Document ZJEDMBvMDR6jBgdwDEg8Kgp0L

DUP 0832035 DUP 0832036 SAFETY GUIDEBOOK NRD-47 gP-EZ 1 2 3 4 5 DISTRIBUTION OF COPIES Assigned to NRD-47 Day Area Operator Operations 11-14 Foremen Operations 15-16 Foremen CNRD-47 Production Assistant Division Supt: NRD-47 Production Division Supt. DUP 0832037 DV! rn*14r.j 1i.'i.' DuPont Victoria Plant Basic Safety Program (Talk given by J. T. Granaghan, S/8/7ii) DDDA First Break Requirements, Thermocouple Removal Safety, Line Clearing Procedure Scheduling of Area Emergency Drills (Letter, Shahan "flak fDodson to Central Safety, U/8/7^) Electrical Grounding (VPS ^G) Identification of Piping Systems (VPS EG) Marking Operating Ranges of Gauges (Letter from S & F Division, 2'17'76) Safety Subjects for Annual Review Safety Orientation for Outside Contractors DEW Dumpster Hauling (Letter, Koomann to Ehrman, and Waste Disposal Locations Operation l6 Fork Truck Safety Returning Empty BTM Sc UM Cylinders (Letter, C. F. Richter to Ed Warwas, l/l6/7^) Accounting Procedure, Acids Production Instrument Operation During Power Failure Coverall JPolicy Microwave Oven Safety Precautions Threatening Contacts a. Bomb Threat Alert b. Bomb Threat Emergency Relief Valve Inspection Procedure Identification of Gas Cylinders Vacuum Truck Usage DUP 0832038 iUHId 1 DUP 0832039 RIP PROOF" TAB fcl n o --Wfer-J' fit: .a,.--Mi majm Hitti DDDA Page: 1-A-l Date: 5-6-68 Revised: 5-11-81 Area Safety Rules Listed below are rules and precautions which specifically apply to operation in the DDDA and Waste Disposal areas. All employees are to read these rules carefully and abide by them at all times when in these areas. Operating supervision must be consulted for additional safety precautions before undertaking any job not covered by standard operating procedures, or when a job requires special application of these rules. These safety rules apply to every individual who may enter these areas. In addition, all employees must familiarize themselves with, and abide by the general plant safety and fire protection procedures, and the area detailed procedures. All unsafe conditions and acts are to be corrected and/or brought to the attention of supervision. * A. The following personal wearing apparel is required in the DDDA and Waste Disposal areas: 1. Hard hat. 2. Safety glasses. 3. Coverall goggles and ear plugs on person. Ear plugs must be worn when working within ten feet of all high noise symbol, or within an area where hearing protection is required. See S & F 39 for further details. 4. Shoes:. a. Safety shoes are strongly encouraged. b. Easily permeated shoes are not permitted. c. Rubber overshoes are provided for use in areas where nitric acid is present. 5. Clothing. The use of Nylon wearing apparel is discouraged in any area where nitric acid is present. Clothing of persons working in an area where ntiric acid may exist must be kept free of oil and grease. Do not wear loose clothing around moving equipment. DUP 0832040 DV i.,s; a Page: l-A-2 Date: 5-6-68 Revised: 5-11-81 6. Minimum Personal Protective Equipment: a. Sampling corrosive or hot (70C) materials. Coverall goggles, rubber gloves, and acid suit jacket are required for routine sampling of process streams. Additional equipment may be necessary for some special samples. b. When using hot water (>70C) or corrosive material to flush, unplug, or clear open ended lines which are not piped to the trench or sump. Coverall goggles, rubber gloves, acid suit jacket and pants, rubber boots are required. If material is molten, a face shield is also required. When using steam, condensate, or process water to unplug or flush open-ended lines (one end or both ends open), the minimum protective clothing required is that required for a first break on the line or that required for use of the flush material (steam, * condensate, process water), whichever is greater. ` Rope off area when using flush material. (Steam, condensate, process water). c. Flushing, unplugging, or clearing permanently installed lines or equipment to trench, sump, or into a closed system. Coverall goggles and rubber gloves are required. d. DBW Dumpster Hauling. Coverall goggles, faceshield, rubber gloves, and rainsuit jacket are minimum protective equipment required while flushing, disconnecting, connecting, or unloading dumpster or lines. e. Condensate. Anytime condensate, hot water (>70C) or process material is used to pressure check or leak check lines, rubber gloves, coverall goggles, face shield, rain suit and rubber boots are considered minimum protective equipment. This includes connecting, or moving a condensate hose, and/or washing floors or spills with condensate or hot water. Rope off area where condensate is being used. f. Washing floors. Coverall goggles are minimum protective equipment when washing down in areas that could contain corrosive material from spills, leaks, etc. This includes areas where cleaning material such as Cesco soap has been applied. D VI DUP 0832041 Page: l-A-3 Date: 5-6-68 Revised: 5-11-81 g. First breaks. Refer to minimum protective clothing requirements for initial breaks chart whenever it is necessary to break open a line or piece of equipment. It outlines personal protective equipment for the worker and standby man, and indicates the'supervision who must be present. See S & F 73 also. h. Gloves. Gloves should be used whenever specified as required protective equipment and, in addition, should be worn when there is possibility of finger or hand injury. Chemical resistant gloves are issued to all operating personnel. They should be worn while performing all field jobs except where it would be impossible to perform the job while wearing gloves or the wearing of gloves would make the job unsafe. B. Know the location and proper use of all safety equipment in your area. Also, know the location of fire alarm boxes, evacuation alarms, and gas escape alarms. C. Do not obstruct fire alarm boxes, gas masks, stretcher boxes, safety showers, hose houses, stairways, access doors, exits or any other safety equipment or alarms. D. Do not use safety and/or fire equipment installed for emergency use for routine or specially scheduled jobs. Necessary equipment must be obtained from the Tool Room'at Acids Shop. E. Service hoses (water, air, nitrogen, or steam) are not to be used to transfer process materials without permission of the Area Supervisor and must be used in accordance with S & F 14A. F. Steam Hoses: (See S & F 54) 1. Rubber gloves, ear plugs, and coverall goggles are to be considered minimum protective equipment required when using a steam hose. Additional equipment should be used as warranted by each job. 2. Rope off areas where steaming creates a hazard to other personnel. 3. Steam hoses are not to have valves at the discharge end, or have the flow restricted in any manner that would subject them to full steam header pressure. Check the hose and nozzle prior to each use for any restrictions or faults. DUP 0832042 Page: l-A-4 Date: 5-6-68 Revised: 5-11-81 4. When steaming a vessel or line which has contained material of a flammable or explosive nature, the hose must be provided with a ground wire, and the grounding wire clamp must be attached securely through any paint or protective coating to the line or vessel. The electrical continuity must be checked to assure the adequacy of the bonded connection and the steam hose ground prior to steaming (S & F 54). 5. Keep a firm grip on the steam hose. Use extreme caution when adjusting the steam supply valve. To lose control may cause a serious burn. 6. Do not steam directly against glass (peep sights, sight glasses, etc.). 7. Do not steam directly into any electrical equipment. 8. When it is necessary to leave the steam hose, it must be attached securely in place. * 9. Do not tie in a steam hose directly to process piping. G. Connecting Service Hoses into Process: 1. Follow S & F 14A if nitrogen, air, or water are tied into the process for any reason. These connections must meet S & F 14A requirements. 2. First break procedures must also be followed when disconnecting the hose, if applicable to the particular process. H. Do not tie in well water directly to process lines or equipment. If well water is to be used in the process, the lines must be physically disconnected. See VPS-76 for further information. I. Do not use broken or chipped glass equipment. It must be put in broken glass containers or a dumpster. J. Nitrous oxide fumes are highly toxic. No person is to enter an area where nitrous oxide fumes are suspected unless he wears a self-contained breathing apparatus (Scott Air PAK). Anyone who suspects that he has been exposed to concentrations of nitrous oxide fumes should report immediately to the plant hospital or first aid. Supervision should be notified as soon as possible. K. If the building evacuation alarm is sounded, all personnel should immediately leave the building and report to the CCR operator. DUP 0832043 '&s: Page: l-A-5 Date: 5-6-68 Revised: 5-11-81 L. All production personnel should report to the CCR when a fire alarm or gas escape alarm is sounded. See EM, Section 1. a. Operations 11-12 CCR operator and Operations 13-14 CCR operator will account for their groups to the Operations 15-16 CCR operator'. b. The Operations 15-16 CCR operator will make a total accounting for DDDA area production personnel, and for people signed into the area, by calling personnel accounting headquarters (Ext. 1453). M. Only regular fire fighting personnel and persons regularly assigned to the area should report to the scene of a fire unless their services are requested. N. Leaks, spills, or other abnormal or unsafe conditions should be reported promptly to area supervision. O. No piece of equipment is to be put in operation unless all guards and other protective devices with which the unit is equipped are in place and everyone is clear. P. Openings in floors or trenches, and overhead work must be properly barricaded. Q. All visitors to the manufacturing areas should contact production supervision of the area to determine its current safety status; and what, if any, precautions should be taken. Inform the CCR operator when entering and leaving the area, and sign in and out on that area's personnel accounting sheet. R. Before maintenance work may be performed on lines or equipment, the equipment must be properly cleared, tagged, and turned over to maintenance per S & F Procedures No. 3 & 73. S. After maintenance work is complete, equipment and/or lines must be tested for leaks before being returned to service. T. Before any closed vessel or open vessel deeper than five feet may be entered (including sewers and electrical manholes), the vessel or area must be cleared, and a permit issued in accordance with S & F Procedure No. 20. U. Only Teflon bottles should be used for sampling hot solutions (70C) or nitric acid streams. Following are some additional precautions concerning sampling: 1. Never fill a sample bottle more than 75% full. Dvi C45ir'.'7 DUP 0832044 Page: l-A-6 Date: 5-6-68 Revised: 5-11-81 .2 Wash down any spillage and clean outside of bottle after sampling. 