Knight) (2) General Maintenance Superintendent (Osburn) General Maintenance Group Foreman (3) Stores Superintendent (Ingersoll) Stores Supervisor (Loving) Maintenance Shop 4 (2) Maintenance Shop 5 Maintenance Shop 6 Maintenance Shop 7 I&E Superintendent (Stultz) I&E Group Foreman I&E Specialist (Williams) (SPM) Contract Group Foreman Shop #1 (EAP & SP Only) Shop #1-I&E (EAP & SP Only) NTA/IDA Superintendent (Steinhauser) NTA/IDA Group Foreman (Purdom) NTA/SAB Tech. Superintendent (Silver) IDA TSD Supervisor (Goodnight) Resins/Formalin/DPO Superintendent(Louvet Formalin/DPO Group Foreman Formalin/DPO Shift Foreman Production Coord.Superintendent (Ogens) Manager Env.Affairs & Tech. (Guilliams) Env.Affairs & Tech.Superintendent(McCurl< Superintendent Mfg. & Services(Ceyanes) Pruchasing Buyer (Reed) Utilities Superintendent (Atkins) Utilities Group Foreman (Goza) Utilities Shift Foreman EU & Site Dev.Superintendent (Blake) Dist.Operations Superintendent (Harlan) Distribution Group Foreman (Menard) Distribution Shift Foreman (2) Distribution Production Spec. (Jolly) Night Supervisors AN & E.C. Mfg.Superintendent (Silva) AN Group Foreman AN Shift Foreman Control Lab Superintendent (Meade) Lab Group Foreman (Faulkner) (2) Env.Control Group Foreman (Strickland) Env.Control Shift Foreman Manager,Mfg.Guest Companies (Murrell) SAB Superintendent (Hamilton) SAB Group Foreman (Mathews) SAB Production Planner (SPM) Technical Superintendent (Fouts) Sorbic Superintendent (Turner) Sorbic Group Foreman (Williams) Sorbic Shift Foreman Sorbic Maint.Coord. (Walters) NTA/SAB Mfg. Spec. (Seals) MHBA mfg.Superintendent (Ochsner) MHBA Group Foreman (King) MHBA Shift Foreman MHBA Process Specialist Rev.2 4/10/86 CBY 3109705 c 001595 Monsanto C -LoeT.oN-PNONi, Erich Birch - Chocolate Bayou Plant Ext.4747 April 21,1986 u.jtcT : PROCEDURE MANUAL REVISIONS KCFKfttNCt TO : Attached Distribution Attached are updates for your SAFETY PROCEDURE MANUAL: SP-013 has been revised. Please remove the old copies from your manual and insert the revised copies. SP-013 - SOLID AND HAZARDOUS WASTE DISPOSAL Pages 1-13 of 13 Attachment #1 Pages 1-3 of 3 Attachment #2 Pages 1-3 of 3 Attachment #3 Pages 1-2 of 2 Attachment #4 Pages 1-1 of 1 C Attachment #5 Pages 1-1 of 1 EMB/sk Attachments i IN - lO * VtEV. 0'77 Erich Birch CBY 3109706 C 001596 SAFETY PROCEDURE MANUAL SP- MONSANTO COMPANY CHOCOLATE BAYOU PLANT SOLID AND HAZARDOUS WASTE DISPOSAL I. PURPOSE This procedure defines solid and hazardous waste responsibilities within the Plant and explains the manner in which waste related activities must be conducted to comply with State imd Federal environmental regulations and Monsanto Company guidelines. II. POLICY Waste storage, processing, disposal and by-product sales will be done in accordance with the rules and regulations of the > Texas Water Commission (TWC), and the U.S. Environmental Protection Agency (EPA), and the U.S. Department of Transportation (DOT). In addition, all practices and procedures must be consistent with Monsanto's commitment to protecting the environment and must conform to Monsanto's guidelines regarding health, safety, and housekeeping. III. SCOPE This procedure covers the classification, storage, processing, transportation, and disposal of solids and hazardous waste generated at the Chocolate Bayou Plant. For waste materials that are recoverable, reusable, or otherwise subject to salvage, this procedure must be used in conjunction with General Procedures and Safety Procedures on salvage and scrap materials (GP-0304 and SP-029). Waste materials generated off-site by contractors doing Monsanto related work are generally the responsibility of the owner/operator of the site where the wastes are generated. Any exceptions must be approved by Environmental Affairs and Technology to insure compliance with all applicable regulations and policies. DEFINITIONS Definitions presented below consist of summaries of established legal definitions. Solid Waste - Any garbage, refuse, sludge, or any other solid, liquid, semi-solid, or contained gaseous material which: 1. is discarded or accumulated, stored, or treated prior to being discharged; or, C 001597 CBY 3109707 ORIGINAL / /, 0 w . REVISED fr 8y M.T. Wagner PAGE 1 OF 13 ISSUE 10/10/74bv S.Chamberla: Bpypiwpn / / ^ ATTACHMENT SAFETY PROCEDURE MANUAL SP- --mm--m------------fill y. .lilLUl.l-'LJJIJlillHWIll--------------iMHWIIM-------- MONSANTO COMPANY CHOCOLATE BAYOU PLANT SOLID AND HAZARDOUS WASTE DISPOSAL hazardous waste as defined by EPA. Class II Waste - Any solid waste or combination of industrial solid wastes which cannot be described as Class I or Class II as defined. Class III Waste - Inert and insoluble solid waste, usually including but not limited to materials such as rock, brick, glass, dirt, and certain plastics and rubber, etc., that are not readily decomposable. Responsibilities A. Waste Generator 1. Complete Side 1 of the "Request for Solid Waste Disposal" form (see Attachment #3) and submit to Environmental Control. 2. Arrange for sampling and analysis of the waste if required for the hazardous/nonhazardous determination or to provide data necessary for the safe handling, treatment, storage, transport or disposal of the waste. 3. Properly decontaminate or package waste when applicable. All drums, piping, or other equipment which may be sold as metal scrap must be decontaminated and tagged prior to delivery to Environmental Control or the salvage yard. 4. For on-site waste disposal the generator weigh the waste and transport it to the proper treatment, storage, or disposal unit as directed by Environmental Control. 5. For off-site disposal the generator must: a. Obtain a TF-837 or TSA (temporary shipping authorization) from the Waste generator is the party responsible for generating the waste and can include manufacturing departments. Maintenance, Utilities, PT, Environmental Control, and contractors. C 001599 CBY 3109709 ORIGINAL ISSUE REVISED 4/iJ Bfey M.T. Wagner PAGE J OF 13 S.Chamberla: fcEVElWED / / By ATTACHMENT SAFETY PROCEDURE MANUAL SP-013 MONSANTO COMPANY CHOCOLATE BAYOU PLANT ni.JiMMUi--------^IBP SOLID AND HAZARDOUS WASTE DISPOSAL ORIGINAL ISSUE e. Insure that contractor operations in environmental control areas meet regulatory and Monsanto requirements. 4. For off-site waste disposal: a. Arrange for an approved transporter and outside disposal agency to handle the waste. b. Prepare and sign the TWC Waste Shipping Control Ticket (Uniform Hazardous Waste Manifest) and shipping papers. c. Inspect trucks after loading to insure that EPA and DOT regulations on waste packaging, labeling, and placarding have been met. d. Initiate follow-up actions on overdue, unreturned manifest originals (white copy). C. Environmental Affairs and Technology '1. Provide assistance to Environmental Control and other units in interpreting solid waste regulations as they apply to classifying waste materials or carrying out this procedure. 2. Obtain TWC waste code numbers and amend the CB/TWC Solid Waste Registration when it is necessary to dispose of new waste materials. 3. Obtain environmental permits needed for the generation, treatment, storage, and disposal of solid and hazardous wastes. 4. Direct and coordinate efforts to reduce or recover hazardous wastes. 5. Develop and implement training programs on hazardous waste regulations, procedures, and emergency response. D. Control Laboratory 3109711 1. Insure that waste samples are analyzed by EPA approved methods and that analytical results are properly documented. C 0^ 01_ 6_0_ 1_ |REVISED V <By m.t. wagner PAGE 3 OF 13 JftEVElWED / / By ATTACHMENT SAFETY PROCEDURE MANUAL _ _ _ _ _ _ _ _ _ --WWW" 111 WIHHI--WWlIIIIWMHWBWBiWBi MONSANTO COMPANY SOLID AND HAZARDOUS WASTE DISPOSAL $p 013 ar* CHOCOLATE BAYOU PLANT ignitability, corrosivity, reactivity, incompatibility with other wastes or materials of construction of hazardous waste handling equipment, and potential health hazards. 3. Sampling and analysis of wastes must be done using procedures specified in EPA Publication SW-846 (copies are available in the Control Laboratory and in Environmental Affairs and Technology). Environmental Affairs and Technology will maintain an updated copy of a CB Plant hazardous waste sampling and analysis plan specifying procedures and minimum sampling frequencies for routine wastes. 4. All waste samples must be accompanied by "chain of custody" forms. Completed "chain of custody" records will be returned to the Control Laboratory for filing. Copies of the forms will be attached to analytical data kept at Environmental Control by Environmental Affairs and Technology. 5. Hazardous waste analyses must be up dated whenever a process modification or other changes which could affect waste composition occur. 6. Records on the results of waste analyses will be maintained by the Control Laboratory. Copies of waste analytical results will be available in Environmental Control and Environmental Affairs and Technology. 7. Each waste must be assigned a TWC waste code number (currently registered waste code numbers for the CB Plant are shown in Attachment #2) and each hazardous waste must be assigned one or more EPA waste code numbers (EPA waste code numbers commonly used at CB are shown in Attachment #1). Environmental Affairs and Technology will register new wastes when necessary and will provide assistance in selecting and verifying p 001 Km ^ applicable code numbers (Ext. 4507). c 8. The waste generator should provide Environmental Control with at least 1 day's advance notice. Additional time may be required to arrange for off-site disposal or 10 A0/1*IKUENAL REvIsED^lT*^ M.-T. Wagner ""..... ................ 13' PAGE OF By S Chamberlai JfeEVE|WED / / By ATTACHMENT SAFETY PROCEDURE MANUAL WMi!ii imia >i-- urn----- ,ua.-u^ n. TramiitMiMM----M--IIKIW SP-013 MONSANTO COMPANY CHOCOLATE BAYOU PLANT SOLID AND HAZARDOUS WASTE. DISPOSAL D. CBY 3109715 2. Wastes will not be accepted for landfill disposal while the Plant is in Area II or Area III of a hurricane alert. 3. Salvageable materials (piping, empty drums, scrap metal, etc.) must be. decontaminated and tagged by the waste generator before delivery to Environmental Control. Materials which are eligible for the salvage yard will not be accepted for disposal. 4. Prior to loading a waste the truck on trailer must be weighed and then reweighed after loading so that the weight of waste cah be noted on side 1 on the Request for Solid Waste Disposal form. (This form should be weigh stamped or a weigh stamped card should be stamped to the form). 5. At the waste disposal area the Solid Waste Disposal Processor will instruct the driver where to dump the waste and will record the location. Entry to the Solid Waste Disposal Area without authorization of the Solid Waste Processor is prohibited. Off-Site Disposal (Class I Wastes) 1. Upon receiving notification and the Request for Solid Waste Disposal form. Environmental Control will arrange for an approved transporter and disposer to handle the waste and prepare the TWC Manifest. 2. The generator is responsible for insuring that there is a TF 837 or an up-to-date TSA (corporate shipping authorizations) available for the particular waste material. If the waste material is not already listed on the outside disposal contract the generator will have to execute a "Schedule A" to the contract for the particular waste. 3. When the transporter arrives at the Plant he will report to Distribution to have his truck weighed and the weight stamped on a weight card. C 001605 4. The transporter will then be directed to Environmental Control, where directions will iSviSED " ^/ 1 jgJG,NAL 10/0/74 ^ S.Chamberlai TtEVElWED / / By ...Wagner* PAGE OF TT ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SOLID AND HAZARDOUS WASTE DISPOSAL SP 013 CHOCOLATE BAYOU PLANT 2. Process related wastes and contaminated materials' must not be placed in Plant trash dumpsters. Each unit is responsible for enforcing this rule for their dumpster. 3. Units generating process related Class II wastes may be required to dispose of these materials off-site. Environmental Control will assist in making arrangements for an outside firm to receive the waste. Once the disposal process is established for a routine waste the generating unit will be responsible for day-to-day contacts with the transporter and disposer. The unit will be required to submit information to Environmental Control on quantity of each type of waste disposed of and the location of the disposal site for each waste load. This data is needed because it must be reported to the State. F. Sale/Disposal of Empty Drums Approved empty drums will be sold to an outside drum reprocessor. Non-approved empty drums will be crushed and sold as metal scrap or buried in the on-site Class landfill. I 1. The generator must: a) Decontaminate all empty drums by triple rinsing with a suitable solvent. (Steam or water may be used if it is effective in removing the residue in the drum), b) Tag the drum as decontaminated, c) Complete a "Request for Solid Waste Disposal" form including a description of what was in the drum prior to decontamination, and d) Deliver the drums to the Solid Waste Processor in Environmental Control unless there is a large number of drums. In the event that the generator has a truck load or more of drums. Environmental Control may elect to have them picked up by the drum reprocessor at the unit where they were generated. CBY 31097X7 ^ 001607 * OISRSUIGEINAL io/o/<Bvs.Chamberli REVISED V1 y Sfasy H.T. Wagner PAGE 11 OF ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP*013 OB CHOCOLATE BAYOU PLANT SOLID AMD HAZARDOUS WASTE DISPOSAL- H. Hazardous Waste Emergenices Hazardous waste emergencies will be handled in accordance with the Chocolate Bayou RCRA* Hazardous Waste Emergency and Contingency Plan. Copies of this.Plan are located in Environmental Control, Safety, Night Supervisor's office, and Environmental Affairs and Technology. C 001609 CBY 3109719 ORIGINAL tISSUE REVIS io/o /u4 By s Chamber la i rfegyElWED 'Ijr // btpy M.t. By" Wagner PAGE 13 OF ATTACHMENT ^ SAFETY PROCEDURE MANUAL MONSANTO COMPANY SOLID AND HAZARDOUS WASTE DISPOSAL SP- 013 CHOCOLATE BAYOU PLANT Attachment 1: -EPA Hazardous Waste Codes Commonly Used at Chocolate Bayou A. EPA Code Nubmers for Hazardous Characteristics HAZARDOUS CHARACTERISTIC EPA HAZARDOUS WASTE HUMBER Ignitability Corrosivity Reactivity EP Toxicity arsenic barium cadmium chromium lead mercury selenium silver D001 * DO 02 . DO03 D004 D005 D006 D007 D008 D009 D010 D011 B. EPA Code Numbers for Hazradous Wastes from Non Specific Sources HAZARDOUS WASTE EPA HAZARDOUS WASTE NUMBER The following spent halogenated solvents: tetrachlorethylene, methylene chloride, trichloro ethylene, 1,1,1-triChloroethane, chlorobenzene, 1,1,2-trichloro-1, 2,2-trifluorethane, ortho dichlorobenzene, and trichlorofluoromethane; and the still bottoms from the recovery of these solvents. F002 The following spent non-halogenated solvents: xylene, acetone, ethyl acetate, ethyl benzene, ethyl ether, methyl isobutyl ketone, n-butyl alcohol, cyclohexanone, and methanol; and still bottoms from the recovery of these solvents. F003 The following spent non-halogenated solvents: toluene, methyl ethyl ketone, carbon disulfide, isobutanol, and pyridine; and the still bottoms from the recovery of these solvents. F005 001610 CBY 3109720 ORIGINAL 10^10^7 4s* ISSUE &EVEIWED / / v Wagnsr- PAGE 1 OF 3 ATTACHMENT l SAFETY PROCEDURE MANUALSP- i----w--will------^Biiiim ii1 "iiiui.mt. aawii1------a--MW--ihhw MONSANTO COMPANY 013 CHOCOLATE BAYOU PLANT SOLID AND HAZARDOUS WASTE DISPOSAL HAZARDOUS WASTE Formaldehyde Furfural Hydrazine Hydrofluoric Acid Hydrogen Sulfide Mercury Methanol Methylene Chloride Methyl ethyl ketone Methyl isobutyl ketone Napthalene Phenol Pyridene Toluene Xylene EPA HAZARDOUS WASTE NUMBER U122 U125 U133 U134 U135 U151 U154 U060 U159 U161 U165 U188 U196 U220 U239 CBY 3109722 C 001612 ORIGINAL ISSUE REVISED 4 >14/86 By lo/io/74 Bv S. Chamber la :FVFiwFn / / ^ K.T. Wagner PAGE 3 OF ATTACHMENT 3 SAFETY PROCEDURE MANUAL .II U.IUMIJJHIII------ggg MONSANTO COMPANY SOLID AND HAZARDOUS WASTE DISPOSAL SP 013 CHOCOLATE BAYOU PLANT Attachment 2: TWC WASTE CODE NUMBERS AUTHORIZED FOR USE AT THE CHOCOLATE BAYOU PLANT A. TWC Waste Code Numbers for On-Site Disposal* WASTE NAME Refractory Process Wastewater Process Sludge Biological Sludge Raw Water Sludge ^ .ent Catalyst Bulk Solids Miscellaneous Discards Miscellaneous Inert Solids Insulation Contain ing Asbestos Biodegradable Wastewater DESCRIPTION All liquid waste materials disposed of in the AN ponds Miscellaneous sludges, polymer, coke, off-spec chemicals, etc. Wastewater treatment sludge Water treatment (utilities) sludge All discarded catalyst materials Piping, empty drums, process equipment, hoses, cans, etc. Filter cartridges, column packing, molecular sieves, silica gel, contaminated shell, dirt, concrete, etc. Noncontaminated shell, dirt, concrete, bricks, etc. All insulation contain ing greater than 1% asbestos All liquid waste materials disposed of in the biological treatment system CLASS I-H I-H I I III I-H I I I-H I WA^TF CODE NUMBEP 909520 949690 149690 249890 340150 970210 170210 170770 979720 179720 III 370510 I 179390 I-H 906680 C 001613 CBY 3109723 ORIGINAL ISSUE / l/ 7%y S.Chamberla REVISED 4 /\tf 8y %EVEIWED / / By M.T. Waqner PAGE 1 OF 3 ATTACHMENT *2 SAFETY PROCEDURE MANUAL SP-013 MONSANTO COMPANY CHOCOLATE BAYOU PLANT C SOLID AND HAZARDOUS WASTE DISPOSAL Attachment 2: TWC WASTE CODE NUMBERS AUTHORIZED FOR USE AT THE CHOCOLATE BAYOU PLANT A. TWC Waste Code numbers for On-Site Disposal* WASTE NAME Miscellaneous Plant Trash DESCRIPTION Office trash & garbage (trash dumpsters) CLASS II WASTE CODE NUMBER 279760 * Wood Scrap Noncontaminated wood scraps III 380200 Carbon Absorbent Spent activated carbon II 280810 Zinc phosphate . Tnsulation Contain ing asbestos Crotonaldehyde Methanol and Water Celite zinc wastes Insulation containing greater than 2% asbestos Crotonaldehyde with <5% acetone and 5% water Methanol contaminated with <40% water and <2% sorbic acid II I I-H I-H 200290 179390 9123210 909640 PCB Contaminated Wastes contaminated with PCB (Polychlori nated biphenyls) including transformers, transformer oil, rags, drums, etc. I 179430 Industrial Wastewater containing organic compounds Wastewater containing MEA (0.86%), methanol (500 ppm), Ethanol (400 ppm) I 109080 *For wastes not listed. call Environmental Affairs & Technology (Ext. 4507). ( C 001614 CBY 3109724 ORIGINAL ISSUE l/l/3yS Chamberla. REVISED 4 YLEVEIWED /l^ // 86By By m.T. Wagner PAGE 2 OF 3 ATTACHMENT |2 SAFETY PROCEDURE MANUAL SP-013 MONSANTO COMPANY CHOCOLATE BAYOU PLANT f SOLID AND HAZARDOUS WASTE DISPOSAL Attachment 2 s TWC WASTE CODE NUMBERS AUTHORIZED FOR USE AT THE CHOCOLATE BAYOU PLANT B. TWC Waste Code Numbers for Off-Site Disposal* WASTE NAME Miscellaneous Wood Scrap Carbon Absorbent Zinc phosphate Insulation Contain- ing Asbestos Crotonaldehyde Methanol and Water PCB Contaminated Material Industrial Wastewater Containing Organic Compounds DESCRIPTION Office trash & garbage (trash dumpsters Noncontaminated wood scraps Spent activated carbon Celite zinc wastes Insulation containing greater than 2% asbestos Crotonaldehyde with <5% acetone and 5% water Methanol contaminated with <40% water and <2% sorbic acid Wastes contaminated with PCB (Polychlori nated biphenyls) including transformers, transformer oil, rags, drums, etc. Wastewater containing MEA (0.86%), methanol (500 ppm), Ethanol (400 ppm) CLASS II III II II I I-H I-H I WASTE CODE NUMBER 279760 380200 280810 200290 179390 912320 909640 179430 I 109080 For wastes not listed call Environmental Affairs (Ext . 4507). C 001615 ( CBY 3109725 ......... --i.u ...I.. --i--jmmua-- ORIGINAL ISSUE 10 /l</ 7%y REVISED 4/14^ 86Bv M.T. Wacner S.Chamberla ^VEIWED / / By PAGE 3 OF 3 ATTACHMENT #2 SAFETY PROCEDURE MANUAL i^--BIMl'W IM * lilllHIM------ggg MONSANTO COMPANY SOLID AND HAZARDOUS WASTE DISPOSAL SP 013 CHOCOLATE BAYOU PLANT ATTACHMENT 14: TYPICAL HASTE DISPOSAL CONTRACT SCHEDULE A FORM . SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 013 CHOCOLATE BAYOU PLANT SOLID AND HAZARDOUS WASTE DISPOSAL ATTA9MENT $ DECISION DXASHkM FOS MTt DISPOSAL AT DDtUMS ORIGINAL A / / ISSUE lQ/KV 7 CBV 3109727 C 001617 REVISED 4 /IV 86By K.T. Wagr.er_| pA^p 1 op 1 5. Chamber la: REVEIWED / / By j ATTACHMENT #5 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SOLID AND HAZARDOUS WASTE DISPOSAL SP- 013 CHOCOLATE BAYOU PLANT ATTACHMENT 13: REQUEST FOR SOLID WASTE DISPOSAL Side 1 REQUEST FOR SOLID HASTE DISPOSAL (This four avst be competed prior to any on-site disposal or shipment of Materials off site for disposal) Solid Haste Disposal Request Fonr. No. 1 To fee Mle 6ut o7 Person Requesting Disposal Date: Department Requestor: Process s--1cretins waste:. Charge Ho: Advance Notice ves O :<o Height: (You Bust have this forr weigh sta-ped):. Haste Description. Atueh analysis If available (a laboratory analysis ay be required Py InvT'Control If available data Is insufficient to properly classify or dispose of waste) -i) \ | Name of Haste Stream_________ _______ _ nscription Organic Q OInorganic Mixture of organic A Inorganic PH flash point He* Cora:nerts Cone: t O'- ppr Analytical Technique Used !I -* ;i 1! (Atueh Additional List if Necessary) EPA Hazard Coce(s):_ TDWR Miste Code:____ Safety Precautions:, SueNAL health Hazard Information: MC1-3Z5 CBY 3109728 c 001618 Bys.Chamberlai REVISED _`I^_L_E*TfV_t EIWED__ 4/TVB /"wM* M/ U 6W B>M.VI.'