3. All samples must be properly labeled when taken. 4. All sample bottles'must be carried in an approved carrier. 5. Smoking is not allowed while carrying flammable samples. V. It is required that employees report all on plant injuries to their supervision, and to Medical Division as soon as possible. See S & F Procedure No. 2 for further details. W. Hard hats and safety glasses are required inside Operation 16 warehouse, except in designated area around the warehouse desk. X. A dust mask or other respiratory protection is required when doing the following: 1. Mixing Boric Acid in Op. 16. 2. Dumping Vanadium Pentoxide Catalyst in Op. 15. 3. Mixing Urea in Op. 16. 4. Checking Crude or Refined filters in Op. 15. 5. Mixing Pyrophosphate in Op. 13. 6. Mixing Precoat and/or Slurry at Acids Waste Area. Y. Urea and sodium nitrite should be stored on opposite ends of the warehouse because of the danger of a reaction. Z. A fire hazard exists from auto-ignition of CDD which may occur because of pump seal leaks or CDD-soaked insulation. Pump fires can be avoided by maintaining adequate seal flush and frequent patrol for seal leaks. CDD-soaked insulation is prone to spontaneous combustion, with steam tracing usually supplying the heat source. This type of fire can be avoided by keeping insulation sealed and in good repair to prevent infiltration of CDD. DUP 0832045 DVI C451E7o ._ t___________ *fta- . icr* .- y: ' ab'iygjFfn ijWTwff^ i-<>r Page: l-A-7 Date: 5-11-81 Revised: CDD leaks onto insulation should be handled as follows: (1) Repair the leak if possible. (2) If the leak is a "drip" type, put it on the shutdown list for repair and place a catch pan or bucket under the leak to prevent soaking of the insulation. (3) If the leak is a steady stream, shutdown the equipment immediately and repair the leak. Any buildup of CDD on insulation should be removed physically or with a water hose - do not use condensate (to avoid melting any CDD). Permanent catch pans on tanks (DCC decanter and decomp, tank) should be checked at least once per shift and any buildup of CDD in the pan reported to the foreman. DUP 0832046 DVI C451P.Tr DUP 0832047 DU PONT VICTORIA PLANTBASIC SAFETY PROGRAM (A Talk l:o Representatives of the British Chemical Industry Association) J. T. Granaghan 5-8-74 D V i C451676 DUP 0832048 DU POUT VICTOPvIA PJ^NT DASIC SAfETY PROGRAM I would like to discuss with you this morning our basic safety program here at the Victoria Plant. In essence our basic safety program is not one program unto itself, but consists of a number of programs which when taken in their entirety enables us, we feel, to run a results oriented safety program which is effective in accomplishing our safety objectives. Unfortunately, I cannot simplify and tell you about one or two activities which constitute the bulk, of our program. There are a number of them which must be put together in order .to effectively do the job. I might add that within Du Pont our safety objectives are quite clear and start at the highest corporate level. Therefore, it follows that all Du Pont locations have clearly stated and consistent safety objectives. There are some other vital ingredients that are required above and beyond the programs themselves and I'll touch on those also. But before getting into any of the foregoing, I would like to put our efforts and objectives into the proper perspective and I believe this can best be done by examining this first chart. (Chart showing Company lost time injury frequency since 1912) This chart reflects the lost time injury frequency per million man hours worked for the Du Pont Company as a whole since 1912. You will note that the Company's frequency over the years has shown a steady decline since 1912, and in recent years has approached the ever elusive goal of perfection or zero. This reflects ever increasing emphasis on safety over the years starting with top Corporate management. Needless to say. Corporate management's objective becomes our objective and the overall Corporate objective for the year is .15 injuries per MM man hours v?orked. I haven't looked at the statistics in quite sometime, but to put our objective into proper perspective if you looked at some National Safety Council figures when I last did, you would find that all manufacturing in the United States as a whole was about 6.0 injuries per MM man hours, the chemical industry about 3.5 injuries per MM man hours, and the worst was the coal mining industry at over 40. These statistics should give you an idea of the league we are trying to play in; G451G77 DUP 0832049 2- - it's obviously not an easy task; and it requires some extraordinary effort on the part of each member of our organization. This will unfold this morning as my remarks progress. Turning now to this chart, I have listed here a number of basic safety programs which when effectively implemented gives us a results oriented safety program which enables us to meet our objective of near perfection. But before touching briefly on each of these, there are, in our opinion, seven conditions that must prevail before any set of basic safety programs can be effective and obtain results. These are shown at the top of the chart. I'll briefly cover each one of these. Overall Direction and Administration In an organization such as ours, any safety program must have overall direction to be effective. Here at the Victoria Plant i. overall direction is achieved through the medium of the Plant Central Safety Committee chaired by the Plant Manager and including two levels of supervision below the Plant Manager. This means that the Central Safety Committee consists of about 20 members. The Committee meets monthly and representation of supervision is such that safety proceedings and decisions are disseminated and imple mented with consistency throughout our entire organization. There are a number of standing subcommittees which are responsible to the Central Safety Committee on various safety matters. Some of these committees are temporary committees that we appoint from time to time to delve into specific matters and pursue them to an agreed upon conclusion. The Plant Manager traditionally at each Du Pont location where I have worked, chairs the Central Safety Committee and assumes the overall responsibility for safety at the site location. Safety as a Job Requirement A few years back, a basic change in management philosophy occurred with a concurrent improvement in safety performance. This involved a shift in emphasis from attempting to sell safety to everyone to firmly establishing safety as a job requirement. We were, before this shift, attempting to achieve good safety performance 6451G7S DVI DUP 0832050 3 with a somewhat heavy emphasis on selling safety to everyone. There were many ways we went about this persuasive approach, however, it was obvious that we weren't getting the job done well enough to satisfy our objective. (Although safety was good by comparison with other U.S. industry). I might point out that it takes only one individual who is not sold to keep us from meeting our objective. Well, we have changed all of this and safety is now a job requirement and this is well understood by our people. An employee who cannot work safel}? is considered to be unsatisfactory despite the fact that all other characteristics may be deemed to be outstanding. This has brought a different perspective to our safety .efforts with a marked improvement. Line Organization Responsibility Another vital ingredient to a good safety program is the establishment of the under-standing with all concerned that the prime responsibility for safety rests with the line organization rather than the plant safety organization. While our safety organization certainly makes a vital contribution to our safety efforts, safety always has been with us a line organization responsibility. Afterall, it is the line organization who supervises those who are susceptible to injury and they are in the position to cause things to happen and take corrective measures to insure our safety objectives are met. This point is well-understood by everyone here at the Victoria Plant. Individual Responsibility Once the safety objectives have been clearly defined by line organization, and practices and procedures clearly understood, then it becomes necessary for each individual to accept his full share of responsibility for insuring that the standards are met. Core sampling by supervision to insure that standards are met is a vital part, but unless the condition of individual responsibility prevails no organization will meet their objective. This is an area that we continually stress at our plant. DUP 0832051 DVI U51L73 4 r. c r uj r in g Attitude _ Another condition v:hich must prevail is the proper attitude of supervision towards sub-standard conditions. Indifference towards sub-standard conditions can only lead to poor safety performance. Every member of supervision here on the Victoria Plant is expected to maintain a requiring attitude with his people, accept nothing in the way of sub-standard conditons or unsatisfactory individual performance, and to take prompt remedial action when such conditions prevail. Daily Accountability There are many who hold to the view that you get your safety7 a day at a time and if you look ahead much more than this, you will be so distracted from what is going on today that safety will fall through the bottom while you are worrying about tomorrow. Although not entirely true, this philosophy has its place in any good safety i program. We have established at the Manager and next level of supervision, daily accountability each morning for the past 24 hours. The main thrust for this activity is to insure that at the Plant Management level that we know what happened, how it happened, and most importantly which remedial action is in progress and by whom. One of the major objectives of daily accountability is to insure that the same incident never happens twice by insuring that appro priate action is taken plant wide to prevent recurrence of an incident. Constructive Discipline Finally, it is necessary7 to insure that the proper degree of follow-up is exercised in the form of constructive discipline where individual performance is sub-standard. It is our intent through proper leadership to get people to perform to the standards necessary for good safety performance. There are cases where even the best of leadership cannot accomplish this. Application of discipline based on my7 own experience range from termination to an informal discussion with an individual pointing out his safety7 deficiencies and our requirement that he must change his ways and live up to his obligations to meet the required standard. Experience has proven that most employees want to do what is expected of them; DUP 0832052 6451680 DVI 5 particularly when the standards of performance are clearly outlined to them. Assuming that the . seven foregoing vital ingredients are present in the organization, then the safety task becomes one of developing and implementing specific safety programs designed to get results. I would like to briefly describe the on-going programs here at Victoria one by one. Operating Manuals (show example) I am sure that our business is no different from yours in that our plant operation consists of a multitude of rather complex chemical processes. Through the efforts of our plant process engineering groups, we continually search for the best possible tech nology through improvement to our processes. In practical terms, this effort is translated and conveyed to our plant operating forces in the form of what we call operating manuals. In essence, an j operating manual is the approved, standard method by which a given process is to be run. It is intended that all personnel who run the plant do so in accordance with this approved method. You can see from the or.e I have here that it is quite detailed and compre hensive. No authority exists to deviate from specified operating conditions without a shutdown or taking specified remedial action. In essence, the operating manual represents the best possible safety and operating technology which can be devised. Our- system accommodates change through proper review and approval, but such change is thoroughly reviewed by our technical groups to insure we stay in a safe area of operation. Although it is a difficult task, we place continual emphasis on keeping our operating manuals up to date. 1 might also point out that operating manuals are invaluable as a training aid and source of reference when taking on new personnel for expansion such as we are undergoing at this plant. Undoubtedly, we have avoided many serious process incidents by the specification of operating conditions in the form of operating manuals. DUP 0832053 D\M 6451661 6- - P,a - i o Sa fctv 1 'anna 1 (show example) There are a certain number of basic safety procedures which are applicable plant-wide to the almost 1200 people who work here. The.se standards of performance are set and conveyed for implementation through the medium of our basic safety manual. Just to give you a feel for what type of procedures I am talking about, I will briefly describe one or two of them. Probably one of the most important procedures in this manual deals with the clearing, locking, and tagging of equipment prior to exposure of personnel to conditions which would otherwise be quite hazardous, (maintenance and inspection) Anyone who operates, maintains, or inspects equipment or facilities has to play It is own individual part in rendering equipment safe for inspection or maintenance through the application of tags and/or locks. This procedure is used plant-wide every day and I am sure it would not be much of an exaggeration to say that its use since start-up of this plant numbers in the millions of times. Another example is our work permit procedure (show example* of permit). This is another procedure which is applicable plant-wide. In all areas of the plant we have designated what we call a proprietor who is charged with the responsibility of approving all maintenance and construction activity in his assigned area. The philosophy behind this is the fact that the proprietor (usually second-line operating supervision) is in the best position to know what specific and extraordinary safety precautions are required whenever any activity is to be undertaken in his area which is not of a routine nature. Therefore, the proprietor is expected to review what is to be done in his area prior to start of work and insure that whatever precautions are necessary are taken above and beyond the basic procedures which are well established and in written form. You will note from the example I have here that die proprietor is expected to consider a checklist of the more common precautions, and in addition there is a space for him to enter whatever other precautions he deems necessary' under the circumstances . The procedure is especially effective when expanding a plant such as we are doing where heavy construction activity is going on in all areas of the plant (700 construction personnel) DUP 0832054 -7 - Although there are many others, the foregoing should give you a feel for the type of procedures which are in our basic safety manual. Incident Reports (show example) Whenever any abnormal incident occurs of a safety nature, it is incumbent upon us, as an organization, to promptly find out what happened, what caused the incident to occur,and what we can do to insure that it will not happen in the future. Similarities of operation between areas on the plant and between plants within the Company dictate that lessons learned in connection with an incident be conveyed to all who can benefit by examining the incident in light of how it might happen to them in the future. We take two approaches here at our Victoria Plant. First, we have what we call our Preliminary Incident Report (show example) which is prepared by first-line supervision usually on the same shift on which the incident occurs. The Division Superintendent (fourth line supervision) is responsible to see that this report is given appropriate circulation to other plant areas. But beyond this a number of incidents require a more detailed treatment than is pro vided under our preliminary incident procedure. In this case a committee is established by the Division Superintendent, including selected individuals on the plant, who by their knowledge and expertise, can contribute to a thorough investigation and the establishment of remedial action. A member of our plant safety organization is always included in these investigations. As you can see from this example, this type of incident report is more formal in nature and receives wide distribution on the plant (all .supervision). In many instances, they are distributed within our department to other locations and some go throughout the Company. Job Cvclc Checks Another important activity that we have going plant-wide is one that concerns itself with detailed observations of how a specific job is being done, particularly from the standpoint of safety. We call this our Job Cycle Check program. It consists primarily of a member of supervision, on a set frequency, examining DUP 0832055 rwj\ U51683 -s - in detail a job bein'? performed in its entirety and determining j f the man is perfcrming per-procedure or if changes in procedure arc appropriate. This activity continues to reinforce adherence to : standard methods and to develop new and improved methods of performing1 work in all areas of the plant. STOP Program (show example) A few years back there was developed within the Company a programmed instruction course which was designed to fill a real need that existed which was one of training all members of the organization to become skilled safety observers. Most of you I am sure are familiar with the programmed instruction technique and we feel that this technique has been quite effective in getting this accomplished. The program emphasizes assumption of safety responsibility, where to look, how to look, and most~importantly, how to follow up. It is a good one and we would highly recommend it to you. One other advantage I might add, is the fact that programmed instruction is * a self-teaching method and as new personnel move through the organ!-' zation it is relatively easy to get them trained as skilled safety insfactors. Unsafe Acts - Unsafe Conditions (show? green card) If I were forced to choose one of our basic safety programs which was the most effective compared to the time required to keep the program moving, our unsafe acts - unsafe conditions program would have to be it. This program is an outgrowth of the STOP program I described a moment ago. Basically, what it consists of is putting to use what all levels in our organization learned in the STOP program about being trained safety inspectors. Each member of supervision spends an assigned amount of time in plant inspections observing unsafe acts and unsafe conditions along with a member of the organization assigned to the area being inspected. This provides an opportunity to assess the overall safety posture of a given area as well as define expected standards of performance on the spot. The program is modern in scope in that it is computer oriented, and by that I mean the scheduling of inspections is via computer and feed back of results yield an index of performance which can be used to detect safety trends. Dvl C4516S4 DUP 0832056 -9- S:j.fe 1 rncticc. Series Another program which has proven to be effective is another programmed instruction course which deals with the employment of safe practices in routine jobs which are done frequently. The example that I have here is one on basic hand tool safety. The major thrust of the safe practice series-is in the area where a single individual by his own action and work habits pretty much makes the determination on whether he will accomplish his assigned task without injury. Housekeeping We hold firmly to the view that the level of housekeeping in any plant area is a direct measure-of the attitude of the organi zation toward safety. We firmly believe that without good house keeping you cannot have good safety. Therefore, we place a great deal of emphasis on good housekeeping. Every area of the plant receives an unannounced housekeeping inspection each month with appropriate ratings. There is real effort among all plant groups to stay in good shape here. We feel that our overall level of housekeeping here is outstanding. I am confident }'ou will agree as you take your plant tours. We would be interested in your comments in any even t. Standard Operating Conditions An outgrowth of the preparation of operating manuals and procedures is the establishment of a number of operating parameters (pressure, temperature, flow, etc.) which must be maintained for safe and smooth operation. In the interest of maintaining standard ized operation, we have gone a step further in that posted on each controller, gauge, or other process monitoring instrument in the plant are markings reflecting a maximum and minimum which can be tolerated as well as a norm. No authority exists for deviation from standard operating conditions without shutdown or remedial action being in progress. Posting of SOC is especially valuable for training new personnel when you are undergoing major expansions such as we are. 0VI C4516S5 DUP 0832057  KV-.