^Wagi7e _V7< ssswMBaKBHeiannwifmM PAGE 1 OF 2 ATTACHMENT 13 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-u CHOCOLATE BAYOU PLANT USE OF VACUUM TRUCKS PURPOSE: This policy and procedure defines the methods and responsibilities necessary to provide control of vacuum truck usage in the plant from the viewpoint of both safety and long-term economy. POLICY: The Environmental Control Department will dispatch all vacuum trucks. Tank trucks hauling material to be disposed of will be cleared by the Environmental Control Department functioning through Production Coordination Scheduling and adhering to the unit procedure for that material. The requesting or originating department must declare the material to be hauled as either a waste or a usable material and as meeting certain requirements as defined further in the procedure. Disposition of all waste material will be determined by the Environmental Control Department prior to scheduling the vacuum truck. All vacuum truck operations should be confined to the hours normally scheduled, 0800 through 1600 Tuesday and Friday. Scheduling -vacuum trucks outside of the normal schedule must be approved by the Manufacturing Superintendent of the requesting department and the Manufacturing Superintendent of Environmental Control. Requests made outside the normal working hours for vacuum trucks must be approved by the Manufacturing Superintendent of the requesting department ancT Environmental Control on-call person. These approvals are necessary to control plant costs." Specific vacuum truck operations which begin during the scheduled hours, Tuesday and Friday, can continue beyond these hours without additional approval. f* PROCEDURE: Attachments 1 and 2 indicate various jobs which may be routinely handled by vacuum trucks under this policy. Materials listed in Attachment 1 are those that have initially been determined to be handled with air in vacuum trucks. Materials listed in Attachment 2 may be handled in vacuum trucks only when the following conditions have been met: CBY 3109730 C 001620 original ISSUE ^wnnffiirTTTiTVTsvruTT!Tr~rii miiriiiT-------- REVISED 8/22/83 By W.B.Jackson 8/1^6^ F. E. Crook PAGE 1 OF REVEIWED 8/22/83 By J .W.K.ongabie ATTACHMENT 4 SAFETY PROCEDURE MANUAL c MONSANTO COMPANY USE OF VACUUM TRUCKS SP-qu CHOCOLATE BAYOU PLANT RESPONSIBILITIES: Environmental Control Department 1. Maintain records of vacuum truck transfers as shown on Attachment #3. Dispatch vacuum trucks for routine jobs on a first in- first out request basis unless an emergency warrants a change. Request trucks through the vacuum truck company dispatcher for jobs needed outside of the regularly scheduled hours. Maintain an up-to-date listing of "approved' vacuum truck users with inputs from user department. Environmental Control Shift Foreman will determine disposition of vacuum truck wastes. 5. Evaluate job plans for approval anytime material is to be pressured into a vacuum truck. Pressuring material from a vessel into a vacuum truck is defined as using air, N2 or some other gas as a motive force or having a liquid head elevation greater than 50 feet above ground level. 6. Perform a monthly safety check of the "in-plant" vacuum truck and perform a safety check for all vacuum trucks called into the pj". plant. (Attachment #5) 7. Review vacuum truck invoices daily to insure proper charges. REQUESTING DEPARTMENT CBY 3109732 1. Determine the composition of material, its hazardous properties, origin, flash point and when truck is needed. 2. Implement the safe handling techniques described in the Procedure. Attachment #4 is included as a guideline on flammability restraints. For chemical compatibility restraints, refer to the Chocolate Bayou "Safety Guide" booklet, pages 7-9. 3. Provide written notification of requested changes in the "approved" user list to the Environmental Control Department. 4. Obtain proper approval for special jobs not included on Attachments #1 and #2 approved lists. 5. .Obtain appropriate approvals for the use of a vacuum truck on overtime. C 001622 t ORIGINAL 8 yiy69^ F.E.Crook ISSUE REVISED 8/22/83 ByW. B. Jackson PAGE 3 OF' REVEIWED 8/22/83 BgJ .W.Kongable ATTACHMENT * fc SAFETY PROCEDURE MANUAL MONSANTO COMPANY C ' USE OF VACUUM TRUCKS SP- 014 CHOCOLATE BAYOU PLANT APPROVED MATERIALS FOR HANDLING WITH AIR IN VACUUM TRUCKS SOURCE DEPT. _______ EQUIPMENT AN ................ Chemical Sump Sump Tanks 31T7 Distribution Tar Pump fip. AN Firewall Phenol Sump (2) and Phenol Tank Firewalls Caustic Sump Barge Slip Storage Tanks (Cleaning) Miscellaneous Lines & Non-Toxic Material With Flash Points above 125F Plant Outfall & North/ South Ditch Traps 334/336 Lifting Stations *#*$&* Miscellaneous Pipeway 334P7 Sump 336P4 Sump & Ponds * * 336P6 Sump & Ponds General Plant.. Process Sewers Septic Tanks NORMAL MATERIAL________ *Acid & Water *Catalyst, Sand, Polymer, H2O Tar AN & Water Phenol & Water Dilute Caustic Water & Oil Water, Soap, Oil Emulsion Miscellaneous Oil, Scum & Water Miscellaneous Oil & Water Sludg Miscellaneous Organics & Water Skimmed Oil Oil & Sludge Oil & Sludge Trash, Mud Sc Water (Check for hazardous materials is required Water & Sewage CBY 310973V If material has an obnoxious odor, handle with special precautions and notify Environmental Control. ^ 001624 ORIGINAL 8 /15/69 F.E.Crook ISSUE / / By REVISED 8/22/83 By W. B. Jackson PAGE 1 OF 3 REVEIWED 8/22/83 By J.W.Kongable ATTACHMENT #1 SAFETY PROCEDURE MANUAL SP- 014 MONSANTO COMPANY C USE OF VACUUM TRUCKS CHOCOLATE BAYOU PLANT APPROVED MATERIALS FOR HANDLING WITH AIR IN VACUUM TRUCKS SOURCE DEPT. Utilities .. EQUIPMENT______________________ NORMAL MATERIAL Miscellaneous Equipment Use Lubricating Oil Acid Storage Tanks Dilute Acid & Sludge Chemline Storage Tank Chemline Sludge & Water Boiler Acidizing Material Spent Ammoniated EDTA 350T15 Sump Water & Oil CBY 3109736 * If material has an obnoxious odor, handle with special precautions and notify Environmental Control. ^ 001626 ORIGINAL 8 /15/69 F.E.Crook ISSUE / / Bv REVISED 8/22/83 y W. B. Jackson PAGE 3 OF 3 REVEIWED 8/22/83 By J.W.Kongable ATTACHMENT #1 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-on CHOCOLATE BAYOU PLANT USE OF VACUUM TRUCKS APPROVED MATERIALS FOR HANDLING WITH INERT GAS IN VACUUM TRUCKS SOURCE DEPT. Distribution ____________EQUIPMENT Miscellaneous Organics with Flash Points Below 125F. . Environmental "Control Fire Training Phenol Sorbic Acid 334T6 Wet Well SNIFO Tanks 67T16 67T8_49T707 ____________NORMAL MATERIAL Miscellaneous Organics Cg, HVR Oil Skimmed Oil & Bottom Sludge SNIFO Waste Oil AMS Waste Oil *0xo Alcohol * If material has an obnoxious odor, handle with special precautions and notify Environmental Control. C 001627 c*y ngiciMAi / / ........ .......... REVlSEiir~87p783 By W.B. Jackson [pakf 1 of! ISSUE 8 A5/69 By F.E.CroolL. REVE1WED 8/22/83 By J.W.Kongabl4 ATTACHMENT#! SAFETY PROCEDURE MANUAL MONSANTO COMPANY 014 .CHOCOLATE BAYOU PLANT Bfil MONSANTO COMPANY VACUUM TRUCK SERVICE RECORD Date:. Dispatcher Name Rtaieshae Sunarviinr Tima Truck flequatttd _ Tima Truck _____ f |Yes |H* ' Tima Track Reieatod__________ If NO, track last carried Personnel Safety Equipment Rtqaired for this job; | [ HardXat (~1 Safety Glasses I 1 Foco Sbiold j^Jcheaical Glovas 1 1 Slicker Suit Tap | | Slicker Sait - 2 Pieca Namu nf Ualatial Helper Required o flNe | | Goggles 1 1 Rubber Boots 1 1 Other Material on "Approved" List No. __ Origieatiag Vojitl Naai and Number Disposition of Malarial jf Vacuoa track lank to hovt air, CDnitrogen in it wbitc boiR| loadld. Vacuoa truck tank to be earthed with ait, Onitroit*. Naaa of Track Driver ------- Naae of Parson ftalaasiof Track_______________________________________ Connects . The personnel safety equipment checked above is available and is to be used by the driver and helper while loading, unloading and washinf out, and the track is equipped with lire extinguisher, relief valve and grounding cable. Signed (Vacuum Track nrin The personnel safety equipment checked above is adequate for the job at hand. --------- Signed (Using Unit Representative).Unit Chg . No. THE UNIT USING A VACUUM TRUCK WILL PROVIDE JOB SUPERVISION REQUIRED AND BE RESPONSIBLE FOR DRIVER'S SAFETY WHILE IN UNIT. C 00162S CBY 3109738 ORIGINAL 8 /15/69By F.E. Crook REVISED 8/22/83 ByW.R ..TaeVsnn PAGE 1 OF 1 REVEIWED 8/22/83 By J.W.Kongable ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-014 CHOCOLATE BAYOU PLANT USE OF VACUUM TRUCKS GUIDE FOR PERMITTED VACUUM TRUCK USE i> _> V {*:" - PRODUCT TEMPERATURE IN DEGREES FAHRENHEIT FIG. 8--Relationship Between Temperature, Rvp, and Flammable Limits of Petroleum Products at Sea Level. Ref: API RP 2003, 2nd Ed., Sept. 1967 Attachment #4, "Guide for Permitted Vacuum Truck Use", will be used as the basis for deciding if vacuum trucks are safe for special jobs not included in Attachments #1 or #2. C 001629 CBY 3109739 ORIGINAL 8 /l5/&9ByF.E. Crook ISSUE REVISED 8/22/83 Byy. b . Jackson PAGE 1 OF 1 REVEIWED 8/22/83 ByJ.W.Kongable ATTACHMENT #4 SAFETY PROCEDURE MANUAL MONSANTO COMPANY f"---- SP-014 CHOCOLATE BAYOU PLANT USE OF VACUUM TRUCKS VACUUM TRUCK SAFETY EQUIPMENT CHECK SHEET STATUS Regular Call-In * 1. * 2. 3. 4. 5. 6. * 7. * 8. * 9. *10. *11. *12. *13. *14. *15. 16. 17. *18. *19. 20. Pressure Relief Valve on Truck Fire Extinguisher on Truck General Condition of Hoses Working Condition of Truck Lights Condition of Tank Drain Valves (With Liquid or Pressure on Tank) Purge Connection Available on Tank Ground Cable Wheel Chocks Chemical Gloves for Driver & Helper Chemical Goggles for Driver & Helper Face Shield for Driver & Helper Hard Hat for Driver & Helper Safety Glasses for Driver & Helper Slicker Suit for Driver & Helper Rubber Boots for Driver & Helper High Level Shut-Off Valve Pressure/Vacuum Gauge Float Gauge Truck Clean (Check by Opening Manway) Overall Condition of Truck: Ask Driver & Helper some arbitrary safety question, such as "How do you summon first aid, what do you do when fire alarm sounds, do you under stand when the personal protective equipment should be used, etc.?" Inspected By: Foreman ^Processor Driver' s Name: Helper' s Name: Truck Number: Date: * Complete for Call-In CBY 3109740 DISTRIBUTION: Original to Environmental Control Group Foreman Carbon Copy to Environmental Control Mfg. Supt/Purchasing Supt. C 001630 ORIGINAL ISSUE i A 5/59 By F. E. Crook REVISED 8/22/83 ByW,B.Jackson PAGE 1 ...T 1 OF x REVEIWED 8/22/83 By J.W.Kongable ATTACHMENT #5 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 015 CHOCOLATE BAYOU PLANT FIRE WATER USAGE PURPOSE Define criteria and approval method for non-emergency fire water use. POLICY i The purpose of the fire water system is to provide emergency fire sup pression and spill control capability. Use of the fire water system for non-emergency situations will be allowed only under strict approval and control as defined in the following procedure. Use of the fire water system will not be allowed when it is determined that 1) its use will detract from the system capability in emergencies or 2) where other provisions can be made with reasonable planning and preparation. PROCEDURE 1. The department requesting use of fire water for non-emergency situations will submit the request to the Safety Department in writing via the requesting department's general superintendent. The request will define a) reason and justification, b) usage duration and control methods, c) alternatives, d) impact on Utilities' capability during proposed usage. 2. The Safety Department will review the requestL_and if justified, give2-Approval. 1 3. The requesting department will then propose a specific work plan incorporating any restraint or control criteria and communication seemed necessary by the Safety Department. 4. Non-emergency fire water use will be immediately ceased when the fire/spill alarm sounds and will not be resumed until the Safety Department has given approval to do so. 5. All communication for non-emergency fire water use related to starting and stopping fire water pumps with Utilities will be via the Safety Department. ISSUENAL12 /2/77By C.A.Coburn revised 9/4/81 By C.A.Cobum PAGE 1 OF 1 REVIEWED 12/13/83By C.A. Cobum ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 016 CHOCOLATE BAYOU PLANT ISOLATION AND DECONTAMINATION OF PLANT EQUIPMENT PURPOSE The purpose of this procedure is to provide for a consistent approach to decontaminating and isolating equipment by establishing guidelines, defining responsibility, and outlining techniques of decontamination and isolation available. POLICY To insure the safety of personnel performing maintenance or other work by requiring that equipment and facilities to be inspected, repaired or modified, be isolated from the operating plant, and de contaminated to the maximum practical extent prior to starting the work. Isolation and decontamination should result in the ability to perform work with a minimum amount of risk of personal injury, using a practical degree of personal protective equipment. DEFINITIONS Isolation is the separation, blinding, or blocking of all lines or other connections leading into the piece of equipment so there is no possibility of leakage or accidental flow of contaminants from associated equipment into that system during or following decontami nation. When valves are used for isolation the valve handle must be secured in the safe position with a chain or special bracket so that the valve cannot be accidentally opened or moved to any degree to allow leakage. ' --- ---------------------- --------------------------- Decontamination is removal of chemicals until there is no reasonable possibility of an explosive, flammable or otherwise harmful (skin contact or inhalation) concentration of chemicals remaining. A system will be considered to be contaminated until positive checks have been made to verify that it has been: 1. Drained and purged free of all chemicals, liquid flushings, or vapors which may be flammable, explosive, or otherwise harmful on skin contact or inhalation; 2. All toxic vapors will be purged down to the threshold -limit value (TLV) or lower. RESPONSIBILITY CBY 3109742 The overall safety responsibility for preparing for and carrying out repair work on process equipment rests jointly with Production and Maintenance. In the planning stage of each job, the Operations and Maintenance &-00W3Z ORIGINAL _ / / ISSUE 6 Z28/73 SAFETY PROCEDURE MANUAL _ _ _ _ _ _ _ _ _ _ _ SP-oie ----an3,,i" M jj-Ti rtf a 00Ttr--np^' - -^ ***>*:*< 1 'm 'TM^MnMWMMrT^wiTMrwriwiimBiwi iiirmiwrMMwwiMMm--w---- MONSANTO COMPANY CHOCOLATE BAYOU PLANT l ISOLATION AND DECONTAMINATION OF PLANT EQUIPEMENT (Cont'd) Determine what the exposure of the personnel performing the work will be in terms of potential hazards. Communicate potential hazards to those performing the work. Production Where isolation and/or decontamination can not be achieved, Main tenance Safety and Production supervision jointly assess risk and define required protective equipment and safety precautions. DISCUSSION Decontamination and isolation are important and highly technical safety functions in all process operations. Selection of the ap propriate method of isolation and decontamination can not be totally proceduralized except in special cases. Those persons involved in preparing equipment for Maintenance are responsible for exercising good judgment in carrying out isolation and de contamination to minimize the potential of personnel injury or equipment damage. Preparations should involve the following points: A. Planning For Isolation and Decontamination ( Each department will be responsible for developing and main taining decontamination plans and isolation diagrams (blind lists) on equipment and systems where applicable. Depending on the complexity of the equipment, the actual plan will vary . in detail. A checklist-type format can prove valuable for communication of the status of both isolation and decontami nation when these activities are extended over multiple shifts. Isolation and blinding lists should be checked periodically for completeness with special emphasis on small connections and other easily overlooked tie-ins to other process equipment, instruments, or test equipment. Preparation of a work plan or written procedure for isolation and decontamination of any piece of equipment, or system, should include consideration of the following aspects of the job: 1. Contaminants and Level of Decontamination What are the contaminants to be removed from the system? To what level can the system be practically decontaminated based on the work to be performed and exposure level of the personnel? What is the nature of the material: volatile, water soluble, sludge, granular, etc.? What are its relative hazards: toxic, corrosive, flammable pyrophoric, radioactive, etc.? -001634 CBY 3109744 ORIGINAL ISSUE 6 /28/73BvW.E.Groce REVISED 7/27/SIByT. A. Harlan PAGE 3 OF 12 REVIEWED / / By ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP ois CHOCOLATE BAYOU PLANT ISOLATION AND DECONTAMINATION OF PLANT EQUIPMENT locations be separated for confirmation? In equipment where we have past decontamination experience what conditions can we expect when decontamination is complete? Is testing done at the points least likely to be decontaminated? If entry is planned the oxygen level must be verified. Can deposits of sludge release contaminants after tests have been completed? Must the system be purged during vapor testing? B. Decontamination 1. Degree of Decontamination The level of decontamination is measured by the concentration of chemicals remaining in the equipment when it is cleared for Maintentance Work. The targeted level of decontamination for the various chemicals that may be encountered is zero. The maximum acceptable is based on the safety of personnel performing the work. Wheiflammable chemicals are involved, the maximum level of decontamination is one where the flammable, when exposed to air, produces a mixture which is too lean to burn. To increase the assurance that a flammable mixture cannot exist when *hot work* is being performed, the level sought is one too low to register flammables on a combustible gas test instrument. When toxic chemicals are involved, the maximum level permissible is the threshold limit value CTLV1. A toxic chemical is one which is capable of incapacitating personnel within minutes of exposure, TLV limits are conditions workers may be repeatedly exposed to every eight hour working day without harm. Portable vapor test devices which measure toxic chemical concentration in the ppm range should be used in testing. Consideration should be given to the degree of' actual exposure of the personnel performing the work in determining the maximum level of decontamination. When corrosive chemicals are involved the target is complete removal of the chemical and the diluted flushings from the system, A corrosive chemical is one which will produce burns immediately on contact. When vessel entry is planned following decontamination, tests will be made to Insure the system is free from harmful con centrations of chemicals and contains adequate oxygen (20% by volume! with a continous fresh air supply. C 001636 CBY 3109746 ORIGINAL 6/2/ 7yW.E.Groce ISSUE REVISED 7 /E7/B1 ByT. A. Harlan PAGE 5 OF 12 REVIEWED / / By ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- oie CHOCOLATE BAYOU PLANT ISOLATION AND DECONTAMINATION OF PLANT EQUIPMENT (Cont'd) equipment while flammables are present. Condensation of steam cam also create 9 vacuum that could suck the equipment in or draw air 'into the system. Water Washing: Used on chemicals that are water soluble or used as a carrier for loose solids trapped in the system. Can be used to "float" oils from low places in equipment. Is often used in flushing large quantities of. hydrocarbons or solids from equipment prior to final decontamination with steam or nitrogen. When decontaminating by water washing consideration should be given to the amount of flow through the system to insure adequate control and mixing. Following water washing, systems are normally drained or blown free of liquid to insure all contaminated water has been removed. Static electricity charges can produce sparks during washings. Mechanical Cleaning If large concentrations of sludge, scale or polymer are present, mechanical cleaning with high pressure jets such as those generated in line "moles" or Butterworth cleaning devices may be required prior to using conventional decontamination tech niques. Static electricity charges can produce sparks during cleaning. Chemical Cleaning Used when the deeming agents dissolve or suspend the solids or other contaminants present and carry them from the system. Purging When steam or water cannot be used, systems may be freed of vapor-type conteuninants by purging with inerts such as nitrogen. Over a period of time the nitrogen will sweep vapor conteuninants from the system while maintaining an inert atmosphere; ( denying the entry of oxygen and pre- CBY 3109748 c venting the potential formation of an _________explosive mixture. Frequently, _ 001638 ORIGINAL 6/W73 By W.E. Groce ISSUE REVISED 7 >27/81 Bvt. A. Harlan PAGE 7 OF 12 REVIEWED / / By ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-oie CHOCOLATE BAYOU PLANT ISOLATION AND DECONTAMINATION OF PLANT EQUIPMENT (Cont'd) C. Isolation 1. Degree of Isolation A properly isolated system is one in which there is no possibility of in-leakage of gas, vapor or other materials from associated equipment during or after the decontami nation process. The techniques used to prevent chemicals from contaminating a system either undergoing decontamination or maintenance vary from the most positive isolation techniques - blinding or pipe spool removal; to the least positive - a closed secured or unsecured block valve. The seriousness of the consequences of any leakage into the system undergoing maintenance determines the degree of isolation required. Hot work, vessel entry, and work on systems which contain highly toxic, corrosive, or otherwise hazardous materials will normally require the most positive isolation techniques available to insure the safety of those performing the work (refer to SP- 019 for Eire-, and Vessel Entry Permits),. . 