\. I ~'f '^ *" -**.!' " *' i ' >4. UP -.> '~ ~ . .jV . ' trsjfr relief Valves and Protective Devices As you might expect we have thousands of relief valves, rupture discs g and other protective devices on vessels and other equipment, Our general philosophy is that adequate relieving protection must be afforded in each instance such that the highest possible pressure which could prevail (decompositions, etc.) wou!d not result in catastrophic failure of the equipment. We place considerable emphasis on periodic inspection of all protective devices to insure that they remain operable at all times. The sheer number of devices dictate a computer oriented system of scheduling, inspection, and recording. I have an example of what I am talking about here on the table if you would care to look at it during the break. In addition, we have established here on the plant a committee known as our Test Standards Committee. This Committee oversees all - matters related to relief valve and rupture disc installation, alteration, etc. ` Process Hazard Reviews Process development is an on-going and major activity within our plant, our department, and the Company as a whole. We are continually eliminating obsolescence in our processes in order to remain competitive. The track record of our technical and research groups is phenomenal in terms of yield improvement, energy consumption reduction, investment reductions, cost reductions, and development of new routes with lower investment and manufacturing costs to make our products more competitive. Certainly safety is a major consideration inherent in any part of process development. But, beyond this our process hazards review' program is designed to take a periodic look at each process (particularly the changes) from the technical as well as the practical standpoint to insure that we havein hand the best possible safety technology to run our plants. DUP 0832058 DVI U51CS6 11 Almost without exception when wc conduct a process hazards review, we come up with many new ideas to enhance our safety position. It will always be this way because process development implies change and change may or may not bring with it inherent safety hazards which did not previously exist. Although strong emphasis is placed on safety consideration before any change is made in the plant, the process hazards review program is designed to insure that a second (and eventually a third and fourth, etc.) look is taken periodically to insure that through constant process change to remain competitive we do not overlook any safety consideration. We get this job done through a sub-committee which reports to our Central Safety Committee. They establish the studies to be made each year, insure that the reports of the committees are issued as scheduled and it is the responsibility of line organization to insure that all recommendations are promptly resolved. Usually a Technical Division Superintendent (fourth level of supervision) j chairs the Process Hazard Review Committee for the plant and has administrative responsibility to insure that ou: objectives are met in this area each year. He renders periodic reports on the status of this activity to our Central Safety Committee. Recommendations evolving as a result of process hazard investigations range all the way from minor changes in procedures., to physical plant changes requiring substantial sums of money. Incidentially, we were going to talk a little bit today about the fault-tree approach to process hazard reviews, but I understand this was discussed in your Houston meeting. Mini Hazard Reviews The adjective "mini" has certainly found its way into the American, vocabulary. Obvious 1)', it is the abbreviation of the work "minature" and the word seems to have risen to its height of popularity in this country at least in providing a finite indication of the length of women's skirts as styles changed to a shorter and shorter length. Mini-skirt is now a household word in this country. I would like to touch upon another mini and that is our mini-hazard DUP 0832059 DV! C4516S7 12 review program. As it implies, our mini-hazard review program is a minaturc version of our rather formal process hazard review program as I have previously described. The objectives are the same, but the scope of these reviews are much narrower, designed to zero in on a specific area requiring safety attention, and taking what remedial steps are necessary. The administration of this program is informal in nature and administered by the Division Superintendents (fourth level of supervision). We feel that this activity certainly has its place in our overall safety program. New Supervisory Orientation We feel that it is extremely important to insure that new' supervisory personnel receive an orientation at the top management level on just what their safety responsibilities are as members of supervision. As new members of supervision are mace, the Plant Manager covers this in individual discussions. In these discussions> the safety responsibility of a member of supervision with respect to those he supervises is the major thrust of these discussions. We feel that this activity is beneficial in letting each and every new member of supervision know the sense of priority that the top manage ment level places in safety. Off-Plant Safety No word about a Du Pont safety program would be complete without a word on off-plant safety. In the past decade or so, we have really asserted ourselves in this area with some degree of success. The basic difference between our off-plant safety and on-plant safety is the fact that our measure of supervisory control is, of course, much more effective during working hours. Without boring you with the statistics, our on-plant safety has always been better than our off-plant safety despite improvement. In fact, there is an old saying within Du Pont that you are much safer in a Du Pont plant than you are at home. We have the statistics to prove this beyond any doubt. DVI 14516S8 DUP 0832060 13 Nevertheless, we-continue to assert ourselves toward improvement in off-plant safety. A standing Central Safety sub committee remains active in developing programs for implementation. A good example is a program_we have going now relative to motorcycle safety. A number of our people are motorcycle enthusiasts and in this country at least, statistics (as well as our own plant experience) confirm a high incidence of accidents and serious injuries invoking motorcycles. We are currently sponsoring a seminar on motorcycle safety for interested employees who ride motorcycles. This is just one of many on-going programs we have to enhance our off-plant safety position. One other comes to mind and that is a defensive driving course on automobile safety which each employee on the plant has received. In conclusion, let me say that we are delighted to have you as our guests today and we welcome the opportunity to discuss our plant safety program with you. If there are any questions, I will be happy to try and answer them. I hope you will enjoy the plant tour as well as the rest of our program this morning. < JTG : jb 5-28-74 U P 0832061 U51659 XrjajES 3ue-[2 gjo swaxAa^ p.TBZBH TUTH SaT;A3^[ pjCBZBH SS0OO.1<J uoxqEquaxxo AxosxA.xadng waN suoxqoadsux aoxAaQ aAxqoaqoxd pue sa^ba 3axis's suoxqxpuoo SuxqBxado paepuerjs suoxqoadsux uxdaa>jasnoH suoxqoadsui suoxqxpuoa ajBSun-sqoy ajBsun mBjSo.xa d01S saxxag aoxqoB.xd axes s^oaqQ axo^o qop squoda^ quapxoux Xenusix AqajES oxSBg 0 o 0 0 spenusH SuxqBJtado o NOIIVIKai-mJWI auipdiospa aAxqoruqsuoq AqxxiqBqunoooy ^JJBQ apnqxqqy Suxuxnbaxi Aqxqxqxsuodsa-g qBnpxAxpux Aqx xiqisuodsa'a uoxqBzxuBSao auxq quauia.xxnba^i qop uoxqBxqsxuxmpv puBUOxqoaxcQ xisxaAQ o e a o e o siiiai-sia iviia DUP 0832062 Rvsoosd Aiaavs oisva INVIdt VIHOIOIA j.NOd aa DVl L451690 NUMBER OR TIME LOSING INJURIES PER MILLION HOURS WORKED DU PONT COMPANY 1912 1920 1990 19-1(1 1990 YEAR 19G0 1970 1900 5-8-74 JTG : DV1 U51691 DUP 0832063 3 DUP 0832064 H,' , _ _ ^ -ID "TV^.,S L Z-Zi ""'"err and S30T . r 2 c ~ - s.'. . * ar--v ~ g .- - _----------^ - V r r/.er r- -v----,3*; Full Acid Full Acid Suit S Gcccles Suit holding the hood & Gloves ' ' - - CS |- - " { ! =* -> to.utters Solutions) ' --_-~~g ; Above 2%) i.SOlH"i.Cn T ~~ 1 ;-oq - eric firres trie Oxides :c Acid (Above 2%) c Acid Props eve 2%) without ^iation. va *1 yog Tenia Full Acid Suit.and breathing air Full acid suit holding'hood i breathing air cask. - Rubber Gloves & breaching air Rubber gloves & holding the braarhirc air cask. :-/A V^,-'-----'-r-al V* /n & Production rv\ Fcrerar. Full Acid Acid Suit 's' /n ! | Suit holding hood. ral Gas Oil -bexsn0 yeci.ari.cai or Production Gloves & Gcccles Acns Gloves & Gcccles .... t DUP 0832065 Solution) UO DUP 0832066 . January 29, 1976 TO: ACIDS MECHANICAL AND PRODUCTION SUPERVISION FROM: THERMOCOUPLE MAINTENANCE COMMITTEE D. C. Hopmann - Chairman T. G. Jones W. A. Schurtz In order to insure compliance and understanding of the recommendations of Incident Report No. 63, the following safety procedures have been established for removing a thermo couple (including dial thermometers) from a thermowell. It is suggested that these be included in the area production safety rules and the Mechanical Handbook. 1. Removal of any thermocouple will be considered a first break. Protective equipment requirements will be those set forth in the first break rules. 2. If possible, thermocouples should be removed only with equipment cleared and tagged. Removal of a thermocouple from any equipment in service should be the exception and will require joint approval of the production and mechanical supervisor. 