2. Isolation Methods. CBY 3109750 Methods of isolation available with considerations for the application of each are: Line Disconnect: The most positive means of isolation. Involves disconnecting lines, removing valves or sections of pipe, and when necessary, blinding the open ends of these lines. Is carried out after the line has been depressured and de inventoried to the extent that flanges can be safely opened. Blinding The most common positive method of isolation. Involves installation of a blank plate (blind) between flanges to block any leakage. Blinds are in serted with a gasket on the side which requires a positive seal. Where venting is desirable to prevent pres sure accumulation, spacers are installed. c 001640 Double Block and Bleed The most positive use of valves to isolate. The open bleed between the closed valves prevents accumulation of pres OISRSUIGEINAL 6^ /29' 7%yW.E.G,, roce REVISED 7 /2.7/BlBy Ta A. Harlan PAGE 9 OF12 REVIEWED / / Bv ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-016 CHOCOLATE BAYOU PLANT ISOLATION AND DECONTAMINATION OF PLANT EQUIPMENT (Cont'd) 3. Securing Valves isolation/ involves inserting plugs, sealing plates into the line dr equip ment opening. Inflatable bags are not to be used unless no other alternatives to stoppling exist. Where the con sequences of failure or leakage of the stopple device are serious, -special purging precautions may be required. (See SP-023) To insure the integrity of an isolated system; i.e., that none of the valves used in the isolation can be accidently opened or moved to any degree to allow leakage, the isolation valves .must, be secured in a safe position. The method used to secure valve handles should accomplish two purposes: a. It should restrain the handle's movement to the extent that it cannot be opened through vibration, accidental manual operation, or through accidental striking against the handle. b. It should clearly identify the valve to be one being used for isolation of a specific item of equipment. Preventing valve movement is accomplished by restraining the valve handle with a chain or special bracket. Production secures the valves while the equipment is being isolated. Where the valve's movement is critical in terms of job safety; the effectiveness of the valve "Lockout" should be tested by attempting to move the valve. Caution should be exercised as some valve designs such as globe valves can be unseated with a minimum of handle movement. Valves used for isolation purposes will be equipped with an Isolation/Lockout tag (.attachment I) to prevent acci dental operation. The'tag will be yellow with black lettering. Locks are not required to secure valves being used for isolation; however, they may be used, if necessary, by Production or Maintenance personnel. REFERENCES 004-G43- Purging Principles and Practice; American Gas Association, 1954. CBY 3109752 ;NAL 6 /2^12 ByW.E.Groce REVISED 7 ^7,/8lByT. A. Harlan pAGEll OF 12 REVIEWED / / By___________ ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- Q16 CHOCOLATE BAYOU PLANT If V 001644 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-017 CHOCOLATE BAYOU PLANT REMOVAL OF EQUIPMENT FROM OPERATING UNITS FOR REPAIR PURPOSE To describe the requirements for removing equipment from operating units for repair. Equipment removed from the area for maintenance will be cleaned and tagged by operating personnel. Tagging is re quired on all equipment leaving the area in which it is installed regardless of service. PROCEDURE 1. Operating personnel will decontaminate equipment prior to re pair or servicing. The Fire-Entry Permit Procedure will be followed where applicable. Methods of cleaning and decontaminating will vary and will be determined by Operations. 2. Prior to removing equipment from an operating area, the equip ment will be tagged by Operations. The tag will include the following information. See Exhibit A. a. Equipment Indentification b. Date Cleaned c. How Cleaned d. Comments e. Signature of Foreman f. Chemical Service "Comments" should include statements and suggestions for safe handling during the repair. 3. Maintenance will not accept equipment for removal from an operating area unless it is tagged. 4. Office Services will stock and issue appropriate tags. C 001645 CBY 3109755 ORIGINAL ISSUE // 3/8/63 Bv REVISED 4 A / 77By D.r.Powledee W.W.Varnado REVIEWED8/7/ 8iBy.C.R.Murrell. PAGE 1 OF ATTACHMENT 1 SAFETY PROCEDURE MANUAL BttumuHiMH 'M'liii 'll ifnainw MONSANTO COMPANY t mroBgaa -HiftHm ffffmmwr SP-018 dlMWMi CHOCOLATE BAYOU PLANT MONSANTO CHOCOLATE BAYOU / DO HOT REMOVE THIS TAG EQUIPMENT LOCKED OUT: EQUIPMENT ISOLATED: Slgnad, Da to. V M6R4M (V. S/7l) COUNTKV MINUff DO NOT OPERATE ACCIDENTAL OPERATION OF THIS DEVICE CAN CAUSE INJURY OR. DAMAGE. TAG REMOVAL. SHALL BE BY AUTHORIZED PERSONNEL ONLY. SEE PLANT PROCEDURES SP-016 and SP-018. PREVENT INJURY THINK! I ^ MCl-tU (MV. IfH) eftttMTUT PNINTCP / C 001652 < CBY 3109762 ORIGINAL ISSUE 3 MA63 By. R.E.Guilliams REVISED 9 /13/ 82 By c.R.Murrell REVEIWED / / By PAGE 1 OF 2 ATTACHMENT #1 SAFETY PROCEDURE MANUAL MONSAN to company LIGHTING SAHEL LOCKOUT TAPE SP- 018 chocolate bayou plant A/AJ*4T Red Letters Yellow Background LECTR1CAL LOCKOUT TO U REMOVED aw--it-- / ONLY 'f BY PLANT ~ PfWO-DURES SP-CX8 & 3P-0I6 REV. 5/78_____ Black Letters CBY 3109763 V C 001653 OISRSUIGEINAL V14/63 gy R,,.E,,. G_uz..ll.ia.mi REVISED r` reveiwedS /zfym u, j.n. ouids n ,p,,huum3I PAGE 2 OF 2 ATTACHMENT #1 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 020 CHOCOLATE BAYOU PLANT MOBILE LIFTING EQUIPMENT SAFETY PURPOSE The purpose of this procedure is to establish a safety quideline to operating all mobile lifting equipment. SCOPE This procedure covers all Maintenance personnel (Monsanto and Contract) performing this function and all motor cranes, carry deck cranes, (Cranes, go-devils, cherry pickers). This procedure does not cover forklifts, manual hoists or line trucks. RESPONSIBILITY It is the responsibility of the Maintenance Foreman to insure that all operators of the equipment are thoroughly trained in the operation of the equipment and the contents of this procedure. It is the responsibility of each person performing this function to follow the guidelines. GENERAL SAFETY 1. Go-Devils and Cherry Pickers will be driven at a safe operating speed. This means that the operator must be confident he is in complete control of the vehicle at all times. Operating speed, therefore, will be reduced to allow for weather, road conditions, congested areas, etc. When moving mobile equipment through congested areas sound horn at appropriate intervals to alert everyone in the area to the presence of the equipment. If the equipment is not furnished with a back up alarm continuous short horn blasts should be used when operating in reverse. It is the sole responsibility of the operator to use good judgment and run this equipment in a safe manner at all times. 2. The following safety rules apply to all go-devils and cherry pickers that have removable cage type platforms installed on the rear. A. No more than three men may ride in a cage platform at one time. B. Men must stand on floor decking or platforms and use handrails. C. Sitting on handrails is not permitted. D. Riding on mobile equipment in any other manner than listed above is prohibited. CBY 3109764 ORIGINAL ISSUE revised 7/1/fel Byd.h. Orrell PAGE 1 OF 4 _8lBy G.A. Dowdy _ REVEIWED / / ATTACHMENT c 001654 SAFETY PROCEDURE MANUAL MONSANTO COMPANY rSP- 2 CHOCOLATE BAYOU PLANT 3.- DO NOT operate machines with worn, broken or frayed cables. Visually inspect cables frequently and replace any damaged cables. B. Operations REVISED 1. Outriggers should be set before lifting. Outriggers on cherry pickers should be lowered to grade until weight is removed from tires and machine! leveled to safely handle the weight it was designed for. . | 2. Do not pull loads sideways with boom. Booms are not designed for pulling loads in this manner and may collapse if used as such. REVISED 3. Avoid working with extreme high boom position.- When determining required boom angle, consideration should be given to a sudden load release which might cause the boom to recoil over the cab. 4. NEVER leave the machine with a load suspended in the air. Cooling brakes or a malfunction may allow the load to lower on personnel and/or equipment. 5. Watch the flagman at all times. If you must look in another direction, stop operations immediately. 6. Keep boom at least 10* away from all overhead power lines and electrical apparatus. See SP-022. 7. Keep hands free of oil and/or grease. 8. Do not move any load until directed to do so by flagman. NEVER anticipate the flagman's signal. REVISED 9. Keep load as low as possible at all times. c . servicing 1. Check hydraulic fluid for adequate level for safe operations. 2. Make all adjustments to brakes and clutches promptly. Make sure all guards are replaced after completing adjustments. 3. Stop all operations before lubricating, deeming, and/or making adjustments. Be sure floors and footpedals are free of oil, grease and mud. Replace all guards after completion of work. Remove tools and store in proper place. ORIGINAL /" ISSUE C 001656 CBY 3109766 /l5/68Bv G.A. Dowdy REVISED ? /j / 8IBy ~dTh REVEIWED / / By QxrelL PAGE 3 OF 4 ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 021 CHOCOLATE BAYOU PLANT SCAFFOLD SAFETY RULES AND PRACTICES PURPOSE The purpose of this procedure is to describe the safety requirements for construction and use of all scaffolds within the plant. SCOPE This procedure applies to all scaffolding erected at the Chocolate Bayou Plant whether tubular Scaffold structures, or special scaffolds erected in unique shapes and supported from Plant structures. RESPONSIBILITY It is the responsibility of the Monsanto Maintenance Foreman and Monsanto Contractor Supervisor to see that all scaffolds meet the established standards of Monsanto. It is the responsibility of each person erecting and/or using these scaffolds to inspect all material used and make sure that it is of good quality and that scaffold con struction is in compliance with the requirements outlined in this procedure and OSHA Regulation #1910.28, including further explanation of safety rules. The following safety guideline for erecting and/or using scaffolds is provided: 1. Inspect all materials for constructing scaffolds for defects. Repair or discard all defective material. The strength of rusted material is unknown. 2. Scaffolds must built large enough to provide space for personnel to perform all required work safely. 3. Adequate sills and base plates must be used, especially in areas that are not concrete, and on grating other than steel. 4. Keep scaffolds plum and level at all times. Do not force braces to fit. Level scaffold until all braces fit easily and securely. 5. Use adjusting screws instead of blocks for adjusting uneven grades, do not extend over 12". 6. Scaffolds must be provided with a safe means of access (built-in ladders, attached (ladder) or access from adjoining platforms or landings. Scaffold ladders should be located to allow direct ac cess to scaffold deck and avoid overhead obstructions and adjacent obstructions that would require unsafe acts to gain access.) ORIGINAL ISSUE REVISED 11/lY 8lBy F. B. Burns PAGE 1 OF 4 ATTACHMENT C 001658 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 021 CHOCOLATE BAYOU PLANT SCAFFOLD SAFETY RULES AND PRACTICES intermediate levels of 25' on tubular scaffolds. 16. DO NOT ATTEMPT to use scaffolds as material hoist towers or for mounting derricks without first determining the load and stresses. 17. One-fourth inch proof coil-chains are recommended for swinging scaffolds. These scaffold chains are proof tested at 2350#; the safe working load is 1175#. The chains should be tested annually. The workmen on swinging scaffolds shall be protected by a safety belt, attached to a lifeline. The lifeline shall be securely at tached, but not to the scaffold. 18. Care must be exercised to insure that all bolts, wing nuts, and clamps are properly installed and tightened. 19. If work is being performed above a scaffold, overhead protection for worker on scaffold must be provided. 20. Erected scaffolds must not prevent or hinder access to safety equipment. HANDLE ALL ROLLING SCAFFOLDS WITH ADDITIONAL CARE. 21. All castor brakes MUST be applied when not in motion. 22. DO NOT RIDE rolling scaffolds while in motion. 23. Removal of all material and equipment from platforms should'be accomplished when work is complete. Loose items should be put in a container on the deck while work is in progress. 24. DO NOT attempt to move a rolling scaffold without sufficient help. Watch for overhead obstructions and holes in pads. 25. Drawings and specifications for all frame scaffolds over 125' in height above the base plates shall be designed by a Registered Professional Engineer. 26. Scaffold shall be tied to and securely braced at intervals not to exceed 30 ft. horizantally and 26 ft. vertically. While erecting and dismantling scaffold a minimum of (2) scaffold boards must be used while the deck above is being installed. 27. All planking shall be scaffold grade quality lumber. 28. 'The Monsanto Contractor Foreman will inspect the scaffold yard monthly for damaged or unsafe items and order replacements. As in any written procedure, every situation cannot be covered. Each person must inspect each situation to make sure all safety hazards have been corrected. CBY 3109770 ORIGINAL n ^5/^8 ^ K. B. Owen REVISED n /u/81 By F. B. Bums REVEIWED / / By PAGE 3 OF 4 ATTACHMENT C 001SG0 SAFETY PROCEDURE MANUAL MONSANTO COMPANY *022 CHOCOLATE BAYOU PLANT MOBILE LIFTING EQUIPMENT AND INSULATED BUCKET TRUCK WORK NEAR HIGH VOLTAGE LINES PURPOSE The purpose of this procedure is to establish safety guidelines for any work in close proximity* to energized power lines and to define responsi bilities for special permits that may be required. SCOPE This procedure covers all Monsanto personnel and any Contractors performing this function. ' RESPONSIBILITY The following guidelines should be used to assure the safe performance of work in close proximity* to energized power lines and to define responsi bilities for special permits. . I. CRANES, CHERRY PICKERS, OR OTHER HEAVY EQUIPMENT Cranes, cherry pickers, or other heavy equipment which must be operated in close proximity to power lines are the responsibility of the owning department where the work is to be performed. It is the responsibility of the owning department to communicate with the Utilities Department and determine the need for outages and/or special permits. The owning department has responsibility for initiating any special permits which are required. At least 24 hours notice will be required. II. INSULATED ELECTRICAL BUCKET TRUCKS Insulated electrical bucket trucks or other equipment to be used in performing electrical work on pole lines which are part of the Plant Electrical Distribution System along Utility right-of-ways are the responsibility of the Utilities Department. The need for power line outages and/or special permits will be deter mined by the Utilities Department. Special permits for this type work will be initiated by the Utilities Department. Jobs of this type must be cleared through the Utilities Department prior to the start of the job. Coordination and communication of outages which affects the operation of adjacent units will be the responsibility of the Utilities Department. CBY 3109772 ORIGINAL ISSUE REVEIWED / / By PAGE 1 OF 3 ATTACHMENT c 001662 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP 022 CHOCOLATE BAYOU PLANT MOBILE LIFTING EQUIPMENT AND INSULATED BUCKET TRUCK WORK NEAR HIGH VOLTAGE LINES III. INSULATED ELECTRICAL BUCKET TRUCKS Insulated Electrical Bucket Trucks or other equipment to be used in performing electrical work within any Department, outside the Electrical Distribution System right-of-way shall be the responsibility of the Owning Department. Outages and/or special permits will be initiated by the Owning Department. IV. ANY EQUIPMENT Any equipment to be used in performing "Hot Work" on electrical systems must be approved according to Plant Procedure SP-024 which applies to any "Hot Work". GENERAL SAFETY If lift is to be made near energized power lines after preceeding guide lines have been completed, the following safety rules will apply. 1. Position rig as far from Electrical Distribution lines as particular circumstances will allow. 2. If a crane must operate within contact distance of energized lines, the following precautions must be observed: A. Contact Monsanto Instrument and Electrical group to install adequate ground. B. Personnel on ground must be kept at least 10 feet away from lifting equipment, and rig must be barricaded on all four sides with barricade tape. C. If contact is accidentally made with energized lines, operator must remain on rig until boom is cleared or lines de-energized. D. Lifts near energized lines should be made during day light hours, if at all possible.* * Close proximity is defined as during execution of the "planned" lift, no part of boom or load will be within 10 feet of energized power lines. This lift will be executed under a job plan which takes into account conditions or circumstances which could cause this 10 foot rule to be violated. If mechanical failure of load or boom could place either load or boom within 10 foot envelope, the line must be isolated or a safety audit must be performed before approval for job is given. B. Green REVISED ^a/ii/ 81By REVEIWED / / By lAGE 2 OF 3 ATTACHMENT C 001663 CBY 3109773 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-022 CHOCOLATE BAYOU PLANT MOBILE LIFTING EQUIPMENT AND INSULATED BUCKET TRUCK WORK NEAR HIGH VOLTAGE LINES APPROVED BY H. C. Cl^k APPROVED BY: G. E. Davenport lr~ CBY 3109774 M/ORIGINAL ,, issue ii 69bv J. B. Green REVISED 8/iy81By R. L. Hockin PAGE 3 OF3 REVEIWED / / By ATTACHMENT C 001664 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 023 CHOCOLATE BAYOU PLANT ORIGINAL ISSUE 9 / 9/7 5ByC.R.Rutan REVISED^ /1 / 77By n y vnrar, PAGE 1 OF 1 REVIEWED 3/81 By T.-A.Harlan ATTACHMENT#! C 001665 SAFETY PROCEDURE MANUAL MONSANTO COMPANY PLUMBERS PLUGS SP- 023 CHOCOLATE BAYOU PLANT D. If a special elastomer is required, contact MTS for spec ifications. II. Installation A. Inside surface of pipe and the surface of the plumbers plug must be free from all foreign matter for proper seating. B. After inserting the plumbers plug into the pipe, the wing nut must be tightened as much as possible (by hand) The plumbers plug must then be pushed, pulled and mbved from side to side (by hand) to insure a proper seat has been made. If the plumbers plug slips or moves, it must be re-tightened. The above procedure shall be followed until the plug does not move. C. Due to heat transfer through metal, welding shall be executed no closer than 6" from the elastomer of the plumbers plug. III. Safe Pressure and Regulation of this Procedure A. Do not exceed 10 PSI on standard plumbers plug. B. A Fisher-type 630 (or comparable) regulator must be used to regulate pressure. C. A 0-30 PSI pressure gauge must be used to insure purge flow. If the pressure gauge indicates more than 10PSI, purge valve should be closed and all valves in the system checked for leakage. D. For high pressure applications, in excess of 10 PSI, A.T.D. W. 1000 PSI plumbers plug must be used. IV. Purging of Pipe System A. Inlet of purging media (nitrogen or inert gas) shall be located as close to the work as possible. (See Attachemet 1) B. Purge flow must be confirmed. Confirmation of flow can be accomplished by: 1. Pressure gauge indication 2. Safety vapor test of exit gases. CBY 3109776 ORIGINAL 9/9/T^C. R.Rutan REVISED 4/ 1/77By C.R.Rutan REVIEWED6/3/ 81 ByT.A.Harlan PAGE 2 OF 3 ATTACHMENT C 001666 SAFETY PROCEDURE MANUAL MONSANTO COMPANY PLUMBERS PLUGS SP- 023 CHOCOLATE BAYOU PLANT PURPOSE The purpose of this procedure is to define safety guidelines for use of the plumbers plugs. A plumbers plug is an isolation device used on piping systems which are impractical to fully decontaminate. SCOPE This procedure covers the selection and installation of plumbers plugs and the use and regulation of the purge gas. RESPONSIBILITY It is the responsibility of the Maintenance Foreman and the Monsanto Contractor Foreman to insure that all personnel know and follow these guidelines. PROCEDURE I. Elastomer Selection A. Services in which the standard off-the-shelf plumbers plug (Neoprene Seal) are used are: Acetone Acrylonitrile Ammonia, Anhydrous Formaldehyde-Formalin Mercaptan Methanol Nitrogen Oil, Lube Paraffin Phosphoric Acid - 85% Snifo-Snifon (Fuel Oil) Sodium Hydroxide (10%--50%) Tertiary Butyl Catechol Triethylene Glycol Water & Steam not over 300F Two Suppliers of these plugs are: 1. McMaster-Carr Supply Company, Model 2P6440 2. Texas Mill Supply, Inc., Model A-0900 CBY 310977? B. All plumbers plugs are to be tagged as to elastomer material. A metal tag attached securely to the plug shall be used. C. Unless the elastomer material is definitely known, do not use the plumbers plug in any service. ORIGINAL issiif _/ Z 9/9/75 Bv C.R.Rutan REVISED 4 / V 7 7 By C. R. Rutan REVIEWED6/3/Si ByT.A.Harlan PAGE 1 OF 3 ATTACHMENT C 001667 SAFETY PROCEDURE MANUAL MONSANTO COMPANY PLUMBERS PLUGS AUTHOR! APPROVED BY APPROVED BY SP- 023 CHOCOLATE BAYOU PLANT CBY 3109778 ORIGINAL / / ISSUE 9/ 9/75Bv C.R.Rutan ---------- * REVISED 4 /1/77 By C.R..Rutan REViFWFn6 / y 81 Ry T. A.Harlan " I-- " ' -i im- PAGE 3 OF 3 ATTACHMENT C 001668 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 024 CHOCOLATE BAYOU PLANT GUIDELINES FOR WORK ON ENERGIZED ELECTRICAL CIRCUITS The purpose of this procedure is to establish guidelines that should be followed before working on energized circuits. DEFINITION Hot work is generally defined as any action performed on circuits of 277 V to ground or higher (480 3-phase). The use of test equipment on energized circuits is not considered hot work. PROCEDURE A. A job requiring hot work will require a Special Fire Permit. B. The following are situations that are generally classified as hot work: 1. Changing or modifying energized circuit continuity. 2. Tightening of energized connections. 3. Removal of top cover of an explosion proof housing when the primary side of the breaker is still energized or any other situations where a conductive metal is moved in close proximity to an energized circuit. C. A job plan should be developed by the Maintenance planner which will include the following: 1. Analysis of personnel safety hazards, and equipment required. 2. Identification of risk and communication of adverse consequences to other parties not directly involved who could be affected if the job did not go according to plan. 3. Identification of all other alternate methods to accomplish the job objective. 4. Identification of preventive and continuing actions that would insure a minimum loss to equipment and production if the job does not proceed according to plan. CBY 3109779 ORIGINAL ,, / / ISSUE 8/9 3 Bv M..E. Neel REVISED 4 /1/77 ByR.E.Guilliams PAGE 1 OF 2 REVIEWEd.Qi2/81 ByJ. B .Williams ATTACHMENT c 001669 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 024 CHOCOLATE BAYOU PLANT 5. A written step-by-step job plan as precautions for insulation of surrounding energized conductors, etc. RESPONSIBILITIES A. Maintenance Planner - Development of job plan according to this procedure. B. Maintenance Foreman - Execution of job plan, except on off-hours where he may also develop the plan. He will also initiate the process of obtaining the Special Permit at least 24 hours before the job. C. Maintenance Supervisor - Review and approval of the job plan method, preventive and contingency plans, safety considerations and other alternates available. D. Maintenance Superintendent - Oral approval will signify the work is necessary, the method practical, and the prescribed precautions, when taken are adequate. He determines the need for and approves any other contingency plans. E. Superintendent, Maintenance - Oral approval will signify that the work is necessary, the method practical, and the prescribed precautions, when taken are adequate. He determines the need for and approves any other contingency plans. APPROVED BY W. H. Collier APPROVED BY G. E. Davenport g CBY 3109780 ORIGINAL ISSUE 3/9 /73BVM.E. Neel 4/1A.7 ^^S,, Quill jams page 2 of2 REVIEWED!^ 1?81 foJ.B.Williams ATTACHMENT C 001670 SAFETY PROCEDURE MANUAL MONSANTO COMPANY PLANT-WIDE GAS CYLINDER REGULATOR AND MANIFOLD SAFETY SP- 025 CHOCOLATE BAYOU PLANT PURPOSE The purpose of this procedure is to provide a guide for the handling of vendor supplied gas cylinders, regulators, and manifolds in a safe and proper manner. Every specific use cannot be covered. Therefore, it may be necessary to review a specific case (example chlorine or other toxic gas) for further safety consideration. SCOPE This procedure covers the use, storing, inspection, and handling of gas cylinders, regulators and manifolds. This is intended for use with bottled gas cylinders which range in size from those used by the lab and I&E for instrument gases to any gas cylinder used by the plant. RESPONSIBILITY It is the responsibility of the department foremen to insure that all people who may use cylinders, regulators, and manifolds are properly trained in this area. It is Store's responsibility to check all incoming cylinders for: (1) The identification tag naming the gas contained. (2) Full, in use, empty tags applied to cylinder. (3) Obvious visual abnormalities of cylinder. It is necessary for each person, having a need for this type equipment, to follow the directions carefully. It will be the responsibility of the department foremen to review this procedure at least annually with their personnel. PROCEDURE Handling Cylinders 1. Accept only cylinders approved for use in the interstate commerce for transportation of compressed gas, stamped with DOT or ICC spec identification. 2. Do not remove or change numbers or marks stamped on cylinders. CBV 3109761 origina.. 9/iy^ K. B Owens REVISED 12/ 3/ 81 By W. R. Stone REVEIWED / / By as PAGE 1 OF 8 ATTACHMENT C 001671 SAFETY PROCEDURE MANUAL MONSANTO COMPANY. CHOCOLATE BAYOU PLANT PLANT-WIDE GAS CYLINDERS REGULATOR, AND MANIFOLD SAFETY 3. Combined storage of oxygen and flammable gas cylinders should be avoided where practical. When necessary to store 25 cylinders or more of a flammable gas, at least 25' of clearance shall be main tained to buildings housing personnel, cylinders of oxygen, or items which should be protected from a fire exposure. In cases where the required clearance cannot be realized, the presence of a separating fireproof partition will suffice. Cylinders kept on oxygen and acetylene cutting racks are specifically excepted. 4. Acetylene and liquified flammable gas cylinder shall be stored with the valve up. 5. To prevent rusting, cylinders stored in the open should be protected from direct contact with the ground. 6. Cylinders should not be stored near sources of heat, such as radiators and furnaces. 7. Cylinder storage should be planned so that cylinders will be used in the order in which they are received from the supplier. 8. Empty, in use, and full cylinders should be plainly identified to avoid confusion. 9. Group together cylinders which have held the same contents. 10. Storage rooms for cylinders containing flammable gases should be ventilated to prevent the accumulation of explosive concentration of gas. No source of ignition should be permitted. 11. Cylinders should be stored with the valves closed and the protection caps in place. 12. Cylinders should be stored in such a fashion as to prevent accidental tipping over of the cylinders. Using Cylinders 1. Hoses are not permitted in any bottled gas system except as a temporary connection from a low pressure system (200 psig or less). CBY 3109783 ORIGINAL 9 /18//67 Qy k. B. Owen REVISED 12/3 /si By w, R. Stone REVIEWED / / By C 001673 PAGE 3 OF 8 ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-025 CHOCOLATE BAYOU PLANT PLANT-WIDE GAS CYLINDERS REGULATOR, AND MANIFOLD SAFETY Close the valve and take the cylinder outdoors, well away from any source of ignition. A regulator attached to the valve may be used temporarily to stop a leak through the valve seat. If jthe leak occurs at a fuse plug or other safety device, take the cylinder outdoors, well away from any source of ignition, open the cylinder valve slightly, and permit the flammable gas to escape slowly, tag the cylinder plainly. Post warnings against approaching with sources of ignition. Promptly notify the supplier and follow his instruc tions for returning the cylinder. 12. Do not permit sparks, molten metal, electric currents, excessive heat or flames to come in contact with the cylinder or attachments. 13. Never use oil or grease as a lubricant on valves or attachments of oxygen cylinders. Keep oxygen cylinders and fittings away from oil and grease and do not handle such cylinders or apparatus; with oily hands, gloves or clothing. 14. Never use oxygen as a substitute for compressed air in pneumatic tools, in oil preheating burners, to start internal combustion engines, or to dust clothing. Use it only for the purpose for which it is intended. 15. Never bring cylinders into tanks or unventilated rooms. 16. Do not fill cylinders, attempt to mix gases in a compressed gas cylinder, or to use it for purposes other them those intended by the supplier.17 17. Check valves are to be installed on both the fuel gas and 02 cylinders of single welding units at the point where the torch hose connects to the pressure regulator it is also adviseable to install check valves on the hoses at the point where the torch is connected. Regulators 1. High pressure cylinders (Above 200 PSIG) which are used inside building must have a pressure regulator screwed directly into the cylinder outlet valve. CBY 3109785 ORIGINAL 9/8/79Bv K~ ISSUE REVISED 12 / 3 / 81 By W. R. Stone REVEIWED / / By PAGE 5 OF 8 ATTACHMENT C 001675 SAFETY PROCEDURE MANUAL --i--IW----raitniHH MONSANTO COMPANY SP- 025 H HUM --wn-------- CHOCOLATE BAYOU PLANT PLANT-WIDE GAS CYLINDER REGULATOR, AND MANIFOLD SAFETY d. Release the pressure-adjusting screw on the regulator to its limit -- turn it counter-clockwise until it is loose. e. Open cylinder valve slightly to let the hand on the high pres sure gauge move up slowly. On an oxygen cylinder, gradually open the cylinder valve to its full limit, but on an acetylene cylinder, make no more than 1 1/2 turns of the valve spindle. 8. Regulators provided should be designed to withstand full cylinder pressure upstream and downstream of the regulator or the downstream side of the regulator must be provided with a suitable relief valve. It should be noted that the regulator can malfunction and full cylinder pressure can be experienced on the low pressure side of the regulator and the downstream system. If the downstream side of the regulator or the downstream system cannot withstand full cylinder pressure relief provisions must be made. .9. Regulators and associated gauges and relief valves should be main tained in excellent working condition at all times. All regulators must have inlet and outlet pressure gauge. 10. The pressure adjusting screws should always work freely. If it is necessary to force the adjusting screw, the regulator should be replaced or repaired. Manifolds Bottled Gas Systems in Building 1. Low pressure manifolds (200 PSIG or Lower) for gases which are not toxic are permitted in all laboratory or experimental areas. However, piping access should follow a path outside of office areas or areas which normally house people. 2. High pressure manifolds (Above 200 PSIG) for gases which are not toxic are permitted in experimental or out buildings which are physically detached from office areas or areas which normally house people. High pressure manifolds are permitted in laboratory or experimental areas which are housed with offices or areas which normally house people only if piped directly.into a hood or enclosed ventilated area. ORIGINAL ISSUE CBY J10918Y /18/67 By K. B. Owen REVISED 12/ 3/ 8lBy W. R. Stone REVIEWED / /____By PAGE 7 OF .8 ATTACHMENT c 001677 SAFETY PROCEDURE MAMMAL MONSANTO COMPANY SP- 025 CHOCOLATE BAYOU PLANT PLANT WIDE GAS CYLINDER, REGULATOR, AND MANIFOLD SAFETY SPECIAL CONSIDERATIONS Breathing Air 1. The Production Department clerk ordering "breathing air" will be responsible for specifying "breathing air" as opposed to "compressed air" when ordering cylinders. 2. Stores' receiving clerk will be responsible for notifying the Safety Department of the delivery of am air cylinder that is to be used as "breathing air". 3. The Safety Department will be responsible for testing each incoming "breathing air" cylinder forj 1. Oxygen Content 2. Flammability 3. Odor 4. Condition Safety will affix a tag certifying the quality. No cylinder of (breathing air) is to be used without Safety Department identi fication label. 4. When outside contractors are using their own breathing air, the Monsanto foreman directing the job must call upon the Safety Department to test their cylinders for oxygen content. Fire If a gas cylinder leak should be ignited, a spray of water should be applied to cool the cylinder. Cylinders exposed to a fire should be cooled with a spray of water or removed from the area. It is not necessary to extinguish the burning cylinder until the cylinder gas pressure is practically depleted. The burning (or leaking) cylinder should be carried to a remote location in an upright position and allowed to empty. Identification No cylinder will be accepted by Stores or Raw Material Section unless identified with appropriate markings. No employee will use any cylinder from any source without proper identification. CBV 3109789 ORIGINAL ISSUE s/is/ 6^, K. B. Owen. REVISED 12/ 3/ 8lBv w. R. Stone REVIEWED / / By PAGEl OF 1 ATTACHMENT 1 C 001679 ansggj EB3Bas3B SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 02s CHOCOLATE BAYOU PLANT PROCUREMENT AND HANDLING OF RADIOACTIVE MATERIALS AND X-RAY PRODUCING EQUIPMENT PURPOSE This procedure outlines requirements for procuring and handling radio active materials and x-ray producing equipment. POLICY Procurement and handling of radioactive materials and x-ray producing equipment will conform to the Texas Regulations for Control of Radiation. LICENSING Authority to possess and use radioactive materials and x-ray producing equipment is granted to Monsanto Company, Texas City, by the State of Texas. The "Texas Regulations" require the naming of a Radiation Safety Officer (RSO), and of the principal users (Isotope Committee) of the materials in application for radioactive material licenses. Members of the Isotope Committee are as follows: Radiation Safety Officer - John E. Fox - Loss Prevention Department, Texas City; 1st alternate. Royal Benson; 2nd alternate, Frank Bryant. Chocolate Bayou Radiation Safety Officer - James C. Edwards; first alternate, Jackie Gaul. RESPONSIBILITIES Persons using radioactive materials or x-ray producing equipment or owning Departments of nuclear devices responsible for knowing and com plying with the safety requirements applicable to their use. The RSO is responsible for assuring that Monsanto meets its obligations to the State for the safe and proper handling of radioactive materials and x-ray equipment at Texas City and Chocolate Bayou. The Isotope Conmittee is responsible for ordering the materials and for training and supervising others in their use. The Chocolate Bayou Radiation Safety Officer (RSO) is administratively responsible for monitoring the presence, storage, and use of radioactive materials and x-ray equipment at the Chocolate Bayou Plant. The RSO will review, approve, and monitor activities that require plant personnel to handle radioactive materials or x-ray equipment. ORIGINAL ISSUE /15^66 BvR.W. Rotzler REVISEDZ""Aa/82 By J. C. Edwards PAGE 1 OF 6 REVEIWED / / By ATTACHMENT. CBY 3109791 c 001681 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 026 CHOCOLATE BAYOU PLANT PROCUREMENT AND HANDLING OR RADIOACTIVE MATERIALS AND X-RAY PRODUCING EQUIPMENT MTS (Night Superintendents on off-hours) will arrange for the servicesof contract radiographers making equipment inspections and insure compliance with this procedure. The Maintenance Contractor Foreman will insure that radiographers reporting to prime contractors comply with this procedure. The CED Construction Engineer will insure that contract radiographers working on CED Projects comply with this procedure. Stores Shipping and Receiving Clerk is responsible for notifying the RSO upon the arrival or shipping or radioactive materials. PROCEDURE A. Procurement 1. Requests for radioactive materials or x-ray equipment will be directed to the RSO. He will arrange for the materials thru the Texas City RSO. 2. The Texas City RSO will obtain the materials and be responsible for monitoring their handling until receipt by the Chocolate Bayou RSO is confirmed. 3. Material received at the plant shall not be opened or removed from Stores until checked by the RSO. 4. The Chocolate Bayou RSO will log-in radioactive material enter ing the plant and the location stored. He will log material out of the plant and monitor their handling until received by the Texas City RSO. B. Storage 1. The RSO will assure that radioactive materials are stored in properly labeled and shielded containers secured against unauthorized access or removal. 2. Sealed sources shall be shielded to reduce the radiation level ,, to a maximum of 10 mr/hr at the surface and a maximum of 5 mr/hr at 12 inches. CBY 3109792 ORIGINAL ISSUE / 15^66bv R.W. Fotzler REVISED 4 /WS2 Bv.t C. Edwards REVEIWED / / By PAGE 2 OF 6 ATTACHMENT C 001682 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 026 CHOCOLATE BAYOU PLANT PROCUREMENT AND HANDLING OF RADIOACTIVE MATERIALS AND X-RAY PRODUCING EQUIPMENT C. Handling and Use 1. Use of radioactive materials for plant tests in operating units require approval by the RSO. 2. Personnel using radioactive materials or x-ray producing equipment shall have been trained by the RSO, or a member of the Isotope Committee. 3. The RSO will log radioactive material in and out of storage including the name of the person responsible for their use and the proximate location of use. 4. The person using the materials will conform to the job plan and maintain physical custody of the materials until they are returned to storage. 5. Sealed sources used in fixed devices shall be installed, placed in operation, or removed only with the approval of ( the RSO. 6. Vessels using sealed sources may not be entered until the source holder has been locked in the shielded position or removed. The owning department is responsible for maintain ing this control. It may be necessary to call the RSO or Safety to verify that the shield is in the proper position. 7. For x-ray equipment owned and/or operated by Monsanto, the installation, operation and repair plans, and any modification to the installation must be approved by the RSO. 8. No repairs or attempted repairs shall be made to nuclear sources. If there is doubt as to whether or not a source is performing properly, contact the RSO. Added - 9. All radioactive catalysts must be handled in accordance with workplans which have been approved by the RSO. D. Contract Radiographers 1. Contract radiographers must follow the requirements of the "Texas Regulations" including the wearing of film badges and dosimeters in pocket chambers. The RSO will maintain up-todate copies of the "Texas Regulations". 2. Radiation areas must be posted and barricaded off in accord ance with the "Texas Regulations". PssifFINAL 9/1^66ay R.w. Botzler REVISED 4 / 82-fo J. C__Edwards.. PAGE 3 OF 6 REVEIWED / / By ATTACHMENT CBY 3109793 3 C 001683 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 026 CHOCOLATE BAYOU PLANT PROCUREMENT AND HANDLING OF RADIOACTIVE MATERIALS AND X-RAY PRODUCING EQUIPMENT 3. The Monsanto Supervisor responsible for the contract radio graphers performance will assure that the contractor is know ledgeable of safety precautions and that they are followed. 4. The Truck Gate Security Officer will notify the Safety Depart ment upon the arrival of contract radiographers as to the contractor's name and location of the work. He will also report departures from the plant. 5. The Monsanto Supervisor will advise the Safety Department prior to changing locations of contract radiographers from one operating area to another. 6. The Monsanto Supervisor will notify operating departments within 600 feet of the actual work of the risk of stray radiation interfering with process instruments. 7. Source strength shall be limited to maximums of 50 curies for Ir 192 and 35 curies for Cobalt 60. Use of stronger sources will require RSO approval. 8. Sources of radiation should be removed from the plant any time the contract personnel leave. The Monsanto Supervisor must obtain Safety Department approval to leave a source in the plant in the radiographers absence. E. Radiation Monitoring 1. The Safety Department shall maintain a map showing the location of all radiation detectors, sealed sources in fixed devices. 2. If radioactive materials are involved in a fire or explosion a radiation survey will be made by the Safety Department or RSO before personnel will be permitted to begin investigative and restoritive activities. 3. Film badges shall be worn at all times by personnel handling radioactive materials or x-ray equipment and by any other person likely to receive doses of radiation in excess of that permitted in part 21.105 of the "Texas Regulations". These badges will be issued by and returned to the industrial Hygiene Department. 