3. Extreme care should be used when removing any thermo couple. No one should be positioned in front of the thermocouple. DCH/dw DUP 0832067 i atMM.: :p cc: All Prod. 6c Mech. Div. Supts. *N i October 31, 1975 TO: J. T. LOWE G. R. EHRMAN D. J. LOGAN FROM: R. F. NORRIS CHAIRMAN, LINE CLEARING COMMITTEE LINE CLEARING PROCEDURE In response to Recommendation 7 of Incident Report No. 43, this committee has reviewed Acids Division practice for clearing lines. Line clearing procedures were found to be adequate with one exception: some materials that are routinely handled (i.e. steam, condensate, Betz 45) were not mentioned in area procedures. Our recommendations are as follows: Definition of Responsibilities Responsibilities are clearly spelled out in S & F 3 (Lock, Tag, and Try). We see no need for further elaboration in area procedures. Level of Supervision Required to Verify Proper Clearup All materials handled in the Acids Division have been listed (see attached table); this list denotes supervisory re quirements for assuring proper clearup for any of the materials handled. Each area should maintain an up-to-date list of this type for all chemicals handled in the area. Maintenance super visors and foremen should maintain a list which includes all these materials. Lists should be reviewed and updated at least once a year. First Break Safeguards The attached table also indicates protective equipment and other safeguards required for first breaks, as well as for repairing leaks on lines which are still in service. This infor mation should be handled as recommended in the previous item. Exceptions to Procedure Any exceptions to the above shall require the joint approval of the area Production and Mechanical supervisors. DUP 0832068 i J. T. LOWE G. R. EKRMAN D. J. LOGAN -2- October 31, 1975 Summary This committee has developed guidelines for handling all chemicals in the division. However, due to the great number of specific situations encountered when clearing lines, our best insurance against unsafe acts remains a thorough safety analysis of each job by the people doing the work. Codes: 1. Level of supervision: 0 - Operator, after advising foreman >f F - Production or Maintenance Foreman 2, Required safety precautions: 1 - Gloves and goggles 2 - Gloves and face shield 3 - Rubber boots 4 - Rain suit jacket 5 - Rain suit pants 6 - Full acid suit, incl. hood 7 - Breathing air 8 - Rope off and caution tag areas below when making break on upper floors RFN:bvk Attachment DUP 0832069 nvi  ~< Service Absorbent Oil Adipic (DRA) Ammonia Betz 45 Betz 419 Boric Acid Brine BTM Butadiene Caustic CDD CDDA CDDK CDDT Chlorine Cobalt Octoate Condensate or Water >60 C Cooling Water Cyclohexane Cyclohexanol Cyclohexanone Dry Solvent Fuel Oil HC1 Hydrogen Lime Natural Gas Nitric Acid (>2%) Nitric Acid (<2%) Nitric-DBA Mixtures Nitric Oxides Area 1 4 11, 5 . 2-4 2-4 13 5 11 11 5 11-14 13-15 13-15 11-12 2-4 1 Level o Supervision Req'd to Verify Proper Clearup 0 0 F 0 0 F 0 F F F F F F F F F All All 1 1-2 1-2 12 5 5 12, 5 5 1,11,15,5 N F 0 F F F F 0 F F 0 F 2-4,15-16,5 F 2-4,15-16,5 F 2-4, 15-16 2-4,15-16,5 F F Req1d` Protective Equipment l' 1 6, 7 1 1 1, 4 1 Entry Suit 1 6, 8 2,3,4,5,8 2,3,4,5,8 2,3,4,5,8 1,3,4,5,8 6, 7 1 2,3,4,5,8 1 1 1 1 1,3,4,5,8 1 6, 8 1 1 1 6,0,8 1, 8 6,2,8 6,7,8 Additional Requirements Remarks * , --* _--. __ --- ... ... ... ----. -- ... * * * -------------- * ---- ... ... -- -- rv a -- DUP 0832070 t 2 Service Area Level of Supervision Req'd to Verify . Proper Clearup Nitrogen NRD-47 NVR 1,11-14,5 16 1, 5 F F F Plant & Inst. Air Sodium Chloride Span-85 Steam UM Versene All 5 1-4, 15 All 11 1, 5 0 0 0 F F 0 Req'd Protective Equipment 1 1,2,4 1, 4 1 1 1 2,3,4,5,8 ,6 8 1 Additional Requirements & Remarks ^Precautions 2,3,4,5,8 req'd if material is normally above 60C. \ **Follow special steaming/flushing procedures. DUP 0832071 p\ v '' 4 DUP 0832072 TO R. F. ULAK w. t. dxgd: QUARTERLY RETORT 1-13-1 April 8, 1974 ' * a.' Area Emergency Drills . The ccrrnittae's (E. J. Yhrvjas, C. E. `Bunn, and V. R. . Bellville) proposal has been accepted. <Their basic proposal is: .- 1. Selection of emergency situations by the foremen v.ith concurrence of the area supervision. 2. Training on four emergency situations by each foreman group during the year. 3. Each foreman v.oulc conduct a drill on one of the sit.ua tions. He v.ould conduct a ' a:c,i on the other three. youId be conducted on cays to avoid excessive inter ruption of daytime activities. 4. A vrit'e-up of each drill or discussion by the foreman vroulcl assist folJow-up by other foramen and the day supervisor. All Production areas are iyjv? involved in the program. DUP 0832073 /? 5 DUP 0832074 ii. - 1 ELECTR1 CAL Grounding 1-14-1 VICTORIA PLANT STANDARD f^ultT ' ' ^ ^ 1/6/69 : i i ... " REVISED 7/72 1 4G | Page 1 of 6 Steam Hoses Grounding of steam hoses is to be of a design comparable to the typical installation shown on Victoria Plant Drawing 57. See S&F Procedure 54 for test frequency. 2. Free Falling Streams Free falling streams of flammable material into the tanks should be avoided by providing a dip tube to near the bottom of the tanks. The dip tube should be bonded electrically to the tank in accordance with Eng. Std. F4G; DE3H-7.6 and 7.11. Metallic equipment not connected to building steel and containing flammable materials should be effectively grounded using 66 AUG or larger copper conductor. Megger readings to ground in no case shall exceed 100 ohms resistance. 3. Drums and Other Containers Drums, sample, buckets, and other portable vessels containing flammable liquid will have grounds according to Standard E3P which will be checked annually by I&E personnel for continuity. Each three months the building Proprietor will visually check these devices for obvious defects. It should be emphasized that despite these inspections it is each employee's individual responsibility to report all damaged safety equipment immediately. A written tickler and record system will be used to detail these inspections. 4. -M----e--t--a--l----L--i--n--e---s-- !i . . Metal lines carrying flammable liquid should be bonded and grounded according to Standard E3P, and these grounds checked annually for continuity by I&E personnel. Any grounding devices for unloading chutes and pipes will be visually inspected onc.e each quarter by the building proprietor in addition to the individual employee's responsibility to report all damaged equipment. A written tickler and record system will be used to detail these inspections. 5. Fault Grounds (Ref. Engineering Dept., Accession Ko. 12592) Electrical equipment frames are required to be grounded to insure that: (a) An insulation failure will quickly operate the fault protection device and open the power supply to the equipment, and (b) A person touching the equipment frame and a nearby conducting surface will not be subjected to dangerous voltages for dangerous lengths of time.! I 5.1 Ground Resistance j The only practical way to evaluate the effectiveness of a ground system is to knew its impedance. From knowledge cf the ratio of resistance tc impedance fur various types of {'.rounding systems, it is possible to determine.- the effective pedantic by measuring its DC resistance. The maximum sualiec DDCC ground resistance has been found to be velativeiy con stant for each sice conduct c"` regard] ess of length cf circuijL,^ar)d given in the fciicuir.;: Lull.-' DUP 0832075 DV! DUP 0832076 1-1 } tr. I VPE I I PIPING IDENTIFICATION OF PIPING SYSTEMS VICTORIA PLANT STANDARD : ISSUED REVISE.0 J.QZ2JLm - ~ `r J i~~i i I. GENERAL 1.1 Positive identification of a piping system content shall be by lettered legend giving the name of the content in full or abbreviated fora. Arrows may be used to indicate the direction of flow. 1.2 Color coding may supplement lettered legends, but it should not stand alone because of limited flexibility and absence of universal understanding. No assumptions as to contents of nine lines shall be rr.ace on color coding alone. 2. LETTERED LEGE1EDS 2.1 Victoria Plant Standard practice is to provide lettered legends on piping as follows: On all header valves where piping to or-from pipe bridges and underground lines leave or enter into a building or area (identifies contents). On all service piping valves which can be used to isolate an area, building or sections thereof (identifies contents and is assigned a number which is shown on a drawing). 0 On all valves that may require operation during an emergency (narked emergency, identifies contents and indicates action necessary). On piping in outside pipe bridges and in pipe lanes inside buildings at locations deemed necessary to positively identify contents of line. In certain cases it may be desirable to label the piping at junction points or points of distribution only, while at other locations the markings may be installed at necessary intervals all along the piping, close to valves and adjacent to change-in-dircctions. DUP 0832077 DVI b451701  p -it iptf sr iftlaifigw-g VP - I PIPING lDENT!F1 CAT 1 CM OF PIPING SYSTEMS * VICTORIA PLANT STANDARD .SSUED }0.73 5G REVISED Page 2 of 3 2.2 Legends are printed on porcelain coated netal tags or fiber glass tags. Tags should be as follows: SERVICE SIZE OF TAG SERVICE PIPING ISOLATION VALVES 8"x8" COLOR OF TAG WHITE EMERGENCY VALVES 10" VIDE 9" HIGH TOP PORTION RED BOTTOM PORTION WHITE COLOR OF LETTERS REO VHITE BLACK HEIGHT OF LETTERS AND NUMBERS 3" EXAMPLE RW 101` 1 1/2" 1" EMERGENCY CAUSTIC SHUT-OFF M oztso dna Dvr 6451702 ! VPE -1 P1P1 KG IDENTIFICATION OF PIPING SYSTEMS VICTORIA PLANT STANDARD ISSUED revised . 10/73 j 5G jpage 3 of 3 3. COLOR COOING '. 3.] The basic color coding of piping systems at Victoria Plant, Is as follows: !| a Air : INSTRUMENT----------- ----Meadow Green (light) PLANT-- -----------------Briney Green (Dark) Fire Protection--------- -------FI re Protection Red 6 Inert Gas----- ------------------- Alert Orange l O Natural Gas---------------------- Clay Tan 6 Piping Most.Normally painted Shale Gray All Outside Service Piping Identified by metal tags Safety Showers-------------------------------- High visibility Yellow striped with Safety Green Water RAW------------- -------------------- Precaution Blue (Dark) SOFT l DEMINERALIZED---Falls Blue (Light) WELL....................................... Black 3.2 Miscellaneous Painting The following should be painted with high heat resistant aluminum for weather protection: Control Valves Steam and Condensate Piping not Insulated DUP 0832079 DVI 1451703 DUP 0832080 THOMAS C. McNUTT February 17, 1976 TO: FROM: ALL SUPERVISION - LIST "A" S & F DIVISION MARKING OPERATING RANGES ON GAUGES We recommend the following procedure be used for identifying operating ranges on all gauges: 1. All gauges will be divided into two categories: a. those covered by SOC's, b. all others. 