4. Areas using unsealed radioactive materials shall be surveyed as necessary by the person using the material and shall be monitored semi-annually by the RSO.- ORIGINAL ISSUE smm.. bv^jl tu-anai luti teinrsi mwi----a------bm-- [revised 4 /IV82 By J.C. Erfcaarvfa PAGE 4 OF 6 Rnl-y.Tia-if REVEIWED / / By ATTACHMENT , c 001G84 CBY 3109794 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 026 CHOCOLATE BAYOU PLANT PROCUREMENT AND HANDLING OF RADIOACTIVE MATERIALS AND X-RAY PRODUCING EQUIPMENT 5. All fixed devices using sealed sources and all x-ray producing equipment shall be surveyed by the RSO for radiation profile upon installation and semi-annual thereafter. 6. All sealed sources shall be "wipe tested" at six month intervals by the RSO. Added - 7. All catalyst burial sites will be surveyed, at six month or less intervals, by the RSO. F. Disposal Revise-1. The disposal of all radioactive sources will be handled by the RSO. (See attachment #1) ( Added - 2. The burial of radioactive catalyst waste will be handled in an approved burial site, with the guidance and approval of the RSO. Added - 3. The Environmental Control Department has the responsibility for the upkeep and maintenance of the burial sites, accord ing to the Texas Regulations for Control of Radiation. G. Records 1. Copies of purchase orders and receipts of all radioactive materials and x-ray equipment. 2. Monthly total of each radioactive material in the Texas City and Chocolate Bayou Plants. 3. Disposal records. 4. Radiation profile on each fixed device utilizing a sealed source and x-ray producing machine taken immediately after installation. 5. Location of radioactive materials and x-ray equipment. 6. Film badge records. 7. Semi-annual wipe test of all sealed sources. ORIGINAL 9 /i5/46 Bv R.W. REVISED 4 AV82Byj.fi ISSUE Rotzle: :revE!WED / / By PAGE 5 OF 6 ATTACHMENT C 001685 CBY 3109795 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 026 CHOCOLATE BAYOU PLANT PROCUREMENT AND HANDLING OF RADIOACTIVE MATERIALS AND X-RAY PRODUCING EQUIPMENT 8. Semi-annual monitor survey of x-ray equipment. 9. Investigation reports of radioactive spills or excess personnel exposure to radiation. Added - 10. Location and survey results of radioactive waste burial sites. The Safety Department at Chocolate Bayou will maintain the log of receipts, storage, use, and return of radioactive materials as indicated above. ORIGINAL 9/;iy66BvR. w. Rptzler REVISED 4 /\W 82 By J.C. Edwards REVEIWED / / By PAGE 6 OF 6 ATTACHMENT C 001686 CBY 3109796 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 026 CHOCOLATE BAYOU PLANT PROCUREMENT AND HANDLING OF RADIOACTIVE MATERIALS AND X-RAY PRODUCING EQUIPMENT ATTACHMENT #1 RADIOACTIVE MATERIALS DISPOSAL REQUEST DateLocation of Material Approximate volume and composition_______________________________________________________ Curie activity of each radioactive element________________________________________________________ External radiation________________________________________________________ Container to be saved or destroyed_________________________________ Disposal requested by____________________________________________________ . Place of disposal Method of disposal Disposed by Date FINAL DISPOSAL Radiation Safety Officer CBY 3109797 ORIGINAL ISSUE As/66Bv REVISED 4/L4/82ByJ.C. Edwarrfg PAGE 1 OF 1 R.W. Rotzlei REVEIWED / / By ATTACHMENT Jk1 C 001667 MONSANTO COMPANY Sp. 027 CHOCOLATE BAYOU PLAN CRANE BASKETS, PERSONNEL TRANSPORTATION PURPOSE This procedure defines the conditions under which crane baskets may be used for personnel transportation and the safety precautions which must be taken. SCOPE This procedure applies to all Monsanto and contractor personnel performing work for the Maintenance Department. DISCUSSION Temporary access facilities available at Chocolate Bayou include portable ladders, stairs, platforms, scaffolds, cherry picker baskets and crane baskets. The crane basket may be used for personnel transportation only when other more conventional means are not practical. Examples are as follows: Where other means of access provide a greater hazard than crane basket utilization or where economics and/or timing have a significant safety or financial impact. PROCEDURE The following safety precautions must be taken before personnel are permitted to ride or work from crane baskets. A Safety Audit will be conducted prior to execution of work which is to include completion of the suspended personnel work basket authorization form (Attachment #1). Personnel will be transported only in crane baskets designed for that purpose and approved by Monsanto Personnel. (Engineering, Maintenance and M.T.S.) Riding on loads Is strictly prohibited. Exceeding basket design load is strictly prohibited. A tag line/lines will be used. (2) A test lift is required consisting of four (4) times the intended load including the swing radius. If a hydraulic crane is being used, the boom hoist cylinders and boom extension, or crowd cylinder, should be protected by pilot operated check valves. This will protect against sudden loss of fluid if a hydraulic hose should fail. ORIGINAL 6 z25/71^ ISSUE CBY 3l9798 REVISED 9 40/85 BV j. M. Harris PAGE 1 OF 3 REVEIWED / / Bv ATTACHMENT C 001688 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 027 CHOCOLATE BAYOU PLANT CRANE BASKETS, PERSONNEL TRANSPORTATION (CONT'D) RESPONSIBILITIES (CONT'D) The Maintenance Supervisor or Monsanto Contractor Supervisor will assure himself that no practical means of temporary access, other than the crane baskets is available and that the personnel lift will be accomplished safely. He will also communicate the need to use the crane basket to the Maintenance Superintendent. The department requesting the job will be responsible for initiating the safety audit. ORIGINAL 6 ISSUE _ 5//71Bv CBY 3109800 REVISED 9 Ao/ asBy J. M. Harris PAGE 3 OF 3 REVE1WED / / By ATTACHMENT C 001690 SUSPENDED PERSONNEL WORK BASKET AUTHORIZATION ]^ * Maintenance Superintendent do approvi Che use of a suspended work basket aton (DATE) (LOCATION) The use of the basket will be in accordance with SP-027 for crane baskets suspended from cranes Is there a way less hazardous? Immediate foreman 1 APPROVAL SIGNATURES MAINTENANCE SUPT. M.T.S. (GENERAL) MAINTENANCE SUPERVISOR SAFETY MAINT . ENGR. OPERAlOR'a. NAME' EQUIPMENT NUMBER SERIAL NUMBER WEATHER CONDITIONS MAKE BADGE NUMBER MODEL DATE OF LIFT TIME OF LIFT SOIL CONDITIONS CAPACITY ARE MATS NECESSARY? total lift elevation ARE OVERSIZED OUTRIGGERS NECESSARY TOTAL LIFT WEIGHT (Blocks, Shackles, anc TOTAL BOOM AND JIB LENGTH (Total on Machine at Time of Lift) WILL JI3 ACTUALLY BE USED? BOOM ANGLE DISTANCE FROM LOAD CENTER TO CENTER PIN MANUFACTURERS RATED CAPACITY FROM CHART WITH THESE PARAMETERS TEST LIFT WITH REQUIRED WEIGHT & SWING MADE ORIGINAL /zs/ 71^ ISSUE CBY 3109801 REVISED 9 /10/85 ByJ.M. Harris REVEIWED / / PAGE 1 OF 1 ATTACHMENT#! C 001691 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 029 CHOCOLATE BAYOU PLANT SCRAP MATERIALS DISPOSITION PURPOSE The purpose of this procedure is to define the responsibilities and objectives related to the disposition of scrap materials. POLICY All unwanted materials classified as scrap and not having any value greater than routine scrap and can feasibly be handled will be made available to Monsanto employees prior to disposition. Additionally, certain materials will be classified as scrap but because of their value potential, will require special handling and disposition; i.e., alloys. These materials will not be offered to Monsanto employees prior to disposal. Further, specific items such as unserviceable vehicles may be deemed as scrap and offered for sale to Monsanto employees. . SCOPE This procedure applies to the disposition of all materials classified as scrap except those items that cannot be adequately and sufficiently decontaminated (see Safety Procedure 013 for disposal instructions). RESPONSIBILITIES The Stores Superintendent will be responsible for the overall operation of the Scrap and Salvage Yard. Individuals generating the scrap (primarily maintenance foreman and contractor super vision foreman) will be responsible for segregating and delivering the scrap materials to the Salvage Yard. The owning unit will be responsible for the decontamination and tagging (Decontamination Tag, MCB 041B) of equipment that has been in hazardous service prior to delivery to the Salvage Yard. The Purchasing Agent is responsible for advertising any special scrap, e.g. vehicles, available to employees and for obtaining the best sales price for all scrap materials sold to junk dealers. The Safety Department (Security Force) is responsible for opening and closing the Scrap Yard when it is opened for employees. They are also responsible for maintaining records of items removed. CBY 3109802 ORIGINAL 4/l9/frl ^ R.E.Belden ISSUE REVISED 9/ 1/ 81 By D.C.Dirks REVEIWED / / By______________ PAGE 1 OF 2 ATTACHMENT c 001692 iHiiM SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 030 CHOCOLATE BAYOU PLANT STATIC GROUNDING & BONDING OF HYDROBLASTING EQUIPMENT AND OTHER PORTABLE EQUIPMENT PURPOSE The purpose of this procedure is to establish a method for grounding hydroblasting equipment and other portable equipment to prevent a static build-up. SCOPE This procedure covers static grounding of all hydrocleaning equip ment and other non-electrical portable or mobile equipment capable of generating static electricity. RESPONSIBILITY 1. It is the responsibility of the department or contract personnel performing the work or using the equipment to make the ground connections. 2. It is the responsibility of Production Supervision to see that hydroblasting equipment and other portable or mobile equipment capable of generating static electricity is grounded. Production, after checking that ground wires are connected on hydroblasting equipment, will contact the Safety Department for resistance check before work is begun. Other portable or mobile equipment, capable of generating static electricity, that has a ground wire attached will not normally require a resistance check by the Safety Department unless the integrity of the gound is question able, 3. It is the responsibility of the Safety Department to make a resistance check of all hydrocleaning equipment before work is begun or equipment is put in service. Resistance checks are to be made, at the request of Production, on non-electrical portable or mobile equipment. 4. It is the responsibility of the I&E Department to determine the proper method of grounding this equipment. PROCEDURE 1. Care should be exercised when connecting and disconnecting ground and bonding connections as it is possible that a spark could be N. ORIGINAL ISSUE , /i 9/7 j1 By REVISED J._E.Crabtre(;rEv|Ewed 4/1 /l 7 6/2^81 foj .E. Crabtree B%R. C.Warren PAGE 1 OF 2 ATTACHMENT C 001694 CBY 3109804 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-Q30 CHOCOLATE BAYOU PLANT STATIC GROUNDING & BONDING OF HYDROBLASTING EQUIPEMENT AND OTHER PORTABLE EQUIPMENT generated when they are connected or disconnected. The person making the connect or disconnect should be sure that there are no combustibles in the area where the connections are to be connected or disconnected. A statement should be included on the Fire & Entry Permit that grounds are going to be connected since connecting the ground could generate a spark. 2. All non-electrical portable equipment, such as air blowers, diesels, pneumatic motors, etc. (excluding hand tools), will be grounded before being used or placed in service. A resistance check is not normally required unless the integrity of the ground is questionable. 3. All hydrocleaning equipment will have the truck grounded. The lance will normally be grounded to the truck thru the steel braid in the hose. The Safety Department will make a resistance check from the lance to the ground. If the resistance is too high or if there is not a steel braid in the hose, the lance is to be bonded to the vessel. (See Attachement ) NOTE: The bond wires are comparatively large because of mechanical considerations, but a bond resistance of 1 megohm or less is entirely adequate to dissipate the static build-up. CAUTION: It appears to be impossible to eliminate all sources of ignition from hydroblasting. The only safe way to eliminate ignition is to eliminate the fuel, air, or both. The water droplets breaking away from the main stream can themselves create sparks. 4. The vessel being hydroblasted shall be grounded. If unsure that the vessel is grounded, contact the I&E Department to check that the vessel is grounded. References: American Petroleum Institute Bulletin API RP 2015, "Recommended Practice for Cleaning Petroleum Storage Tanks" American Petroleum Institute Bulletin API RP 2003, "Recommended Practices against Ignitions Arising ORIGINAL ./l^j REVISED A /1/77 By J.E. Crab tree PAGE 2 OF 2 ISSUE LByJ^E,.Crabtree)REVIEWED^2/81 By R.C.Warren ATTACHMENT c 001695 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-030 CHOCOLATE BAYOU PLANT ITEM No. 1 2 __ a_ _ _ 4 DESCRIPTION T8B CLAMP No.3847 T B CLAMP No. 31217 No. 6 WELDIN8 CABLE (MIN. SIZE) T ft B LUG NO. 71005 c 001636 SAFETY PROCEDURE MANUAL MONSANTO COMPANY HYDROCLEANING SP- 31 CHOCOLATE BAYOU PLANT PURPOSE The purpose of this procedure is to establish guidelines that must be followed before and during high pressure water cleaning of Plant equipment. SCOPE: This procedure shall apply to all In-Plant, (including Salt Dome), high pressure water cleaning. POLICY: All high pressure water cleaning nozzles are spark-producing tools requiring a Fire Permit to operate. All high pressure water cleaning equipment shall be inspected and tested periodically and written information on the unit's hydrostatic test provided to Monsanto. DEFINITION: High pressure water deeming is generally defined as "hydrocleaning", tube lancing, shotgun blasting and line moling, inclusive. PROCEDURE: Request for hydroclearning will be submitted through the General Maintenance Group or the Night Supervisors. The execution of hydrocleaing jobs shall be conducted by outside contractors specializing in this type of work who have supplied Monsanto with written information on the unit's (pump, hoses, PSV and piping), current hydrostatic test. All contractor hydrocleaning equipment shall be tested as a unit in January and July of each year. Each unit shall have a visible metal inspection tag mounted on the unit indicating date and test pressure. The test pressure shall be 10,000psi, or the unit's maximum operating pressure whichever is less. CBY 3109607 ORIGINAL ISSUE C 001697 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP 31 CHOCOLATE BAYOU PLANT PROCEDURE (cont'd) The decontamination checklist (Attachment #1) and the hydrocleaning checklist (Attachment #2) must be completed in order to do the job on a .regular Fire Permit. A "special, permit" will be issued if hydrocleaning requires vessel entry by the operator, if applicable items of Attachment #1 and Attachment 2 cannot be completed, or if unusual hazards are associated with a job. The hydrocleaning equipment (Truck and nozzle) shall be statically grounded as per SP #30. Prior to the start of hydrocleaning plant equipment, all hoses and fitting shall be inspected to assure they are in good condition. Upon assembly of -the hydrocleaning unit, the work area will be cleared of personnel amd the pressure brought up on the system slowly to 10,000psi or the unit's maximum operating pressure whichever is less and held for five minutes with no leaks. Maximum working pressure shall be 2,000 psi for columns and 7,500 psi for all other equipment without approval from Operations and Main tenance manufacturing superintendents. RESPONDIBILITIES: Operations: The owning department of the equipment to be hydrocleaned will be responsible to see that; 1. The equipment is ready for cleaning 2. All applicable items on the decontamination checklist are completed 3. The appropriate permits are issued. 4. Any departmental safety precautions b&ve been reviewed with the Contractor and the Maintenance supervisor. 5. The decontamination checklist is completed. 6. The equipment is clean following hydrocleaning by inspection. Contractor: The Contractor performing the hydrocleaning will be responsible for: 1. Understanding and complying with all the requirements of the hydrocleaning checklist (Attachment #2). 2. The equipment being used to have a dump valve on the nozzle handle that will react in 3/4 of a second or less, a relief valve and pressure gauge at the pump and trigger guards. ORIGINAL ISSUE A&A REVISED ! 0 / 7 a By R n n-rnrsn .Harx___ REVIEWED 6/2^81 By R.C.Warren PAGE 2 OF 3 ATTACHMENT c 001638 CBY 3109808 SAFETY PROCEDURE MANUAL MONSANTO COMPANY _ _ _ _ _ _ _ _ _ _ SP- ,, CHOCOLATE BAYOU PLANT RESPONSIBILITIES {cont'd) 3. A qualified and experienced nozzle operator. 4. Testing of equipment at the -job site. Maintenance:' The Monsanto Maintenance Supervisor in charge of the hydrocleaning job is responsible for: 1. The general welfare and safety of the Contractor. 2. Insure that the Contractor is in compliance with hydro testing precedure. 3. The signing of all permits required for the Contractor to perform his duties. 4. Insuring that the Contractor understands and complies with all of the requirements on the hydrocleaning checklist. 5. Notifying the owning department when the hydrocleaning job is ready for inspection. 6. Installation of any scaffolding required for hydro cleaning. CBY 3109809 ORIGINAL // REVISED in/ 7r By R- n. RrniUAfiF 3 OF ISSUE -4Zlg-7gyJk-W.. Ware. REVIEWED 6/2y 8lBy R.C.Warren] ATTACHMENT C 001699 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-31 CHOCOLATE BAYOU PLANT DECONTAMINATION CHECKLIST FOR ' HYDROCLEANING This checklist covers all types of hydrocleaning that does not require a vessel entry by the operator, but personal judgement must be used in issuing permits. EQUIPMENT NO Date/Int 1. Equipment is decontaminated, chained, and tagged out* 2. For lancing exchanger tube side inlet, outlet line is blinded and vapor tested for flammables. 3. For exchanger with CTTS' on shell side, block inlet and outlet, purge with N2 and vapor test for flammables. 4. For exchanger with, hydrocarbons normally on shell side, the inlet and outlet must be blinded and shell side vapor tested for flammables. 5. For reboiler with steam on shell side, inlet and outlet blocked, shell purged with N2 and vapor tested for flammables. 6. For reboil'er with hydrocarbons normally on shell side, the inlet and outlet must be blinded and shell side vapor tested for flammables. 7. Process piping to be line moled must be disconnected or open^on one end and blinded at all other connections. 8. Piping to be line moled has no pressure from steaming, N2, or water purgings. 9. Piping to be line moled must be vapor tested for flammables at as many points along the line as possible. Any job that cannot comply with, all applicable items of this checklist will require a'special permit. CBY 3109810 78By r___XDL-.__Brown- PAGE i OF 1 REVIEWED 6/2y81 By R.C! .WWarren ATTACHMENT f 1 c 001700 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 031 CHOCOLATE BAYOU PLANT HYDROCLEANING CONTRACTOR HYDROCLEANING CHECKLIST JOB NO. ________________ EQUIPMENT NO. ; UNIT JOB SCOPE ____________ ____________________________________ FIRE SPILL CODE HYDROBLAST CO. _ SUPERVISOR DATE THIS FORM IS TO BE FILLED OUT BY CONTRACT SUPERVISOR AND RETURNED TO MONSANTO MAINTENANCE FOREMAN PRIOR TO STARTING JOB. Equipment is decontaminated, chained, tagged out and tested for flammables as verified by operations. DATE/INITIAL __________________ Nozzle operator experienced __________________ Contractor, employees shown location of nearest shower/ eyebath. ___________ ______ Contractor, employees have hard hats, safety glasses or goggles, face shields, rubber boots, slicker suits, and rubber gloves. __________________ Truck located to minimize ignition source exposure and blockage of fire lanes. __________________ Hydrocleaning equipment has inspection tag and has been inspected and pressure tested as per SP-31. __________________ Hydrocleaning equipment has a dump valve on the nozzle handle that will react in 3/4 of a second or less. __________________ Hydrocleaning equipment is grounded as per SP-30. ________ Hydrocleaning truck is chocked. ________ Area is barricaded a minimum of 15 ft. and no one is allowed in the area except hydrocleaning personnel. ________ BACK SHIELD in place where applicable. ________ Scaffolding installed to Maintenance Standards where applicable and verified by Maintenance. ________ Contractor employee informed of injury reporting requirements, fire/spill alarm requirements, engines are off if to be left unattended, what permits are required, maximum operating pressures, no lunches in area, no sleeping, no smoking, and any-other safety information deemed necessary including tampering with nozzle triggers to prevent automatic closing will not be permitted. _________ ISSUE,NAL 4/18/76Bv M.W. Warr REVISED r A /hi ByR.C. Warren Ireveiwed / / By PAGE 1 OF 1 ATTACHMENT#2 C 001701 CBY 3109811 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- ^ CHOCOLATE BAYOU PLANT TESTING AND OPERATION OF FUME HOODS PURPOSE To define the procedure to be followed for normal operation and testing the draft of fume hoods. SCOPE This procedure outlines the equipment, test procedure, and minimum allowable standards to follow in testing hoods for their proper functioning. Operating guidelines are presented to insure safe performance between inspections. A hood (fume hood) is any forced draft enclosure or vent used to remove fumes or vapors. This pro cedure does not include exhaust systems used for welding. RESPONSIBILITIES Each owning department is responsible for testing, proper operation and repair of their own hoods. The Control Laboratory will assist in initial training of other department personnel in the procedure to be followed for testing hoods. Each department will maintain a written record of their test results. Stores will stock the test labels. PROCEDURE 1. All hoods in categories B and C below must be checked a minimum of once every three months. Category A hoods twice per year. Hood-owning departments will be responsible for maintaining proper test interval for their hoods. If work being conducted in a hood is suspected of having an adverse affect on the func tion of the hood motor, testing frequency must be increased. 2. Minimum flow rates for hoods are as follows: A. 65 FPM for nuisance materials, i.e., oil bath vent hoods, etc. B. 100 FPM for corrosive or moderately toxic materials. This is the typical laboratory hood used for most chemical analyses. C. 150 FPM for highly toxic materials. (TLV less than or equal to IQ ppm.) Contact Industrial Hygiene if TLV data are not available. , 3. The draft on hoods is checked with an Alnor Velometer Type 3002 (Alnor Instrument Co., Div. of Illinois Testing Laboratories, Inc., Chicago, IL). A velometer will be kept by the Control Lab for use throughout the plant. The PT/OR Lab also has an instrument. MBB. .'Ui-LTTniin'JT^ ORIGINAL g / 4/77^ W.W. Klemme REVISED 8A4/8lByH, REVEIWED / / By Klrkoatrlc kunr 1 of ATTACHMENT 3 c 001702 CBY 3109812 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 032 CHOCOLATE BAYOU PLANT TESTING AND OPERATION OF FUME HOODS Work should always be at least 6" from the plane of the sash; optimum worker positioning is 3" from the plane of the sash (9" total separation). Heavy vapors will flow back out of a hood from in front of equipment placed too near the front. Strong drafts interfere with air flow patterns into hoods. Air flow from A/C registers, circulating fans, etc. should not blow directly across into the hood opening. Adjacent hoods can interfere with each other's performance. Adequate fresh air makeup must be provided for proper operation of any exhaust system. Equipment, piping, etc., should not prevent normal closure of the hood door. The door glasses are safety glass and should be available for use as normal shielding or hood closure in case of spill. AUTHOR: W. W. Klemme L. C. Peeler CBY 3109814 HLK/sm ORIGINALa ISSUE 8 /. / tf ,, HY.!!.!P-8-V8l M,: Kirkpatrick PAGE- 3 OF ' < <By W.W. Klemme reveiweD / / By ATTA( ATTACHMENT C 001704 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 32 CHOCOLATE BAYOU PLANT TYPE OP HOODS AND POINTS OP TESTING Normal Laboratory Bench Type Hood Normal Laboratory Walk-In Type Hood Oil Bath Vent Hood Type 4 Points of Test CBY 3109815 ORIGINAL 8 /> /77b^. W. Klemme REVISED 8 /iy 81B>H. Kirkpatrick^ l OF 1 REVEIWED / / ATTACHMENT 1 c 001705 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 032 CHOCOLATE BAYOU PLANT Note: 150, 100 and 65 FPM labels-are stocked in Stores. CBY 3109817 ORIGINAL ISSUE o A / 77BvW. Klemme REVISED C / 1 / OlByH. Kirkpatric Page i of REVEIWED / / By ATTACHMENT C 001707 A) h J SAFETY PROCEDURE MANUAL_ _ _ _ _ _ _ _ _ _ _ SP-o34 MONSANTO COMPANY CHOCOLATE BAYOU PLANT CORROSION - INSPECTION OF PROCESS EQUIPMENT & TANKAGE Maintenance is responsible for: Providing manpower and equipment to make vessels ready for in spection. Execution of any needed repair in accordance with plant standards, codes and accepted engineering practice. DEFINITION An inspection is defined as a visual inspection of internal and external sur faces by MTS with supportive non-destructive examination as required. PROCEDURE MTS and Operations will agree on what equipment needs periodic corrosion-inspec tion. MTS will set inspection frequencies and get Operation's concurrence on frequencies. A monthly status report on inspections will be issued by MTS to the Operations Planner. This report will serve as a guideline for scheduling inspections and planning shutdowns. MTS will inspect the equipment, issue inspection reports and update inspection records. MTS will issue a,quarterly report of past due inspections. FRP Equipment Fiberglass reinforced plastic (FRP) equipment requires special considerations as outlined in attachments 2 and 3. Requirements for the use of FRP equipment are: 1. Selection of FRP for new equipment must be approved by MTS engineer. 2. FRP will not be used for a. lethal service b. flammables stored above ground rgY 3109818 3. All FRP equipment design will be reviewed by a Monsanto equipment design specialist. ORIGINAL n /19/80BByy. R. E. McGuire REVISED REVE1WED / / / / By By PAGE 2 OF ATTACHMENT C 001708 SAFETY PROCEDURE MANUAL MONSANTO COMPANY $P 034 CHOCOLATE BAYOU PLANT CORROSION - INSPECTION OF PROCESS EQUIPMENT A TANKAGE FRP Equipment Cont'd 4. All FRP equipment design will be purchased per CED standards for FRP equipment. 5. Each new FRP vessel must pass an acoustic emission (AE) test at the fabricator's shop and again in the field after erection. MTS is re sponsible to conduct the AE tests. 6. Each FRP vessel must pass an AE test and be internally Inspected on a regularly scheduled basis (not to exceed two years). 7. Special considerations must be given to FRP vessels located above grade when contents can cause chemical or thermal burns. AUTHOR: APPROVED BY: APPROVED BY: R. E. MCGUIRE i. E. DAVENPORT ORIGINAL ISSUE n/9/8% R. E. REVISED McGuiri 77 REVEIWED / / By By CBY 3109820 C 001710 PAGE 3 OF 3 ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- TM CHOCOLATE BAYOU PLANT June 12, 1978 Page 1 of 2 SUBJECT: VESSEL AMD STORAGE TANK INSPECTION PROGRAM NUMBER 30 ABSTRACT In recent months, at least three serious and costly incidents of ment failure have occurred -- two in Monsanto and one in another These failures highlight the need to reexamine our practices and dures for inspection of vessels and storage tanks. equip company. proce-` The seriousness of the situation requires that every location throughout the corporation take appropraite steps to inspect and monitor existing equipment. RECOMMENDATIONS 1. A master list of all vessels and storage tanks should be established. 2. Establish an inspection frequency for each equipment item on the master list. The frequency is to be based on all available experi ence and data; however, the maximum recommended interval between inspections should not exceed that in Appendix D of this Tecfact. 3. The time interval for future inspections should be based on the findings of the current inspection. This frequency and associated activities should be continuously reviewed and altered, based on the findings in each subsequent inspection. The dates for the next inspection should be set after the current inspection and noted on future inspection lists. 4. All equipment on the master list should be inspected in accordance with the established frequency. 5. Equipment failures which could result in personnel injury or fatalities, and the condition of which is uncertain must receive the highest priority for early inspection. 6. Inspection results should be recorded and kept current. A suggested equipment data information shoot/card is attached. CBY 3109821 ORIGINAL ISSUE // // Bv /REVISED / REVEIWED / f By By ' PAGE 1 OF 2 ATTACHMENT I c 001711 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP' 034 CHOCOLATE BAYOU PLANT 7. Deficiencies discovered as a result of inspections must be corrected as necessary. Corrections may consist of repairs, modifications, additional instrumentation and controls or complete replacement. DISCUSSION All Monsanto locations have some types of preventive maintenance and safety inspection programs. Monsanto's total experience with catastrophic' tank failures for structural or operational use reasons is very good. Recent failure of two water treatment/waste heat recovery systems, the near failure of a diamine storage tank and several other failures in industry, including the sulfuric acid storage tank failure reported by S&PP in November, 1977, indicate the necessity to review and strengthen our inspection programs. Appendices A, B, and C are forms containing suggested information for this program. Appendix D "Critical Ratings" should assist locations in determining vessel inspection frequencies. It is recognized that formal inspection programs exist in many locations. The attached forms are suggested for use at your location. The "what kind" and "how to" specifics of inspection methods and,techni ques and the correction of deficiencies should be established by location technical personnel with assistance of CED specialists, where appropriate, and are not covered in this Tecfact. Additional information or assistance on the above recommendations can be obtained by contacting George Ostroot, S&PP Manager Property Loss Control. Questions concerning "what kind" and "how to" should be directed to R. B. Puyear, CED Manager Materials Technology Section. DISTRIBUTION U.S. & INT'L: Manufacturing Management, Directors of Personnel, Location Managers, Personnel Managers, Safety Engineers, Division Research Management, Branch Directors, Engineering Managers, CED Construction Personnel Professional and Technical, Supplemental Safety Engineers, S&PP. Copies for suppleswntal distribution are available upon request to S&PP, St. Louis. ORIGINAL ISSUE // / / By REVISED / 7 REVEIWED / / BV By PAGE; 2 OF 2 ATTACHMENT I C 001712 3109822 CB* SAFETY PROCEDURE MANUAL MONSANTO COMPANY ----wmm.! a.iajM $p. 034 CHOCOLATE BAYOU PLANT M-- ENGINEERING TECHNOLOGY & SERVICES TECHNICAL BRIEFS NO: DATE: DIST: 30-66-244 December 11, 1979 List 480 Tab 489 RECOMMENDED PRACTICE FOR CDS OF FRP EQUIPMENT J. P.. Middleton S. I. Proctor Fiber reinforced plastic (FRP) equipment has been involved in a number of incidents over the past months and years ranging in severity from nuisance to sudden rupture and nearly catastrophic discharge of the contents of a large tank. This situation has been the cause for concern and procedures have been instituted within CED to insure that FRP equipment installed on current or future projects will be properly selected, designed, fabricated and inspected. However, not all new FRP equipment is installed by CED. A signif icant number of items are installed by the plants as replacement for existing equipment or as part of small, plant-run construc tion projects. For this equipment, we recommend that the following procedure be observed. These are similar to the present CED practices: 1. Selection of FR? as a material of construction will be made by or reviewed in detail with a qualified materials specialist at the time of initial materials selection and again if changes are made to the process which affect temperature or composition of the process fluids handled by the equipment. (The CED Engineering Technology Depart ment will provide assistance if requested.) 2. FRP equipment will not be used in those applications involving: a. lethal service b. flammable materials stored above ground. 3. All FRP equipment designs will be prepared or reviewed by an equipment design specialist. (ACM department in CED will assist if requested.) ORIGINAL ISSUE _ // // Bv REVISED / / REVEIWED / / By By C 001713 PAGE 1 OF 2 ATTACHMENT II cay 3109823 SAFETY PROCEDURE MANUAL MONSANTO COMPANY $P.34 CHOCOLATE BAYOU PLANT Tech Brief 30-56-244 4. All FRP equipment should be purchased in accordance with cur rent CEO standards. Deviations from these standards should require specific approval by FRP equipment design specialists. In those situations where the deviation might affect chemical resistance of the equipment, the concurrence of the materials specialist approving the materials selection should also be required. 5. In addition to the other inspection requirements, all FRP vessels should be inspected by acoustic emission in the fabricator's shop and again in the plant after erection and piping connections have been completed. 6. All FRP equipment should be inspected on a regularly scheduled basis. The schedule should include both visual inspection and acoustic emission.test (but not necessarily concurrently). Inspection frequency will be dictated by such factors as severity of service and consequence of failure. 7. When FRP equipment is used with fluids which can cause chemical or thermal burns to personnel, every effort should be made to locate those vessels at grade elevation. If location above grade is needed, protective devices (such as catch-pans) should be used for safety. For assistance, contact one of the following: For Engineerina Technology supoort: GC, F4WD R. B. Puyear, 694-5660, For ACM support: 3. G. Earnheart, 694-6067, GO, F3WA ORIGINAL ISSUE _ // // Bv REVISED / / By REVEIWED / / By CBY 3109824 PAGE 2 OF 2 ATTACHMENT H C 001714 SAFETY PROCEDURE MANUAL MONSANTO COMPANY iHani 2. M. Brasfieid - June 5. 1979 FR? Vessels D. Shave. rr* *pW.j"rt SP- 034 CHOCOLATE BAYOU PLANT iQ i ee H Cl Clark - G4JIS :y. Dmytrystyr. - G4W C. Downing - G4M2 R. W. Flint - G4N2 R. G. Potter - G4NA F. S. Reese - G4NH Manufacturing Management Council MCI "Plantv-Man&gers We have new received the June status report on MCI Plants Vessel Inspection Program, which contains the latest update or. our FR? Vessel Testing.. Based on this input, and other discussions, we are removing our ban on new FRP Vessel installation in MCI facilities, subject to the following conditions. 1. That new FRP Vessels pas3 tests (acoustical emission, visual and dimensional inspection) at the factory to assure compliance with our vessel specifications prior to shipment. It is our understanding CSD has an existing program already in place which does these tests. Testing off vessels purchased by the Plants will be the Plants responsibility. 2. That r.ew ??.? Vessels pass a test (acoustical, emission, and -visual inspection) after installation, with all piping-and equipment connections completed, and 3u3t before being placed in service. Obviously this would ba a joint C20/?lant effort to be accomplished curing water batching. 3. That valving, bypass piping, or other facilities be providad on new FRP Vessels to permit removing them frem service for inspection, without incurring a Plant shutdown. 4. That each MCI Plant performs an inspection (acoustical, emission and visual inspection) at least every tve (2) years on each FRP Vessel. Mora fraquer.t inspection may be necessary on more severe service and the Plant will be responsible for evaluating that need. ORIGINAL / / ISSUE .... / / By REVISED t ) By REVEIWED U- By CBY 3109825 PAGE 1 OF 2 ATTACHMENT HI C 001715 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP` 034 CHOCOLATE BAYOU PLANT I think wish chase four scats of control built into our procedures, that ?a? Vessels con be safely used. In addition, the above points reflect the added expense necessary to use T?3 Vessels, and I assume you will build this total life cycle cost into your original materials selection decisions, when comparing FRP Vessels with those of other materials. /> J-7.U, 2. N. Srasfield SJJB/lw / /ORIGINAL ISSUE By _ REVISED / / By REVEIWED / / By CBY 3109826 PAGE 2 of ATTACHMENTT11 C 001716 PROCEDURE DISTRIBUTION Plant Manager (Davenport) Project Director,Mfg. (Frizzell) General Superintendent (Hagood) Employee Relations Supervisor (Colbert) Employee Relations Representative (Watkins) Benefits Representative (Sebesta) Management/Development (Steele) Safety' L&ss Preyi^uperidkgndent (Usrey) Safety Engineea^fBrovm) Safety Engineer (Coburn) Plant Security (Captain) Industrial Hygienist (Gaul) Plant Accounting (Wall) Area Accounting Prop.s Maint. (Jackson) Data Processing Manager (Attra) Manager of PT (Yeretsky) PT Group Supervisor (J.P. Graham) PT Group Supervisor (Saunders) General Superintendent (Clark) MTS Group Superintendent (Ingersoll) Engineering Superintendent (Ingram) Projects Group Superintendent (Ramsay) Projects Group Superintendent (Pickett) Project Group Superintendent (Marvin) Engineering Services Superintendent (Moore) Central Files (2) General Maintenance Superintendent (Gray) Maintenance Engineering Superintendent (Fisher) General Maint.Group Foreman (3) Stores Superintendent (Ingersoll) Stores Supervisor ( Loving) Maintenance Shop 4 (2) Maintenance Shop 5 Maintenance Shop 6 Maintenance Shop 7 I&E Superintendent (Sheppard) IE Group Foreman Contractor Group Foreman Central Files Supv. (Lyng) Manager,Mfg.Guest Companies (Jones) SAB Superintendent (Hamilton) SAB Group Foreman SAB Production Planner (SPM) 12/19/83 NTA/IDA Superintendent (Sheridan) NTA/IDA Group Foreman NTA/SAB Tech.Superintendent (Ochsner) NTA/IDA Tech.Supervisor (Wilbeck) Resins/Formalin/DPO Supt. (Louvet) Resins/Formalin/DPO Group Foreman Resins/Formalin/DPO Shift Foreman Phenol Shift Foreman Mgr. Terminal Operations (Bramlette) Prod.Coord.Supt. (Ogens) Manager,Govern.fi Env.Affairs (Pappas) Environmental Health Superintendent(Marquez) Supt.Mfg. Services (Gulliams) Purchasing Superintendent (Henkes) Purchasing Assistant (Beall) Utilities Superintendent (Atkins) Utilities Group Foreman Utilities Shift Foreman Energy,Utilities & Site Dev.Supt. (Blake) Dist.Operations Supt. (Harlan) Distribution Group Foreman Distribution Shift Foreman (2) Night Supervisors General Superintendent (Kongable) AN Superintendent (Murrell) AN Group Foreman AN Shift Foreman Control Lab Superintendent (Meade) Lab Group Foreman (Faulkner) (2) Environmental Control Supt.(Silva) Environmental Control-Group Foreman General Superintendent (McDannold) Technical Superintendent (Fouts) Sorbic Superintendent (Steinhauser) Sorbic Group Foreman Sorbic Shift Foreman MR/Projects Manager (Seals) MHBA Manufacturing (Ceyannes) MHBA Group Foreman (Menard) MHBA Shift Foreman MHBA Process Specialist CED Superintendent (Ganschinietz) CED Construction Safety Consultant (BrooksF2EG) CBy 3109827 0 001717 Monsanto AMK--LOCATION--PHONE) Earl Moore - Chocolate Bayou Plant - Ext. 4300 lT* August 27,1984 cc. SUftJtCT ICE TO PROCEDURE MANUAL REVISIONS Attached Distribution Attached are updates for your' SAFETY PROCEDURE MANUAL: SP-035 is a new procedure. Please insert the attached pages in your manual. SP-035 HOT TAPPING AND PLUGGING Pages 1-2 of 2 Attachment #1 - pages 1-5 of 5 EDM/sk Attachments Earl Moore i. \ IN lO <HEV, 8/77) CBY 3109828 C 001718 SAFETY PROCEDURE MANUAL MONSANTO COMPANY HOT TAPPING AND PLUGGING SP- 035 CHOCOLATE BAYOU PLANT PURPOSE This procedure outlines planning and job preparation requirements for safe hot taps and line plugs performed at Chocolate Bayou. SCOPE Hot tapping and/or line plugging is a last resort for connection or isolating a piece of equipment or piping system. This procedure covers all hot tapping and/or plugging including valve bonnet tapping and process or utility systems. Valve packing by tapping and injecting is not included (refer to MSP #10). PROCEDURE Introduction Hot taps and hot line plugging are permissible only as a last resort; i. e;., when the time required or expense of isolation and decontamination is unreasonable. A special permit is required according to Safety Procedure SP-019 Fire Permits Vessel Entry/Fire Permits. Check lists (Attachment #1, pages 1-3 of 3).are provided to assure pertinent questions are answered and -due consideration is given to back-up drills, cutters, etc. RESPONSIBILITIES Requestor The Operations Planner, with the assistance of the Maintenance Foreman, is responsible for specifying department number, line or equipment number, process conditions, and justifications for hot tapping or hot plugging. Design Engineer Engineering responsibility includes design of nozzle and its support, valve section and specification of test pressures, and method of testing media. Special consideration must be given to testing media due to parent wall temperature and thickness. Materials Technology CBY 3109829 The MTS representative will review and determine materials of construction, hot tap location and wall thickness. MTS will also specify welding procedure. The Design Engineer and MTS Engineer will make joint decisions concerning X-raying of the hot tap valve and any other special testing or inspection procedure. ^ 001*719 ORIGINAL 8/15/84 J.C.Usrey REVISED / / ISSUE _ ' ' By REVEIWED / / By By PAGE 1 OF 2 ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 035 CHOCOLATE BAYOU PLAN' HOT TAPPING AND PLUGGING DATA LIST I. REQUESTOR DATA RESPONSIBILITIES Data Responsibilities Operations Representative Date _____________ , Dept. No., , Process Max/Min Pressure /, Max/Min Temp / Size of Hot Tap Required ______________________ Line No. Why is this hot tap/plug the efficient way to perform this work? Note: Please attach a Polaroid snap shot of desired hot tap area. SAFETY EQUIPMENT NEEDED (1) Fire Extinguisher [ ] Yes [ 3 No (2) Radio Communications [ 3 Yes [ 3 No (3) Fresh Air Mask [ 3 Yes [ 3 No POTENTIAL PROBLEMS (1) Loss of Coupon - Action to Take: (2) Burn through during welding - Action to Take: (3) Metal shaving in line and/or valve - Action to Take: (4) ORIGINAL 3 /is/84bv J.C. Usrey REVISED / / ISSUE REVEIWED / / By By CBY 3109831 PAGE 1 OF 5 ATTACHMENT *1 C 001721 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 055 CHOCOLATE BAYOU PLAN HOT TAPPING AND PLUGGING DATA LIST Repad Details: [ ] No, ID = , OD , Thickness Can a weld-o-let be used? [ ] Yes [ ] No Split Tee: [ ] No, ID = M, t= H Length = " Type of Flange on Split Tee ________________________________________________ _______ __ Valve Specs: Spec. No. , Size Flange ;, Rating Type , Size Valve intergity assured by ____________________________ name of MTS tech. 