2. Operating ranges for either category can be indi cated in several ways; arrows, triangles, or other symbols on gaxige face; shaded area on gauge face; range on embossing tape-on gauge "glass" or on panel board by gauge. 3. With any of these ways the color green (green ar rows, green embossing tape, etc.) will be used to indicate that the operating range given is covered by an SOC, and the color blue will be used on "all other" gauges. DUP 0832081 D VI W-^I 8 DUP 0832082 falTHSt' SAFETY MEETING TOPICS H 3 co m -CDi 3 r--l Du <fa3 4c-o) CO i 14 CO OV CM a< Ow od r4 fa cd l--l fcan a) DS aj C a ' ctf 14 *--t a. m tw *H 4-J 14 <c CO w cc w d0) I fCaO fca fMca l fa COOJ H f>a-, fa<u ct) c/o co J04) X fCaO 53c_( fda w4*-1 Ca;j L, r-i __ X-/ u ui <L) C/3 r^ o (u ci: f--^1 f) o r--i od 14 do CL OJ c rH i- 14 CD CJ 4-J <CO Cl -- - o fa " .-CfOa ac "0 0d vfaO1 oocoo too 00 in to ca od r4 fa C>aO4i fa O L*T 9 DUP 0832084 csT*iu>imoo? E. !. du Pont de Nemours & Company titcoftroMArto Zr-^/h^2--- -/oP/y//iA//y /V TO: GENERAL managers/department heads OSH COORDINATORS PLANT MANAGERS WAREHOUSE MANAGERS LABORATORY DIRECTORS SAFETY SUPERVISORS NON-COMPANY EMPLOYEES ON DU PONT LOCATIONS In October 1973 Roy Richardson, a non-Conpany truck driver. suf^evz-H terribly disfiguring injuries when he was*sprayed with sulfuric a cid while delivering this product to our Lcuviers, Colorado-, plant, } \ and his wife subsequently instituted suit against Du Pent to reco ver dar.ages. This case has just been settled at substantial cost to the Company. Since many deliveries are rado to our plants every day, and since what happened in this accident could have occurred at*many Du Pont plants, you should be aware of the facts and take every" possible precaution to avoid injuries from this type cf situation in the future. In May of 1973, a railroad bridge was washed out, and rail deliveries of sulfuric acid to the Louviers plant were no longer possible, Beginning in August of 1973, tank*true k deliveries were made by American Bulk Transport (ABT) , a comma n carrier. Initially plant personnel familiariaed the ABT drivers with cur sulfuric acid unloading area and instructed them in proper unloading procedures, Subsequently, plant, personnel provided little unloading supervision, although they provviiddeed assistance upon request. Because ABT's deliveries were irre: ular and the p 1 an t experienced difficulty in maintaining an ad( qua to supply of a cid, ABT was permitted to make deliveries during off nours One Saatc in R 0 v R i c h a r d. s 0 n new ART employee, arrived at the 11- ns rusen DUP 0832085 2 handled sulfuric acid or any such hazardous material before, and he had received absolutely no instruction from his employer concerning the proper method of unloading the acid or the proper safety procedures to be observed when handling it. ABT had not furnished him any safety equipment. Upon reaching the administration building, Mr. Richardson informed two wage roll employees that he had never been on our plant and that he had never unloaded sulfuric acid. Hr requested assistance in unloading. The employees were unfamiliar with acid unloading pro cedures, and they told Mr. Richardson that no one was present who could assist him. No supervisory personnel were on the plant. Our employees showed Mr. Ricnardson the acid unloading area and indicated the pipe connection to the sulfuric acid tank. Mr. Richardson, working alone,, hooked up his truck to our acid receiving line and pressurized the truck. He wore no protective ^ equipment and was unaware of the nearby safety shower. Later, believing the truck was empty, he shut off the air and disconnected.the acid unloading line. A quantity of acid came cut of the line and covered the front part of his body. lie wandered about the plant for some time screaming for help, but no one heard him. Finally, a salvage contractor working on the plant found him. As a result of this accident, Mr. Richardson suffered very severe facial injuries, including permanent 'blindness. The case was con cluded with a very costly settlement. This accident was certainly preventable. It is urged that all situations in which nonemployees perform services for us or enter our sites for other reasons be rc-examined. In reviewing procedures and practices, a number of questions may arise. These questions should be referred to your management or the Safety and Fire Protection Division in Wilmington. The following guidelines should resolve most, questions! 1. Be familiar with the materials received or shipped (particularly those received or shipped in bulk or large quantities) and services performed on the site by non-Du Pont personnel. This includes the effects of personal exposure to splashes, spills, or vapors and the appropriate countermeasures and treatment for such exposures. 2. Only safety practices acceptable to Du Pont should be permitted. liven practices generally followed in an industry , if r ccrrxi i nade -.ante , shew Id not be pe r: i' : . DUP 0832086 Uv 3 3. Establish procedures to insure that all work done by non-Company employees is authorized at the time by proper Company personnel. In case of handling bulk chemicals, this should include a thorough review of procedures to be used. Knowledgeable personnel should be present in order to give instruction or offer service and advice if problems are encountered. 4. Post adequate identification of hazards, procedures and safety facilities at locations where hazardous materials are handled in bulk. 5. Wherever practicable, unloading of flammable and corrosive materials should be accomplished by pumping. Whether unloading by gas pressure or by pumping, the safety precautions set forth in plant or industry standards, such as the Manufacturing Chemists Association Chemical Safety Data Sheets, should be followed. Also, where gas pressure is used for unloading, facilities for safely shutting off the pressurizing supply and venting the system are recommended. j It is regrettable that such a serious injury occurred. Our broader responsibilities to "outsiders" must be more clearly understood and accepted. Proper follow-up can essentially eliminate this type of accident. SAFETY AND FIRE PROTECTION DIVISION Ned K. Walters, Manager DGW:j ag DUP 0832087 : Date: n-v-ai DDDA CONTRACT PERSONNEL SAFETY TOLEDO SCALE I. SAFETY 1. The following personal wearing apparal is required: a. Hard Hat b. Safety Glasses *c. Coverall goggles on person 2. All visitors should contact production supervision of the area to determine its current safety status, and what, if any, precautions should be taken. 3. Inform the Central Control Room Operator .when entering and leaving the area and sign in and out on that area's personnel accounting sheet. 4. It is required that all plant injuries br reported to Medical Division. 5. If the building evacuation alarm is sounded (2 minute* horn blast') all personnel should immediately leave thearea and report to the Central Control Room. 6. Should the fire or gas escape alarm (short blast'* sound, all personnel should call (via P.A. phone") or report directly to the Central Control Room. __ _ II. CHEMICAL EXPOSURE 1. DDDA Dust - Breathing of the dust should be avoided. It may cause chaffing of the skin and irritation of the eyes and nostrils. DDDA dust is white in color found in the warehouse area. 2. Nitrous Oxide Fumes - Are highly toxic - anyone who suspects that he has been exposed to concentrations of nitrous fumes should report immediately to plant hospital or first aid. Supervision should be notified as soon as possible. Nitrous oxide fumes are brownish in color and have a strong smell. Not likely to be encountered but the possibility exists. 3. Nitric Acid - Nitric acid is a very strong oxidizing agent. In contact with the skin, mucous membranes or respiratory system, the acid penetrates the tissue_ causing destruction proportional to the concentration of the solution. In addition, there is a time factor, and concentrated acid, even washed off, immediately will cause minor burns. Not likely to be encountered but possibility exists. DUP 0832088 4 TO: NRD-47 PERSONNEL FROM: T. C. McNUTT T. N. MARTIN M. G. HIGGINS B. THORNBRUGH cc: 1) H. W. Shahan 2) D. C. Hopmann 1) D. J. Logan 2) S. H. Markette 3) D. Sandborg 1) J. T. Lowe 2) T. J. Anderson Safety Guidebook i* September 20, 1976 CONTRACTOR WORK SAFETY HYDROBLASTING Due to the injury to a vendor's employee earlier this year and the high potential of injury that exists to Du Pont employees, it is time we reconsider our safety philosophy during hydroblasting operations. Browning-Ferris Industries (Cesco) does essentially all of our hydroblasting in NRD-47. The water pressure at the hydro blast nozzles can run as high as 10 M psig. At this pressure the water spray from the nozzle can cut through a 4"x4" board in approximately 2 seconds. The damage it could do to an arm or leg is just as incredible. The only saving grace is that the energy dissipates rapidly and that there is little danger farther than 12"-18" from the nozzle. A second hazard involved with a hydroblasting operation is the possibility of a hose rupturing. Our vendors do not inspect or test their hoses in the same manner or frequency we would. Conse quently, the condition of their hoses is questionable at best. Eventhough the spray of water from a ruptured hose may not be sufficient or of long enough duration to cause direct harm, the whip ping action of the hose could. DUP 0832089 nwi * r It is for these reasons the following safety guide lines have been adopted. They should be followed for all hydro blasting jobs in the NRD-47/Waste Treatment areas: Barricade area (via safety rope) within 10 feet of all high pressure hydroblasting equipment: truck, pumps, hoses, nozzle, and equipment to be hydroblasted. Signs have been ordered which should be used to warn of hydroblasting operation. Area personnel should not enter barricaded area during hydroblasting operation. * Tie down high pressure hoses every 5-10 feet where practical to prevent hose from whipping excessively should a rupture occur. A Work Permit and Contractor Safety Checklist (attached) should continue to be filled out to cover every hydro blasting job. TCM/TNM/MGH/BT: dm Attachment DUP 0832090 ACIDS DIVISION SAFETY ORIENTATION CHECKLIST FOR OUTSIDE CONTRACTORS DATE: PRODUCTION OR MECHANICAL SUPERVISION, WHICHEVER REQUESTS THE CONTRACT GROUP, IS RESPONSIBLE FOR CONDUCTING THE FOLLOWING SAFETY ORIENTATION: WORK DESCRIPTION: 1. AREA EVACUATION ALARM AND PROPER RESPONSE. PERSONNEL ACCOUNTING PROCEDURE-WHOM AND WHERE TO REPORT TO IN CASE 2. OF FIRE, EXPLOSION OR GAS RELEASE.