'Valve intergity assured by [ ] X-Ray [ ] Dye check [ ] Ultrasonics [ ] Visual inspection Tapping Machine Clearance: See Drafting Manual SAFETY AUDIT IV. Safety Audit [ ] Yes Special precautions required: Date _____________________ V. Test procedure and media specified by engineering and MTS. Where possible the nozzle should be filled with mineral oil during hot tapping. ORIGINAL g /15/ REVISED / / REVEIWED / / By By CBY 3109833 PAGE 3 OF 5 ATTACHMENT #] 0 001723 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-035 CHOCOLATE BAYOU PLANT HOT TAPPING AND PLUGGING CHECK LIST VII. FOREMAN DATA FOREMAN Before Tapping Begins Special Scaffold Required Is Backup Cutter On Hand Is Backup Pilot Drill On Hand Does Pilot Drill Have Twc "U" Pins (Alum) Are "U" Pins Of Right Material & Size Is Backup "U" Cups (Packing) On Hand Confirmed Pilot Drill Is Not Too Long Confirmed Cutter Will Pass Through Valve [ ] Yes [ ] Yes [ 3 Yes [ 3 Yes l ] Yes ( 3 Yes [ 3 Yes [ 3 Yes [ 3 No i 3 No [ 3 No i 3 No t 3 No [ 3 No r 3 NO i 3 NO VII. Problems Encountered During Tap Plugging (Send these three sheets completed to MTS) ORIGINAL 8/1^848vJ.C.Usrey KSI IF Trevised // 1 RFVFIWFD / / By Rv CBY 3109835 C 001725 PAGE 5 OF 5 ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-039 CHOCOLATE BAYOU PLANT RESPIRATORY PROTECTION PROGRAM PURPOSE To establish a Respiratory Protection Program which will set overall objectives and policies for che selection, maintenance, training and use of all respiratory protective equipment at Chocolate Bayou Plant. SCOPE This procedure covers respiratory protective equipment for both normal and emergency situations. POLICY In the control of occupational exposure to air contaminated with harmful gases, dusts and fumes, the primary objective shall be to prevent atmospheric contamination. This shall be accomplished as far as feasible by accepted engineering controls and good work practices. When effective engineering controls are not feasible, or while they are being initiated, appropriate respiratory equipment shall be used. The company will provide respiratory protection equipment which is applicable and suitable for the purpose intended, when such equipment is necessary to protect the health of the employee. Individuals who need towear a breathing protection device in the performance of job duties must be clean shaven in the area between the sealing surface of the respirator and the face. PREMISE FOR RESPIRATORY PROTECTION PROGRAM The following are the basic premises for an acceptable Respiratory Protective Program: 1. Written departmental operating procedures will define the proper selection and use of respiratory protective equipment. Selection will be based on: a. Nature of hazardous operation. b. Type and concentration of air contaminants. c. Period of time for which protection must be provided. d. Functional and physical characteristics of the protective device. CBY 3109836 8ueNAL 9 /lb/77bv D.L.Meade REVISE0 3 / 2/81 By j. c UgXfiX PAGE 1 OF 8 By ATTACHMENT C 001726 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-039 CHOCOLATE BAYOU PLANT RESPIRATORY PROTECTION PROGRAM 2. Users should be adequately trained in the use and limitation of the protective equipment. Training will include information presented in Attachment II (attached). 3. Where practical, respirators will be assigned to an individual. These routinely used respirators must be cleaned regularly, inspected before each use, and repaired as necessary to insure proper protection. 4. Respiratory equipment must be stored in convenient, clean, sanitary locations. 5. There should be regular inspections and evaluations to determine the continued effectiveness of the respiratory protection program. HAZARDS The classification of breathing hazards and reconmended protective equipment is presented in Table I (attached). RESPONSIBILITIES Respirator Fitting; 1. The purpose of any protective mask is to isolate the wearer from the surrounding atmosphere, by providing a leak-tight seal between the mask and the face. To insure the best possible opportunity for a good face piece to face seal, all employees wno are required to wear respiratory equipment, must be free of facial haxr protruding' `'into the sealing portion of the respiratorT ~ NOTE; A fit test will not be conducted on anyone not meeting this requirement. User Responsibilities: 1. The user must test for fit each time it is put on. 2. The user must check for fit by the following methods: a. Positive Pressure Test; Close the exhalation valve and exhale gently into the face piece. The slight positive pressure can be built up inside the face piece without any evidence of outward leakage of air at the seal. For most respirators, this method of leak ORIGINAL ISSUE // 9/2y77By D.L.Meade REVISED 3 /2>8lBy'J~ C. Usery PAGE 2 OF 8 reveiwed / / Bv ATTACHMENT CBY 3109837 C 001727 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-039 CHOCOLATE BAYOU PLANT RESPIRATORY PROTECTION EQUIPMENT testing requires that the wearer first remove the exhalation valve cover and then carefully replace it after the test. b. Negative Pressure Test: Close off the inlet opening of the canister or cartridge(s) by covering with the palm of the hand(s) or by replacing the seal(s). Inhale gently so that the face piece collapses slightly and hold the breath for approximately 10 seconds. If the face piece remains in its slightly collapsed condition and no inward leakage of air is detected, the fit of the respirator is considered satisfactory. c. Manufacturer's Instructions; Follow the directions provided by the respirator manufacturer. d. Movement Check; The employee using the respirator should also turn his/her head from side to side and up and down to ensure that the respirator is sealed and will not become loose during wear. 3. User must wear the respirator as originally designed: a. All functional parts must be in place and worn in appropriate positions. b. All straps shall be secure. c. Modification to the respirator straps shall not be made. 4. If special glasses are issued for use with respirators, they will be used in fit testing. 5. Dentures may seriously affect the face piece fit and therefore should be worn during fit testing and use. Departmental Supervision is responsible for: 1. Providing written operating procedures for selection and use of breathing protection. 2. Insuring adequate breathing equipment is provided for all situ ations requiring its use within that department. 3. Proper storage, identification and inspection of the equipment in the department. ORIGINAL ISSUE REVISED 3 /2/BI By J. C. Usrev PAGE 3 OF 8 Meade REVEIWED / / By ATTACHMENT CBY 310983B C 001728 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 039 CHOCOLATE BAYOU PLANT RESPIRATORY PROTECTION PROGRAM 4. Insuring personnel in their department are adequately trained. A detailed training and fitting guideline is presented in Attachment II. 5. Maintaining records of training (name, date, type of equipment). Industrial Hygiene Department is responsible for: 1. Specifying proper equipment. 2. Providing Stores with a list of approved equipment for purchase. 3. Training supervision in the use of respiratory equipment. 4. Inspections and evaluations to determine effectiveness of ^ Respiratory Protection Program. Saf'aty^Department is -responsible for: 1. Training supervision in the use of respiratory equipment. .2 Training of new employees. 3. Conducting Quantitative Fit Testing. Stores is responsible for: 1. Maintaining an adequate supply of approved respiratory equipment. 2. Providing services for collection, cleaning, repair, repackaging, restocking of respirators as required. PROCEDURES 1. Requirements to Obtain Equipment Non-routine use: a. When a need has been established, the using department will complete a respiratory equipment request form (Attachment I). b. The completed request will be reviewed by the Industrial Hygiene and/or Safety Department for approval. c. The approved form can then be taken to Stores, where the required equipment will be provided. ORIGINAL ISSUE 9*6/77* D.L.Meade revised 3 7 2/81 By J.C.Usrev REVEIWED / / By____________ PAGE 4 OF 8 ATTACHMENT CBY 3109839 c 001729 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 039 CHOCOLATE BAYOU PLANT RESPIRATORY PROTECTION EQUIPMENT Personal Issue for Routine Use: a. Departmental supervision in consultation with Industrial Hygiene Department will determine need, type and numbers of equipment needed. b. As specified by Industrial Hygiene, Stores will stock the appropriate equipment. c. Department supervision will return used respirators and obtain new ones at least once per year (as per schedule in Attachment III) or more frequently if needed. Broken or malfunctioning respirators can be turned in to Stores for a replacement at anytime. 2. Procedures for Use of the Various Kinds of Breathing Protection Following are listed the various types of devices currently in use in the plant and procedures for their use. Any new appli cations should be carefully considered and selection should' be made only after consultation with Industrial Hygiene and Safety Departments. , a. Self Contained Air Mask Systems (15 and 30 minute MSA Air Pacs). THIS EQUIPMENT IS INTENDED FOR SHORT-TERM EMERGENCY WORK IN CONTAMINATED ATMOSPHERES (i.e. ATMOSPHERES WHICH IRRITATE OR POISON THROUGH THE SKIN, SUCH AS HCN, CONCENTRATED AMMONIA, HF, ETC.). THE 30 MINUTE UNIT IS APPROVED FOR USE WITH THE VAPOR SUIT. THE 15 MINUTE UNIT IS FOR SHORT DURATION WORK BUT HAS A LIMITED AIR SUPPLY NOT ADEQUATE FOR VAPOR SUIT USE. 1. The Safety Department has the responsibility to inspect and maintain the 30 minute MSA air mask. The owning department will inspect and maintain other respiratory protective equipment. 2. The owning department will train on this equipment at least once per year. The Safety Department will provide training aids and assistance in this training effort. b. Escape Masks ORIGINAL ISSUE 1. Only Robertshaw (formerly Lear-Siegler) self contained, pressurized air unit with a hood shall be used as an escape mask. 5J/1 J PAGE 5 OF 8 |ATTACHMENT CBY 3109840 c 001730 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-039 CHOCOLATE BAYOU PLANT RESPIRATORY PROTECTION EQUIPMENT 2. The owning department will inspect this equipment weekly. 3. The owning department will train on the proper use of this equipment at least once per year. c. Supplied Breathing Air Systems 1. Monsanto Maintenance Breathing Air System (Portable Manifold) a. The Maintenance Department is the owner of this system and has the responsibility for its use and maintenance. b. The Safety Department shall be contacted when it is to be used, to insure that the using personnel have been trained in its use. NOTE: ONLY BOTTLED BREATHING AIR THAT HAS BEEN VERIFIED AND TAGGED BY THE SAFETY DEPARTMENT TO CONTAIN 20.87. OXYGEN SHALL BE USED IN THIS SYSTEM. (1) The Safety Department must be notified when breathing air is brought into the plant, both for Monsanto and contract personnel. (a) They will verify the oxygen content to be 20.87,. (b) They will then place a dated and initialed tag on the bottle. (2) Stores will notify the Safety Department when breathing air is brought into the plant through normal deliveries. (3) Maintenance or CED supervision will notify the Safety Department when breathing air is brought into the plant by an outside contractor. 2. Air Compressor Systems THE PLANT COMPRESSED AIR SYSTEM MUST NEVER BE USED FOR BREATHING AIR SUPPLY. CBY 3109841 ORIGINAL ISSUE ,, 9 /2(y77 By D.L.Meade REVISED 3/2/81 By J.C.Usrey reveiwed / / Bv PAGE 6 OF 8 ATTACHMENT C 001731 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP. 039 CHOCOLATE BAYOU PLANT RESPIRATORY PROTECTION EQUIPMENT a. The only air compressor systems for breathing air in this plant are: (1) Fixed system in the SAB department. (2) Portable breaching air compressor system used in sandblasting. The air cornpressor must be of the type certified for hum$n consumption or have the required safety features as required by federal standards (OSHA Standards, 1910.134). d. Air Purifying Respirators 1. Chemical Cartridge Respirators (full face and half mask respirators) a. A cartridge type respirator is worn generally when there is a possibility of exposure to a very light concentration of a harmful or irritating vapor. Cartridge type respirators should be limited to use in atmospheres containing at least 19.5% oxygen. Selection of the appropriate cartridge respirator (size and type of cartridge) are dependent on the chemicals and concentration to which the individual will be exposed. A listing of the proper equipment for various chemicals is presented in Appendices (Attached). b. Where respirators will be used on a routine basis (such as in benzene areas), respirators will be issued to individuals for his/her exclusive use. Department supervisors will insure these respirators are used and maintained in accordance with this procedure. Respirators issued to individuals for routine use will be returned to Stores at least once per year for cleaning/repair/repackaging. c. Where air-purifying respirators are used (cartridge), the air-purifying cartridges shall be replaced prior to the expiration of their service life or the end of the shift in which they are first used, whichever occurs first. An adequate supply of spare cartridges will be maintained in individual shops/ control rooms. CBY 3109842 ORIGINAL 9 ISSUE - /lb/n / / By D.L.Meade revised 3/2 /Si By J. C. Usrev REVEIWED / / By PAGE 7 OF 8 ATTACHMENT C 001732 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP*HE 039 CHOCOLATE BAYOU PLANT RESPIRATORY PROTECTION PROGRAM 2. Dust Masks a. Dust respirators are to be used when there is exposure to dust which is irritating to the nose or throat or which may cause trouble in the bronchial tubes or lungs. b. Only Industrial Hygiene Department approved masks obtained from Stores will be used. Only NIOSH approved masks will be considered. AUTHOR: J. C. Usrey APPROVED BYs APPROVED BY: CBY 3109843 OISRSUIGEINAL Q9 /A26cr /7,7,bv ,,D.LT .Mweadje REVISED 3 / 2 >81 By J . C. Usrey REVEIWED / / By PAGE 8 OF 8 ATTACHMENT c 001733 SAFETY PROCEDURE MANUAL MMWMMWMBWWM----Wc ru IMIBTil h I'll IJ Jill-- MONSANTO COMPANY wrwnTBMMniTMMwwi^M-MMirriTniriiiir mi ~i hi n 1111111 rm ------------1 ~ir SP- 039 CHOCOLATE BAYOU PLANT mmi--iMimrwTi--~r------n-------- ATTACHMENT 1 STORES REQUISITION RESPIRATORY PROTECTIVE EQUIPMENT DEPARTMENT ____________ REQUESTING SUPERVISOR INTENDED USE TYPE &IDENTIFICATION NUMBER OF RESPIRATOR NUMBER REQUIRED TYPE & IDENTIFICATION | NUMBER OF CARTRIDGE j' NIIMBF RFOUTRFn NUMBER REQUIRED APPROVED BY DATE INDUSTRIAL HYGIENE DEPARTMENT CBY 3X09844 ORIGINAL 9/26/77^ D.L.Meade ISSUE REVISED 6 /6 A0 By J . C. Wi 11 jams PAGE 1 OF I REVEIWED / / By ATTACHMENT # I C 001734 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP039 CHOCOLATE BAYOU PLANT ATTACHMENT III RETURN & REPLACEMENT SCHEDULE FOR INDIVIDUAL ISSUED RESPIRATORS DEPARTMENT Ethylene Hydrocarbons Utilities SAB NTA Resins AN Phenol Environmental Control Distribution Maintenance I&E Sorbic All Other MONTH FOR RETURN/REPLACEMENT July August September October June November May April December March January February September June ORIGINAL ISSUE 9 REVISED / / Meade REVIEWED / / Bv By CBY 3109846 PAGE 1 OF 1 ATTACHMENT #3 C 001736 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 039 CHOCOLATE BAYOU PLANT APPENDIX A RESPIRATORY PROTECTION FOR BENZENE Approved respirators for use in potential benzene exposure areas are as follows: CONCENTRATION OF BENZENE OR CONDITION OF USE RESPIRATOR TYPE IDENTIFICATION NUMBER a. Less than or equal to 10 ppm 1. Chemical cartridge respirator with or ganic vapor car tridges and half mask; or MSA - Comfoe II #459433 or #460968 MSA - Type GMA Or ganic Cartridge #459315 b. Less than or equal to 500 ppm. . 2. Any supplied air respirator with half mask 1. Chemical cartridge respirator with or ganic vapor car tridges & full facepiece; or MSA - Full Facepiece respirator #460560 MSA - Typw GMA Or ganic Cartridge #459315 2. Any supplied air res pirator with full facepiece; or 3. Any organic vapor gas mask; or 4. Any self-contained breathing apparatus with full facepiece. c. Less than or equal to 1000 ppm 1. Supplied air res pirator with half mask in positive pressure mode cay ORIGINAL ISSUE f/ll BvD. L. Meade REVISED 7/25^ 80Bv J.C.Williams PAGE 1 OF 2 REVIEWED / / By ATTACHMENT^ c 001737 SAFETY PROCEDURE MANUAL MONSANTO COMPANY _ _ _ _ _ _ _ _ _ SP039 CHOCOLATE BAYC|U PLANT APPENDIX A RESPIRATORY PROTECTION FOR BENZENE CONCENTRATION OF BENZENE OR CONDITION OF USE RESPIRATOR TYPE d. Less than or equal to 2000 ppm e. Less than or equal to 10,000 ppm 1. Supplied a.ir res pirator with full facepiece, helmet, or hood, in posi tive pressure mode 1. Supplied air res pirator and auxil iary self contained facepiece in posi tive pressure mode; or f. Escape 2. Open circut selfcontained breathing apparatus with full facepiece in positive pressure mode 1. Any organic vapor gas mask; or 2. Any self-contained breathing apparatus with full facepiece IDENTIFICATION NUMBER ORIGINAL ISSUE /^6 fll CBY 3109848 Meade REVIEWED '725/ SOlty J. C. / / By William "PAGE 2 OF ,2 ATTACHMENT#^ c 001738 SAFETY PROCEDURE MANUAL MONSANTO COMPANY APPENDIX B RESPIRATORY PROTECTION FOR ACRYLONITRILE SP- 039 CHOCOLATE BAYOU PLANT Approved respirators for use in potential Acrylonitrile exposure areas are as follows: CONCENTRATION OF AN OR CONDITION OF USE RESPIRATOR TYPE IDENTIFICATION NO. (a) Less than or equal to 20 ppm (l)Chemical cartridge respirator with organic vapor car tridge^) and half mask facepiece; or (2)Supplied air respi rator with half mask facepiece. MSA - Comfo Ii: #460968 MSA - Type GMA Organic Cartridge #464031 (b) Less than or eaual (l)Full facepiece res- MSA - Full Face- to 100 ppm or maxi- prirator with (A) piece Respirator mum use concentration organic vapor car- #460560 (MUC) of cartridges tridges, (B)organic or canisters, which vapor gas mask chin- MSA - Type GMA ever is lower. style, or (C) or Organic Cartridge ganic vapor gas #464031 mask canister,front or back mounted; (2)Supplied air res pirator with full facepiece; or (31Self-contained breathing appara tus with full facepiece . (e) Less than or equal to 4,000 ppm (l)Supplied air res pirator operated in the positive pres sure mode with full facepiece, helmet, suit or hood. C8Y 3109849 ORIGINAL ISSUE b/ 6/80Bv J.C.William REVISED 7 REVEIWED /2 <y&0 // By .7 . C , Wi 11 jams By PAGE 1 OF ATTACHMENT 2 #5 C 001739 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 039 CHOCOLATE BAYOU PLANT APPENDIX B RESPIRATORY PROTECTION FOR ACRYLONITRILE CONCENTRATION OF AN OR CONDITION OF USE RESPIRATOR TYPE IDENTIFICATION NO. (d) Greater than 4,000 ppm or unknown con centration. (.5) Firefighting (4) Escape (1) Supplied air and auxiliary self-con tained breathing apparatus with full facepiece in posi tive pressure mode; or (2) Self-contained breathing apparatus with full facepiece in positive pressure mode. (1) Self-contained breathing apparatus witli full facepiece in positive pressure mode. (1) Any organic vapor respirator, or (2) Any self-contained breathing apparatus. CBr 3109650 &'gNAL 6/6/80 ByJ.C.Williams REVISED 7 REVEIWED /2^79By J C.Williams / / By PAGE 2 OF 2 ATTACHMENT# 5 c 001740 SAFETY PROCEDURE MANUAL MONSANTO COMPANY _ _ _ _ _ _ _ _ _ SP- Q39 CHOCOLATE BAYOU PLANT m <u -P -p o c10 55 'O -P >H c S -H UH P -P PC IP CO 10 O P O O 45 8 CL O TI3I OO' -P 0) 1--P1 Si g c to <P 10 g ro d -h to H tJ O iH 43 8 g g H to cl tO g CL H H& D. to O H1 P <0 0 -P a10 c10 > cH Po -p ID C ID O OU 0O) X ID o X 0) (0 0) X contam inant. (0 a> CD <D w (0 0) 0) X X XX EN to o ao O V Si XXX tn co of .n i ro ta te lr it fn o to 0) to o Si X X i* conce p ria te on p ro s p d a n (0 (1) X (0 a X o0 Si Si depe have Type Must (1) (2) > u c01 co O' -H XU X -H o <pa) Q to o tn o o Si o o to 55 Si XX B 0o) O' *cH E +0J) (0 *HH .4CJ CO CU A3 a P <D M MH CO O) < tv o 4J o eH S CH ro 4-> CU C 0 o M-* i--1 C0O) (r0o H < wg roo 48-> cfl w in CXO H H < <CO ORIGINAL ISSUE H <N ,, /,, / REVISED / / By 9 Z26/77 By D. L. Meade REVIEWED / / By ro JCZO Xcroo P (D P 0) CroU Ao u (0 OS w M 0O)' -OP *Ho Pro P -H p a P (0 ro a> O 0$ Xwro 4J (0 3 Q m in PAGE 1 OF 1 ATTACHMENT #6 c 001741 awwH!iiigHwrwaaaBiai"i''H i n SAFETY PROCEDURE MANUAL MONSANTO COMPANY MnaMOHMini SP- 040 CHOCOLATE BAYOU PLANT GUIDELINES FOR CHOOSING SAFE SAMPLE CONTAINERS PURPOSE The purpose of this policy is to define minimum acceptable safety standards for sample containers used for in-plant use only. SCOPE This policy covers all types of sample containers that are acceptable for use in sampling any material or product at this location. It also defines some very basic guidelines for the safe use of these sample containers. This policy does not intend to define complete safe sampling rules. It is the responsibility of each individual unit and/or operation to define their own safe sampling procedures to fit their mode of operation and sampling conditions. This policy does not cover DOT rules and regulations for shipping samples outside the plant. RESPONSIBILITY It is the responsibility of supervision at any unit or operation area to assure that personnel doing sampling are aware of and follow the guidelines defined in this policy when catching samples. DISCUSSION Many types of samples are handled at this location, the physical char acteristics of which vary from gas to liquid, to solid at ambient con ditions. Samples also vary from basic to acidic, from very toxic to non-toxic, from non-flammable to varying degrees of flammability, from non-corrosive to very corrosive. This policy will define, by the nature of the sample and hazards involved, the type containers to be used for sampling materials. Proper labeling is very important. If a sample is clearly and properly labeled, the dangers inherent in handling and analyzing the sample will be known. Samples from the acrylonitrile process must be labeled with the special labels marked "Danger, contains Acrylonitrile (AN). Hazard". Cancer SAMPLE CONTAINER GUIDELINES CBY 3109852 Sample container type is defined according to the physical properties of materials sampled. In all cases, the safest type of container is re commended. 