___________________________________________ 3. CURRENT WIND DIRECTION '* 4. LOCATION OF NEAREST SAFETY SHOWER. 5. FAMILIAR WITH PLANT WORK PERMITS. 6. SPECIFIC AREA SAFETY RULES. 7. AREAS WHERE EAR PROTECTION IS REQUIRED. 8. SAFETY ROPE BARRICADE. 9. KNOWLEDGE OF WASTE DISPOSAL SYSTEMS AND DETAIL FOLLOW-UP. 10, CHEMICAL COMPATIBILITY, CORROSIVE PROPERTIES. PRESSURE RELIEF REQUIREMENTS. 11. CLARIFY EXACT RESPONSIBILITY FOR OPERATION OF AREA VALVES OR EQUIPMENT. 12. THERMAL BURNS FROM EQUIPMENT OR PROCESS MATERIALS (HOT OR COLD) AC PLANT CHEMICAL HAZARDS 11. nano2 * k tf\ il Adipic ' 23. Acia 1. BD 2. TBC 6. CDD 7. VCH 12. UREA I3.H3BO3 18. DBW 19. NVR 24. EAW DCC 25. Aqueous 3. H2 8. COD 14. Catalysts 20. 26. Other . 4. NAOH 9. NH3 15. HNO3 21. Cvane 5. CDDT 10. CH4 16. NRD-47 22.&S1* RECOMMENDED SAFETY EQUIPMENT 1. Coveralls 2. Boots 5. Hard Hat 6. Acid Suit Pants 9. Breathing Air 10. Safety Glasses 3. Goggles 4. Gloves 7. Acid Suit Hood 8. Acid Suit Jacket 11. Other Special Tools RECOMMENDED SAFETY CHECKS 1. Acid Suit Condition | 3-Breathing Air Leak Test 2. Acid Suit Leak Test ! 4. Other Safetv Equip. DDITIONAL INSTRUCTIONS ;| " CO. IAN PERFORMING ORIENTATION SIGNATURE^ INTRACT OR VINI H >R fPR LM AN SIGNATURE';. -I l'i >\ m '\\! I \^S|( \| ;; t; i Vi \\| j, iij .1. :! ! I C . :!> TO Ai<LA 'l Pi \< V l>OK -- DV\ ------- - - - - YELLOW COPY TO CONTRACT TORT VAN roCWoO iiaiiafea .sixifes. 10 DUP 0832092 TO: G. R. EHRMAN .FROM: D. C. HOPMANN cc: W.' A. Schurtz L. F. Getz J. W. McDonald J. W. Board January 2, 1974 DBW DUMPSTER HAULING A meeting was held on December 18 to discuss and resolve recent problems encountered in DBW dumpster hauling. Specifically, this involved low or flat tire on the truck with a subsequent shifting of the dumpster after it was picked up. Those attending the meeting were Lionel Getz, John Board, Red McDonald, and myself. The following items were resolved at the meeting: j 1. Existing dumpster trucks(V-21 and V-22) have adequate capacity to safely handle full DBW dumpsters. 2. Tire pressure on the trucks should be checked with a gauge each time before picking up a dumpster. 3. There is little hazard of a loaded DBW dumpster (see attache shifting sufficiently to present a hazard in control ling the truck while it is moving. The lifting arms hold a'loaded dumpster in place, essentially allowing no sideways movement. 4. DBW dumpsters should be hauled on days as much as possible. 5. The possibility of modifying the existing DBW tank or using another storage tank to allow sufficient holdup of a full day's DBW' production should be investigated. This will allow all hauling to be done cn days. 6. The feasibility of piping DBW oil to a waste pit should be investigated co eliminate dumpster hauling and increase productivity. DUP 0832093 I ... :- _.--S --i .Mmm -2- The following pertinent facts were brought out to support the above: 1. Each dumpster truck (V-21 and V-22) has a capacity of 7500 lbs. net with an approved dumpster (approxi mately 1500 lbs). Our DBW dumpsters weigh 3100 lbs. with ca. 5900 lbs. net DBW in a full dumpster. 2. The truck tires at 75 psig inflation each have a rating of 7090 lbs. Vehicle weights are 14,000 lbs. for V-21 and 14,540 lbs. for V-22. DCH/dw Attachment DUP 0832094 , 4- < > t cc: "J^P^=1iamnvondsD. C. Ilopmann S'JO J4=W=r=Do err- December 19, 1974 TO : ACIDS SHIFT MECHANICS FROM: RED MCDONALD V 21 - has lead in front bumper, 4 good tires on rear and a new hydraulic system - should be able to handle DBW dumpster. V 22 - has no ballast in front. Tires are fair - new hydraulic system and according to transportation drivers is ok for DBW dumpster. e Rear tires on both trucks should be checked with a pressure gauge to 70 psi. o Lighting for pit area are 50% complete - power, etc. has been run. Waiting on fixtures. Hie Construction truck is not adequate for DBW dumpster and sh/nild NOT BE USED. Please keep me informed of problems you incur. JWMcD:dbp DUP 0832095 DV } TO: NRD-47 PERSONNEL FROM: T. C. McNUTT January 29, 1976 NRD-47 WASTE DISPOSAL Site Designation 3 6-b 6-d 8 Item Copper Shot Cans 2 Paper Dumpster NRD-47 Sxamp Material. Scrap NRDn-J DBW Oil Dumpsters Empty Lever Packs ^See S & F 17 for maps. 2 Keep polyethylene bags out of this pit. (Discard polyethylene liners into a separate container and leave next to the open-topped dumpster on the south side of the warehouse.) 3 For ease of handling by transportation this material should be collected in metal drums rather than lever packs. TCM/dw DV! * ` 4 , DUP 0832096 ( ACIDS WASTE PIT NUMBERS AInT) WHAT IS DUMPED IN EACH PIT NO. 6A * PIT NO. 6B PIT NO. 6C PIT NO. 6D OPERATION 11 & 12 TRIMER WASTE WASTE TREATMENT FILTER SLUDGE OPERATION 13 & 14 WASTE ORGANICS POD FEED FILTERS OPERATION 15 & 16 DEW * PIT NO. 6A WILL BE USED FOR DISPOSAL OF TRIMER AREA WASTE THAT MAY CONTAIN TRACES OF UM ANT) BTM CATALYST. THIS WASTES WILL BE COVERED WITH A LAYER OF DIRT AT THE TIME THEY DUMP INTO THE PIT, TO PREVENT THE POSSIBILITY OF A PIT FIRE FROM THIS SOURCE. DUP 0832097 i- < - ~ .a * -55 REV (.12 DON'T SAY IT--WRITE IT TO______ I\n?r)-l7 Production Vor-ompn AT________________________________________ from Tom McNutt___________________ DATE 2/25/?? WASTE DISPOSAL ACCOUNTING To help the Engineering Department comply with our State Permit requirements, we need to start keeping better records of our Waste disposal (dumpsters, drums, vacuum trucks, etc.). When the following waste material is being disposed of, the attached "Waste Transfer Ticket" should be filled out (whether it's j on shift or on days). The white copy should be sent to the Engineering Department, the pink copy given to the truck driver, and the yellow copy laid on my desk. * DBW dumpsters Sludge dumpsters Trash dumpsters Scrap NRD in drums 1 Rather than filling out a "Waste Transfer Ticket" each time we use the vacuum, let's account for its use internally. Keep' a copy of the attached sheet in the vacuum truck at all times. Each time the truck is used, fill out the appropriate blanks. When the sheet is full, lay it on my desk and I will forward it to the Engineering Department. When we completely clean the DBW Pit, fill out one "waste Transfer Ticket" and show how many dumpsters, dump trucks, and/or vacuum trucks were used. DUP 0832098 SECURITY IS AN INDIVIDUAL RESPONSIBILITY i D\ 'i DUP 0832099 - L? " 4 f * ** i ca < Lt VACUUM TRUCK WASTE DISPOSAL USAGE SHIFT 12-8 8-4 4-12 NO. LOADS NEUT. P IT M IX . P IT SET. P IT OTHER rmflii-iiii' lt-4 i H1I P VO P vo O2 K SOLAR OTHER bBtEMfej- f-a "MB'imw- wiisnM;4Wit.|\>-.a^aiHatitwta<<llwwiiilt'gww msmmam r 11 DUP 0832100  3igggL- lir-fl jSpfSiliV^'S OPERATION 16 FORK TRUCK STABILITY Stability calculations per Du Pont Engineering Standard VIA were made for the Yale Model MR30 electric fork truck to be used in Operation 16. This preventive step was taken for two reasons: ` Size and weight of the battery and counter balance are different than the truck design specifies. ' All counterbalanced-type lift trucks should be rated in accordance with Standard VIA to determine if limitations should be placed on manufacturers' ratings. The maximum load and lift height that will be required of the truck are 2100 lb and 8 ft, 9 in, respectively. Attached are calculations in which a load of 2100 lb was used to determine the maximum stable lift height, which was found to be 9 ft, 11 in. Therefore, the truck is adequate for its intended use, but is not stable at Yale's 3000 lb, 13 ft rating. The truck will he plainly marked to show the 2100 lb .. load limit, and stops will be installed to limit the lift height to 9 ft, 11 in-. These measures will prevent unstable truck operation. *. / nno DUP 0832101 i uc.inm mm*, u'jj coMnnArioN :'.iiirr ./^Jr.iii t r tin t >M t rt Sttjnv f/o Fc-givL L i r"T* - .*Tr.oc.t..__'STmiiutv .jCf^aou^TtaG^,,,,,,, - . ________ __________________________ _ C nwrim w Dat a, S^AUfT M "bO & T rifLEA IL'hTT TcualC. Catied -CapaC-itv* TjOoO^ ow A " LoAO Maximum Uuct - \"o` C<t/jTcc. .Hast. > Limits ! Fcsw\eo , fo0 oack. Calc UUATICHi Per ; Pu Posl *r *5 r O VIA DUP 0832102 b- o- V 4VT. CO - *r. V DV' bi-S i#^***!^j !;& -jiUM'i ^il--WBii#tthWr;< 1 i*1 - 4^'mg.;;r.jrr- - 1 - -ftfiww i 4/z. Fb, rK L if* True K S`K\bi 1 i`{"i ` J CT i cw W-4 icr.r R V. O. to- JO - 63 Jocwi'c rcTabi lift' av'd rorujj.'rd w^ur-,*4* be 7 Td-o'T'ie'e* rI- ,*A iIna,c'' aT1. I'iu ^ 8 iA>: vi! r, : ,Tbtr hi! 1.1, 1 > -- /8<L -',"- z.joo r ^ -p/nd : \ fY* / C. r i ( co^dl -I lor in v/nV\ mac4 -pilfed IO Lsc Fw*.y TiNiwj Tn iyv>--v<' cka^ez dI merislaves cc <J 4 a <d b- d/ a1 = d' - <58 27, o,- /' (X s:: u vw n c* a 1'ff hcrd.'f' of / 2. From S4d. VIA, p. d ^ rn ax = d-X" (\V4 L)(b - d^ + L /*l bL d^) VJ X~ L rz. hi -- ii1- n" --r.COuwp'i iovi *for d e 4 c v mi ^ d d i S VA. I 1 <d F<0 r y.v a r J T4 ^ f f 11 4 ij - (sc //'- //" > J I \ *)* i y\ Q - w\ c- / J co>d>4ioY\ s vj'td h rntf-cf 41 i i'ed cd - 3d, d* * d u u/Kcn H = II - II 2 -forward DUP 0832103 "From S4d. VI A} p. 4> } L- WlAX " W( io A1 - Xs) 2- -f /O i(7 2.725" y_y/-- DVI 6451722 /c'CVV/C-2 dTTi i 4 - , J / ;C-C / r ,'{ I1 / i T . ' -5 t\ ", 7'.' I / iVn i T i Wi cor side ca f i o o , j H-ICO n`"C O'-ll" tI ... <u/ vJL. Sw ' fJ 2 ^ Ac/ a ______ cc: J. W. Board L. R. Gentry R. L. Bednorz NRD Foremen May 20, 1977 TO: B. W. HARDY S. H. MARKETTE C. McNUTT B. THORNBRUGH. ELECTRIC FORK LIFT INSPECTIONS As a result of an incident involving one of the electric fork lifts in the Operation 16 Warehouse in March, a recommendation was made to perform periodic preventive maintenance on them. This letter is in response to that recommendation. 