001T4I2 The following guidelines are to be strictly adhered to in sampling any material or stream which falls under the group definition. Where ne cessary, subgrouping is used to further define safe sample containers. ORIGINAL ISSIIF 8 Bv R Xj ( VREVISED / rout* r'RFVFIWFn / / By IK/ 1PACF 1 OF 5 1 ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY $P- 040 CHOCOLATE BAYOU PLANT GROUP I Samples which are or tend to be gas at ambient conditions. Any sample or material in this group tends to be gas under ambient condi tions and therefore must be sampled in pressure containers (saniple bombs) . This group includes any hydrocarbons of C5 & lighter molecular structure. Exception; Some streams are of very low pressure and may, .with lab supervision's approval, be sampled in special bombs. Sample bombs must be tested and/or approved by the Control Lab before use. See Safety Procedure, SP-008. Bombs of either 300 ml or 1000 ml volume and manufactured by either Hoke or Whitey are'approved for use. (Hoke is preferred due to its structural design.) These bombs must be fitted with Robbins valves. Special bombs are used for HF and MeSH samples, see 3 and 4 below. Sample bomb types, used at this location, and how they are to be used is as follows. 1. Liquid Bomb Samples These bombs must be fitted with dip tubes which extend into the bomb an adequate length to allow for thermal expansion of the liquified gas to be sampled. At this location, our standard liquid bombs, other than Olefin's bombs, are fitted with dip tubes which extend into the bomb at 'least 20% of the bombs length. The "dip tube" end of the bomb is painted yellow and stamped "out". Olefins Department bombs have longer dip tubes which extend into the bomb at least 50% of the bombs length. These bombs are yellow on the dip tube end and white at the other end. The longer dip tube is provided to assure expansion room when sampling streams which might contain liquid C2's. After a liquid is caught, the bomb must be supported in a ver tical position which the yellow end uppermost and depressured through the upper valve until liquid cdases to vent from this valve. At this point, the sample is safe for handling and transporting. .2 Vapor Bomb Samples 3109853 Vapor bombs have no dip tubes and are therefore unsafe for catching liquid samples. These bombs are painted red and stenciled "vapor only". They must be used for samplinq streams which are known to be vapor only. 3. HF Bomb Samples C 001743 These bombs are for use in sampling Hydrofluoric Acid only. They R.Garroutte REVISED REVEIWED / / / / By Bv PAGE 2 OF 5 ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- 040 CHOCOLATE BAYOU PLANT are made of monel, a corrosive resistant metal. Valves are also ' made of monel. These bombs are manufactured by Hoke and valves by Whitey. They are recoqnizable by their smaller size and the total absence of paint. They are not to be used for anything except sampling HF. These bombs are not fitted with dip tubes and "must not" be used in any other service. 4. MeSH Bomb Samples MeSH (Methyl Mercaptan) samples will be caught in either 40 or 75 ml Whitey or Hoke bombs. These bombs must not be used in any other service. 5. C2's and Lighter Hydrocarbon Samples Samples of this group are of a particularly hazardous nature if liquid C2's are left in the bomb. After depressuring, these samples must contain only vapors, under pressure. (See instructions for proper depressuring above). These samples which may possibly contain liquid C2's are primarily from the Olefins Unit (C2 streams) and the liquid C2 pipeline samples from Mt. Belview. If samples from the Olefins Unit are caught in the proper olefins bombs, with the white end, and depressured properly, the possibility of liquid C2's will be minimized. Sample bombs must not contain liquid C2's. 17D2 Bottoms and Ethylene Product, from Departments 17 and 18 may possibly contain liquid C2's. It is essential that they be properly depressuret after sampling to assure their safety. 6. Liquid C2's (Ethane & Ethylene) Samples Samples from Mt. Belview pipelines are not to be sampled in sample bombs. A special liquid C2 sampling device is used for these samples. This sampling device is available from Conoco pipeline personnel. These sampling devices are manufactured with hand operable piston type sample mixers. These devices are rated @ 1800-2160# PSl @ STP and are tested 3600 PSI @ STP. Valve bodies at each end of the devices are fitted with PSV's rated @ 1800 100# PSI. Oil filled pressure gauges, at each end, are rated @ 0-2000# PSI. Quick dis connect couplings are provided at each end. These devices are manu factured by Welker Engineering Co., of Sugarland, Texas. 7 AN Recovery Runs AN reactor recovery off gas samples are taken in clear plastic con tainers. These containers are designed for this analysis only and are not to be used for any other samples. GROUP II Samples which are liquid at ambient conditions. c 001744 CBV 3109854 Samples in this group vary from non-flammable to varying degrees of flamma bility, from non-corrosive to very corrosive, from non-toxic to very toxic. ORIGINAL 8 /24<62 R.Garroutte ISSUE / 7 By PAGE 3 OF 5 ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY ssexscnaii SP- 040 CHOCOLATE BAYOU PLANT from very basic to very acidic. Sample containers approved for this group may be glass or plastic bottles, metal cans, or metal thermos bottle for liquid HCN. Container sizes vary. Bottles may be either clear or amber. The proper sampling container must be chosen by considering all unsafe properties of any sample. Quality requirements of products must also be considered. The container which is the safest, considering all of the sample hazards, and which will not interfere with minimal quality guidelines will be chosen. Container guidelines 1. The basic most useful container for this group is the glass bottle. These bottles must have Polyseal lined lids (see exception) to protect product quality. Exception: Some units use french square bottles for catching pro duction samples. When these bottles are used, lids made entirely of polyethylene must be used. Do not use polyethylene lined lids with french square bottles, as these liners sometimes are sucked into the bottle when opened splashing sample on personnel. If the sample is subject to deterioration by exposure to light, it must be sampled in an amber bottle, e.g., AN & Acetone. The minimum size bottle, which will allow enough sample for required analyses plus retain will be used. This information is available in unit and Distribution sampling procedures. The bottle will be filled no more than 80% full. The plastic bottle is the second most useful container for this group. These bottles must be provided with a cap which will seal to prevent leakage. Plastic bottles will be used for any sample which is highly corrosive e.g., strong acid or caustic solutions, crotonaldehyde, etc. Exceptions to this rule are Hydrofluoric Acid, which must be caught in a special Monel bomb, phenol which must be caught in a glass bottle, and HCN in a metal thermos bottle. The minimum size bottle, which will allow enough sample for required analyses plus retain will be used. The bottle will be no more than 80% full. 2. The metal can will be the least used for sampling this particular group, but for sampling materials which tend to build up pressure or which require high temperature for melting, they are absolutely essential. Corrosives (e.g., containers. acids, caustic) will never be sampled in metal CBY 3109855 C 001745 ORIGINAL ISSIIF ^REVISED / / 82 BvR.Garroutte RFVFIWFH / / Byi PAGE 4 OF 5 Bv I ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY * SP- mo CHOCOLATE BAYOU PLANT Materials which might be expected to contain light ends (C5's & ltr) in small amounts must be sampled in cans with screw caps and/or press on covers so they are vapor tight. Note: If the material contains primarily C5's & lighter, it must be sampled in a bomb. Materials must be melted for analysis or disposal must be sampled in "open topped" cans. If a material contains small amounts of light ends and is also corrosive, then a can lined with polyethylene must be used for sampling. The minimum size can, which will allow enough sample for required analyses plus retain will be used. The can will be no more than 80% full. GROUP III Samples which are solid at ambient conditions. Samples in this group may be in the form of a powder or granules. They may also be materials which will melt on heat application, and in fact, must be melted for analyses. Materials of dry powder or granular form will normally be sampled in plas tic containers, but glass or metal are acceptable. If the sample is corro sive, a metal container must.not be used. Any container used for sampling dry powder or granular products must have a tight fitting lid which will prevent contamination of the materials, es pecially moisture. Materials which are solid at ambient conditions and must be melted for analysis or disposal, must be sampled in "open topped" cans, with the exception of Phenol, which is sampled in glass bottles. (Open topped cans have lids which are the size of the top of the can. The top of the can is, therefore, open when the lid is removed). Materials such as Tar, Resin PR, and Naphthalene must be sampled in such containers. The minimum size can which will allow enough sample for required analyses plus retain will be used. The can will be no more than 80% full. This policy establishes some guidelines which, if adhered to, will make the jobs of sampling, sample handling, and analyses much safer. In con sideration of their own personal safety, each individual who handles ORIGINAL ISSUE REVISED 8 /ia/8! 2 By R.Garroutte REVEIWED / / By By PAGE 5 OF ATTACHMENT 5 mB SAFETY PROCEDURE MANUAL ' MONSANTO COMPANY $P- <w CHOCOLATE; BAYOU PLANT INSTRUMENT AIR CONTAMINATION WITH NITROGEN PURPOSE The purpose of this procedure is to establish guidelines to be followed when nitrogen is added to the instrument air headers. SCOPE This policy and procedure defines the communication method and actions required by all units in the event nitrogen is added to the instrument air headers. . .. DESCRIPTION OF SYSTEM The plant instrument air headers have a potential of nitrogen being admitted due to shutdown/trip out of the air compressors that normally provide these headers. Should the instrument air pressure drop to 90 PSIG the nitrogen back up system comes into service adding nitrogen to the instrument air headers to main tain header pressure at 90 PSIG. This nitrogen being added to the headers creates a potential safety problem if any people are inside an analyzer house and depending on the location of pneumatic instrumentation may ac cumulate nitrogen in other confined spaces within the produc tion departments. Nitrogen will also result in chromatograph analyzers shutting down in labs. PROCEDURE 1) Upon loss of compressors or any time that the nitrogen control valve is activated which will permit addition of nitrogen into the instrument air headers the Plant fire and spill alarm will be activated. The fire and spill alarm for nitrogen being admitted to the instru ment air header is 3-3-3. 2) Upon activation of the 3-3-3 fire and spill alarm all personnel are to vacate analyzer houses that use in strument air for instruments, purges, and etc. or any other confined spaces that may accumulate nitrogen. 3) The owning departments of the analyzer houses and other confined spaces that may accumulate nitrogen will take the following actions immediately upon activation of the 3-3-3 fire and spill alarm: a. Inspect the analyzer houses and or other confined spaces to be sure that all personnel have vacated the premises. C 001747 CBY 3109857 S'NAL W A* a. w REVISED / / REVIEWED / / By By PAGE 1 OF 2 ATTACHMENT SAFETY PROCEDURE MANUAL ' MONSANTO COMPANY " SP-041 CHOCOLATE BAYOU PLANT Instrument Air Contamination with Nitrogen (cont.) Page Two b. Lock doors closed to anaylzer houses or other confined spaces. c. Attach sign to entrance doors indicating that a vapor hazard exists. d. The shift foreman will contact the main guard gate to verify that they are aware of the nitrogen being in the instrument air systems and have taken appropriate action as specified in items a,b, c listed above. 4) a. The guards are to call the shift foreman of'any unit not making contact with them immediately to be sure they are aware of the problem and request that they take action as specified.. b. Upon completion of verification check list the guard will sound an all clear on the fire/spill horns. This all clear does not signify that the instrument air headers are back to normal, only that verification of notification is com plete and that other routine work may be resumed. 5) . After air compressors are returned to service and nitrogen is blocked away from the instrument air headers, utilities will notify all units and the main guard gate by telephone that instrument air headers are back to normal. 6) If it is necessary for immediate entry into analyzer house or other confined space, after instrument air headers are returned to normal, a vapor test should be performed before entry to be sure that oxygen level is normal. Otherwise, a period of 2 hours should be allowed before removal of locks and entry is permitted on a routine basis. 7) In the event nitrogen is admitted to the instrument air headers and the fire and spill alarm does not activate automatically, the Utilities Shift Foreman will call the main guard gate and request the guard to activate the fire and spill alarm code 3-3-3. SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-M2 CHOCOLATE BAYOU PLANT FIRE EQUIPMENT IMPAIRMENT CONTROL PURPOSE The purpose of this procedure is to establish a method of effectively handling repairs to the fire protection system. POLICY It will be the Safety Department's responsibility to insure all fire equipment is kept in a ready to use condition, also to communicate to all units and areas affected when equipment has been taken out of service for repairs and returned to service. PROCEDURE ' 1. An Impairment Permit will be filled out by a member of the Safety Department prior to the equipment being removed from service. 2. The permit will be approved by a member of supervision in the Safety Department. Approval may be granted verbally during off hours. 3. The original hard copy of the permit will be fastened to equipment impaired or area of impairment. 4. Supervision in areas affected by the impairment will be informed verbally before and after repairs are made. The supervisor's name will appear on permit. These areas will minimize operational changes or hot work that could case an incident while the fire equipment protecting the area is out of service. 5. The use of this impairment procedure does not preclude the usage of SP-009 (By-passing and Testing Protective Devices) or SP-019 (Fire Permits and Vessel Entry/Fire Permits). The affected department supervisor is responsible to make the appropriate decision to invoke SP-009 or SP-019. ORIGINAL // ISSUE 11 /30/82 Bv C.A.Coburn REVISED / / REVEIWED / / By Bv c CG1749 CBY 3109859 PAGE 1 OF 2 ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP- cue CHOCOLATE BAYOU PLANT FIRE EQUIPMENT IMPAIRMENT CONTROL 6. - After repairs are completed the safety department will return all equipment to service then complete the impairment permit form. 7. The soft copy of the permit shall be retained on file at the Safety Department. This copy will then serve as a permanent record. NOTE: Impairment Permit has green border, white background with black lettering. A0/82ISSu|INAL 11 8vC.A.Coburn REVISED / / REVEIWED / / By Bv CBY 3X09860 C 001750 PAGE 2 OF 2 ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY FIRE EQUIPMENT IMPAIRMENT CONTROL SP- 042 CHOCOLATE BAYOU PLANT 04 ECdJ 04 O03 Fir* Pumo zEd EOCdd Hkji3 Valves Cloeed for Isolation -- KgSaj&aa Valves Opened After Repair -- 0t Reoain Comolete 1. Has Supervision in Affective Area Been Notified? wJS fYl Otntr Precautions Taken INITIAL Fire Safety inspector 4*if8ii? ^ Safety Supervision . ORIGINAL 11 Ao/b2 IF / / Bv Coburn REVISED / / REVEIWFD / / By Rv CBY 3109861 b*1*- C 001TS1 PAGE 1 OF 1 ATTACHMENT n SAFETY PROCEDURE MANUAL MONSANTO COMPANY m SP- 043 CHOCOLATE BAYOU PLANT HEARING CONSERVATION PROGRAM PURPOSE To establish a Hearing Conservation Program (HCP) which will set the guidelines, consistent with OSHA and Monsanto's HCP for hearing protection training, monitoring and protective equipment selection. SCOPE This procedure will apply to all Employees who are exposed to a noise level of 80 dBA full shift TWA. All contractors at Chocolate Bayou falling in this category will have a HCP complying with OSHA guide lines, and will also comply with Monsanto's policy of hearing protection areas an approved equipment. POLICY A HCP will be administered where there is exposure to a full shift TWA greater than 80 dBA, or where hearing protection is worn. Hearing protection equipment will be used only when feasible engineering controls do not reduce noise sufficiently. New or retrofit engineering projects will have noise levels below 85 dBA. RESPONSIBLITIES Industrial Hygiene * Overall responsibility for administering the Hearing Conservation Program (HCP). * Monitoring areas and new Projects to determine noise levels and establishing plant noise profile. * Supply stores and purchasing with a list of approved hearing and protection equipment. * Evaluation of hearing protection equipment. Manufacturing * Supervision will be held accountable for worker compliance to Hearing Conservation Program. * Insure personnel have annual Hearing Conservation Training which complies with OSHA standard. * Maintain training records including dates, name and type of equipment used. * .Address the reduction of noise through engineering design. C OOl'/ffZ Medical CBY 3109862 * Informing employees of results from audiometric tests. REVISED / / By PAGE 1 OF 5 ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-CW3 CHOCOLATE BAYOU PLANT HEARING CONSERVATION PROGRAM A. Each unit having a HCP will have hearing protection equipment available for any personnel going out into the unit. Each unit will have the option of selecting its own hearing protection equipment. However, the equipment used must be on the Purchasing Department approved list. HEARING PROTECTION EQUIPMENT 1. Industrial Hygiene will evaluate Hearing Protection using NIOSH Method No. 1. 2. For purpose of real world effectiveness, the calculations should be made using 50Z of the attenuation value at each frequency. 3. Hearing Protection equipment will also be evaluated on the basis of administrative controls. AUDIOMETRIC TESTING Audiometric testing will be the responsibility of the Medical Department and will meet the following requirements. 1. All employees exposed to 80 dBA full shift TWA will be tested annually. 2. A preplacement audiogram must be done before any employee is exposed to or starts work in a high noise area. HP cannot be used, and 48 hours free of loud noise must preceed this baseling test. 3. Audiometric testing equipment must meet OSHA, HCA, and Monsanto Medical Policy guidelines. 4. Acoustical Audiometer calibration must be done at least semi-annuallj 5. An exhaustive calibration is required when acoustical calibration results show 75 dB or at least every 2 years. 6. Annual follow-up audiometric tests need not be tested. If a STS is noted, a rested retest will be done within 30 days. 7. In the period between the audiometric test and the retest, any employee suffering a STS will be refitted with HP, retrained and required to wear properly selected HP. TRAINING CBY 3109864 c 0G1'7S4 The training and education of workers and their supervision in the hazards and control of noise is an essential element in the Hearing Conservation Program. ORIGINAL /l6/s *vK-A- Lindberg ISSUE _2 PAGE 3 OF 5 ATTACHMENT SAFETY PROCEDURE MANUAL SP-M3 ORIGINAL ISSUE 7 CBY 3109866 C 001756 REVISED / / 5 flv K.A. Lindberg REVIEWED / / By By PAGE ^ OF 7 ATTACHMENT