1976, Attachment 1 is checked and filled out once per shift by Production. Attachment 2 will be initiated once per month by Production. It will be routed in turn through Maintenance and I & E. Their respective work will be performed, the checksheet filled out, and returned to Production for filing. Once per year, Attachment 2 will be sent to Shops and Services for an annual check of the fork lifts. DUP 0832104 TCM/BT:dm Attachments ' Viw-r r TRUCK NO . OPERATOR N O . SHIFT DATE * iH ~~X~ CM 4<--. i CM * i-1 * CM * *H * CM * rH * CM * rH * CM * rH * CM * rH * CM * rH * CM * rH * CM *i--{ swi rT i-- isn MD3H3 A133VS >Onai aOd DUIID313 SPEED C O N T R O L Smooth Spaed Change All Speed Ranges Work TILT Smooth Thru Full Range LIFT Smooth Thru Full Range OVERHEAD GUARD e No Broken or Loose Parts CO ND. OF FORKS e No Broken Welds Forks Are Level Forks Properly Secured To Lift Mechanism STEERING No More Than Vi Turn Play HORN BRAKES Will Stop Within 16 Ft. Fully Loaded BATTERY WATER SPECIFIC GRAVITY If The Above Requirements Are Not Met The Truck W ill Not Be Operated Until Corrected. * 1 = 6 a .m . to 6 p .m . s h ift 2 = 6 p .m . to 6 a .m . s h ift S0LZC80 dflQ QT-0 1 C ondition/R em arks 60 r3 o Z 4-1 nO _t> ua) <4H4 3 4-1 4-1 3 i-4 o 2 3 3C4 a. m to 3 z bo OHC SO o M Page number fro m Y ale In s tru c tio n s and P a rts M anual X -ra y once per year 901ZC90 dna 1 ELECTRIC FORK LIF T S _ aj i-l AJ Ca3A. Pi crA 3 2 re4 3 2 c CO 2 w AJ vS M *ar4 CO 2 CQ AJ 3cHd 2 aj eH CO X Cd H AJ *crA 2cd AJ cH 2cd Cd IH AJ cH cd 2 'C3r>V3a/A04 * zo 2 4<-10 mm r-A VO voOo Jr--^*i irn*^ CoO O04O r>. 00 cn o\ Oinv ao\ ai N 4-1 6s U 4-1 43-1 -Mu Ofi 43-1 ZU CII T6J ZO SOWS u os hi o' E-i hi os' H i--i cs ro <f a6cd)0 (0 )04) 54 4vCS-t V>H4 ACJQ AcoHJ 3JicCw3-dJl AHJ 3c 0>H) Ou r--CH3A "C33H hJ r-C4d O^r-o>4> TJ e(u0 to 41cJo1 46cxSo J1scSd1 CO 23 C>Q4 Ci4Q 4C3c5SQ-d. )4 o aj o X Q3>!H-t a -a CCO 36cd0 r4--J1 *WC bae3. r-A *H t-4 H r*"A 4hc-4n1- oM Caj 3O OO 60 rc4 CAaa/3Jji t-rOAJ 13c34d 3 33CH4 aj ro"3A 3 3 2 AJ u33 CH 36w0 a, 3 O>v rHA--HJA r--X3A Cras/A3. 3uAc53>0dJ4v CQ Sr35-AH4 **CQ 3 1O4 U-4 1 1 i afcsasttfe; l s+ ccl: R. L. Bednorz Safety Guidebook ("see. 1C DOIV'T SAY IT--WRITE IT Tn Op. 1S-I6 Production Fnrpmpn AT * FROM______ Tom McNutt DATE FORK LIFT OPERATION In the recent past, we have had many mechanical and electrical problems with our forklifts^ in the Warehouse. Many of the electrical problems could be a direct result of operating the forklift in a discharged condition. The specific gravity of the battery water should be checked at least once per shift. Attached is some general information concerning the specific gravity. The following general rules should be adhered to: The fork lift should not be operated when the specific gravity of the battery water is less than 1.140. The battery should not be recharged if the specific gravity of the battery water is greater than 1.230. Due to the dilute sulfuric acid in the battery and since gases are evolved (and pressure can be built up inside the battery), GLOVES AND GOGGLES are considered minimum protective equipment when checking specific gravity of the battery water. DUP 0832107 I1 SECURITY IS AN INDIVIDUAL RESPONSIBILITY F ig u re 3 B ( A ia a m b le d Slyvmr-Clad C e ll Top) _________________ | K) M M M m mm M <C o> w i MN MN MO =2S VNi 0N* VS N N --N >-J 1 I I I +++i K) >0 Ok U o u O <0 M Os 0e0 51 A o 2. bb ft M 3 IA fns3t ii. IP'S* Sc O Oft m o2 'r?" _2 s S xa 33 oi C . B a a ft A ;55e^o>J:#ft.2U^ .3o1A1 s* " < - i s 2 2 5 r1? * 5 < C m ft ^ 3 3 * S__Msft t<fttH<ft ^ " 3 ai-gS* * " e ^ s_3s.w o!;Jh # (i SJ -x |- S' fS-O 3--n s_ -34"T22. _ S'iSn=. o. -r -25-n_: 2 n& o0S'--S5-So2. so 2.--J2J .3o-^-S?. ? * o U^* s.f E--o c 2 25- s ss>< 3ft. 0 : .no.. c ft Z ft ft 2 050 < 2 "O OH Z 2 ?oi I2ft_S Tt ** a-- C,u,,s.< o-_>*2"o?I Aas2J -1 5" n3^ 5 e ft 5 2. o 5' 2 O tun iiAaTr 53rOfQt 55*' m cC Sft* Q> 2^ .M^ -rT 3 m3ftm SAs=f.t.Tr -3ftI 2S>.&5:5m5 ^SI'T' ----* --> fEt 3ffHtt"-_S=o3,r 3 3 o* gn ~3 O'? 2o = 1o-Se !3.-jo; o o 2 s. 2 S3af|<Sl.2.Sil<5 o' 2 a8 2. S| *' <' * - 2Z <v< ;S 2. E. 2. 2 S:2."-&o o 0 - r ii ^ 5 slai?!.'" " - 2. 2- 3 5 s- <.-< g " - o S"80 8 " 5 S *^ S-S - I B. 3 ><T3 ^ S 2X 4-?>SSr22n,,*2. ?y * ; --5 22 -- " 2 o 2. 0 ? & -Q m n 5 Q- S' ? Cl 20805a, as5in!i:f5 ft 3n ST" < 5- 2 _ l.*S 'Js 2M * * * 2 o. * n -575-2 3 o a ______ a* o AST Ao! *r s* Aft Aft_--2tt_-H5> e 3 2-- --^ *^ O3O 3- II. ST 5- O " "2 2 " S' o iJ'O S o'- o sJrs |sii killq. ft 2* a* C ^JL o3 ft _sr -- 3 -fi ? - 2 Si.5 00 O <70 3 3* 3' S' S' <5 o.s.2 ?<s'|'s -- i! o gj 1 CL ~ " ft ft ow 5 ^ Q. 33 an -g I'S 3 ii.5s-iat 0ST O ft -- a I r o 3* rt D* o~ CT r* ^ ? 5 3 ST a 2 -- S* ft T3 0 *3 a. a 3?-.Q*ft r. 2--Oft* ^ ft 2^3 -- o a0a3.. Sa*"2 o"3 x ^ bj Q* 5 2. 2t l;?'5-2. 3Sft'2C 3ft _ B a < 2 3 3 2. 3 CU ft 0 H3*'S9. ft < ^A 3.00 0O Q. 1" * n ?-< --0 ar 30 -g-S-5 2, r.SS'5- 3 , cr 3 S. ft -r. a = o a ft " *t3 ^ OST^ CB1 03 O n * Q. M _ r. 2.a. -- &oX i ft ft ST S' S ? 5' 8. ts/t =t/t ;1 o c o o 00 co to o 00 'J n. V $mA&: r-i-f-wtwn-- ^fiCTHf ' irfty !" 'I1, '-i~ - 11 * ** ""yRTVl ^ i: g S3 ^rs t-^.xS: 52Sg 30 &!? *! j? 03 O -ft O o5*ic*so >n*^.|-; 3 tn a; o^x ^ a: >j z; d ci >- f>5 d 5 Qs > "n 5 > c* >- ci *. *i; *n 55 X **> ft23: hi ft) S 3-gr =O; S'5. n 2, H S--B "--* (ft f*t" <=r o --o=! * * 3 O-- qn 003=00* i2Coj*T..03510.2-3353 -- ss 3 3 3^^ v* ssr o 3 H3- S S c w _. 320n--.^-30--09--=31 o0-- "2. p. IT o S. s 3 , 3**ft 3f> fi 3 o3"-"= 030 S'3 3 --.*_. 2. <` " n' <* 1" o-o O -C O--> *fit 0m.0f0t AL2 IJiS -- ft < '-e e=<sSS*S?-"S*Z2 Z | ix 5` S' ^ C S - --s 0 3 x2 "D " 3 3 ssf y 2S. 3 n O -- . ao >c3-- o ---- ' "H. =r o. 5' fr a 3 3o?J2 M"w"> _. _Q.5- ow s: 2 3 --3 a G o 2" 3 * a o* S I 3- = 1 ffls 5` 5* ^ ^ S* ^ ^2; 3*^ 0 00 S3T qC. ?rt 5J 3, 5 3 Q.*T3 Si O 0 0-0 2. O. n o 09 ^ "n2 ms w HS_ ' sr 9: 3 sO" 3Mar> ?! 11. a. " 3* O 00 fr o _CO 21 Iff 0f-0a=3 so S' ^--30.. ~Soa-. o'3 -^ 3.^' o. c n .2 3i-g-5?3?0 7.r0S0 ort 5= 3^ !J?? ^n " - ? = 3-1 o r: c 3*oo a_ 3 fiot*Jf3t S-- fBt W> % ?==0 3 n w* nr fnt 0ft f* = 2 cr a O 1 aS "* sO.-: - s i3 c s.- 3^ f2t.<A3 9 Of ^3 Ss<* (ft A * ^ ft* - 3w-21#-. 3>S I n* n--2Q0SS-<s'-=oR.r-5n"^2'lPo53o9 323ag0sOS0.' .. 00 3` . S -09 a00 tS'ffffg- M3 !<g f |-o ' a.3O _ --* o ` 030 <! -- 2 ergS sa S. --d3 33 -r <* jr* o <* sr Hi!-a o sr 33 <s 3-5 ?3 o* = = -09 3 ^ * n ST S- a-'^- 3^ 09 . T" r- 2! a. o o O O. 5 3 2,1-2. g * Z 2 sr -- ~ < 3 *"n s23.3=*A<?23 8s5C; "3foot 8n53?; ^>0 =3'2.<? 8 3 ? ? ">i"2. o 5- 2 x- 65` 2 = " 3 << ^Jlli r.I'Sr >V<. a3rTt _2, nn n 3 *ft 3* 3-0 2 s r% 3jj 2. -ft 2 g o* 0=0f0t><nQ .SoC*-3O3_W^_3' #o2g ^< o3.*5o/1 oX -o ^ s* c cr * isVif * B <> a M 3rSo a. s- n *r _ o 0-1 22. 3o a^l 3 2- 3. y X 5* ? 00 00 3--*. an. 7o "r * s? -- 3 5 =f = 5~ 8 | o ft o fn'S o3 sr 5 o 3 -. S* cr-< 32.0. -- 3 < q2 a- i? ? S n 9"-- <t = 25 3 v 30 ii 00 s oo O Sb o.^< S. 2.^ a"g Is 5-as -- o ^5 ST 55?. SnT Mcl fftt > n *O M5. Oo 3lO* c(ft jrS.3 ^<> Xft ft ---t on-- _ 3 R --^ft ^ft jj* 5,v^ " o- S o o-Ss * mq2o n2. 3=--* --3- ^2o 3-- St <> 3 0 Ofot -- X* ~ar O< <* o 2. o3 `22.3* 2- -^<5. 3- 3 -- sr W f> 3" O fmt n-ft 52* Art -- O3 2<. 3rtj 3 2.0^- < -- " O `''i I -- 1 3* 3 ^ nn 3-- <* 0.3 J - _ 3 O ? <% - a o tj n a. M rt o' =* <* 0 sr Mi 2 *3 "-Srt sO..-s <m ~ a ^ .o S've'5'w2518 s-c^ 3 w =5. 3= n o -1 a <*0^2 O (ft y ? 5?g 3 5*5 3 ?a < ft 00 2 --< Q.v< 5-S.Va. "r--- W> A m 99 o-sr-.q oS . 3.5: 5S ==c .52--T-oe S'- 3 3 n 3 n < ft ui3 s r. fgftt>rAa* 81 s5ft. ?_O --fftt o ft oo . =a0f0t NO o3* Q3T 5*cs 2s"8 ^^ --3^ 3 = n - 309 o* X<>_ f Cl ^ ! 3= o *J. *; 2 5oll; cl a.- 3 i O =. a H ' ^ 'Cr ,T^ *--- 2tft:: -<7 "O2 Irt' 3^ ^o 2-. O-1 3<* B ft 3 3 ft --. 8* Sfe f S-5'o c a* g<q3 <% 33<=a qn smr a--. 2 o S-o2* J(Ai ' *3 o Z ao~o = 5- TM 0 ~a n d. "CB>*l on OXX 3rXt Tf_Xt1* "3^o 0 o. : -^3r"J e SPECIFIC GRAVITY DUP 0832109 ; ggBT4M^tBi . 0-01 O aso-:.OS=e*T1-o2vo<. r--2: 2. 2- n 3 o I. 3m o 9O o99O 3 3* r* 3 Q. S STOO g'S'g I io3'-OO 3 G 3 o OoO 2? VI E O a 2. S' = 3J 3" |3 fs-Sa a S' VI O. 5O C3 --o a -n * - "8 r<t 2Q f f. oO i g-s ii '-< ^ 7 3 3 o-- 3 oa 2 o er" g g o <* rO> cvi no- - a. . 2 v> 2 o-o ~o 3 ---p 3 " S S i;so| fMl IS.B VI l Slf S3.oo =--r 3 5-2IS. Q oS 2_ A 09 ig-s =r w sHa<* _oo O-i a. 11O O O (D 3* S' , -5 gs* ? ;g 3 35 O 7Q 3 -= s Ss*. or6*'T3o*-E3a g*-f.5 i 2oSgaooCgL 3r *-< 5 5a sr osrT23. -MT1 _Q . 2 ; 5 *o (w <2-8 o3o oOp o--> 32 23 23 n =1 5<% > -5iT 33" 5s' rt --. To-Ji 3 fi 3s."oa vs 0) 3 -- 2?-1a SAW f|s S. nrt* o3 *T3 M ^ i%sl 3^ 3o 3 3* 3 ortr 25 0S: on <a%. a n 2 rr-"* o o r --. a 03 5".'-? -3 5 r5 IssSS.'v3-S Hs,,r i: 1-3 2,^ - o' 3. 5^ o2o? so *r2t*2*. ga S S! < g^ 2 " 2: 3 3 JCG S3'"_ 3f 0r-0 -|: =. < qs.-- -fi) 7*cmw3^g4 _ bb 3 o' ?T"< fgt SO"2 3" w 5 jf r> O * s: 5o a,,5T3rt -1 2 5 f5 315 on 3 o5. o- 5<bSn* "<<<--=51>1y O 35_O-On crS' n j, --- ^--5. 2- 3 0=3 0O0 _ si. o.-a ^ " -< 3 g-,,o . g S.? S^ s1 i ` SPECIFIC GRAVITY . Stabtllxid charging v o lla g * condition. (The charging voltage will stop rising when the battery is fully charged.) !. Battory w ill bo gassing froaly. . Specific g ra vity w ill stop rising and' may ovon start to d be i ta ly s i It is '. jo b 200 P 3 W "S S0og y 1 _ jo>a3 -35 2--. >s ^3 3 H0 POH 2 ^ -A 3O I0_? "O "I 5T3 Z =S 3 3 5' 3 - re s| 3 2 i." Jo a- o --0r3a&<*l sMno_O io13'k-". 2"x^g-r=gir_2ES?ao JC 3 "* 3 5 O t 3# | S 2 " o-S Z ni'ig 2 n S 5 3 9Q 1 = !^ - gsS'Sffi n a- o -o "0 2 <5or .J2.3=,=3-* oso 1 & 2 mB 53 a- "> = o2.^w ?- ;e*2 gi 3 , -- 03* 3^ .3 3 Q 0"0 PO 5* -i Of< w s CT - 3 3 3-* 2. 5 S-"s 3 u r* -a j o*<3 3 oo1* S o C> " = rt W n ^C3 -- - 3- n ^ 2 2 " 3 -- r-o-*'^l2.T33 "S 2 -j TM i 3 = 3-La M3* ^ 0=3- o s ? O-Tgi S-Oo s3s. -a. 5' 3*. -j a. 3" O : Ov03ros*',H2O"SBfO3.331^(1 3* s 0 O o' O j 2SCl.. -023.-0n" 3O* 3O --. 050 ' s.3 sor e 32a" a s 3:, n ^ s. sr >"=o 3-S 5: B o B 3g-93o1 !!1 904 323 o o-<i QM" o 3* Vi 3 ^K* < .S2&3" -fv<0t** o o< S**t o2^. 5,,*<o wwI. <To 1S -35.2ST.<o2 o^ 23>---*a0S2 osR. s o 2*1 a-, & S* 3 2.S-o ^ V* SB SS O O < 2 So,- o* S ^rosAr o 2 2 .oe fSf--o-2 3. n o * 0a0 3>_s3.oS<* n*o s e 0-3 A n *2. 3 u vt D 3" * S -- a. S 2 IIS"3 I >3 o 2 5 o szfH S--i 55 =r a. S'E'I'S i. 3^ S. s ~ sr A) O ^00 0 s rr3o " * * A VI Xf " = - 3 A 5 3- A 1-g1 s<11 otcaG*^s< 2 o Hg 3 3 -2 ? " S=5.*^2. o-.r iq?sS - j'SwSi ?5 313l 5MK> OC "o<%1f-t - O v 2 ^ sr 2C~O~3^SLb3?2SS*`i.LS02-. *p2 ^-srJ5? 2" . EW-W0^0-loftfl#j0SJ <_<r ^^8 S < S-- o =-a 2. " 2. ~ o CuS g-3 * 3-"-3j a"- 2 2 3 mil g<s -O 3(5 s 5 -S.2 <% O 2 3 oO. 1*32*00 5* n A r? v0<0i 2<20 "a O>3< 0 * & a* -- : 3-ff 3 2a 3 M <ft fig 0Oso002ST*f323 -"n w3' T2. < nao ft UM & o i CeL if , 3 . -*9 oo 3 a 3 a a* -- = O' S tft * - Cn CL Sx0 'o2OC. 13 Q9 79^ 2 32 3fl esra' o. v29---7. ss9o<-rn--t Q. ^ a Tl rti Q ^A**t*l O -" 3-* C1 gm: _o<i o9. ill 3* cr ^ si* ** S Ssi ro* CL 0 - =or 2< MMD 5'2-C STS 9 wo _9"* C9-- Z < f2 3~ 5a."So so2*"r -rn"9> --Qne<. S-S-2. 3 5 ,, --m " 5v=c 33 ffs-s: STS J5? SrJS I sJ?5 9(/> *TV3> Q. A3S'302>. Sg0 Is" V) g 3 3*^2 3. " gX. c&. 5<*- VvnI n 3r S-*- -9 <<Bo 2s** va>r 23 0sr 9-03*9TM d9o^Sdo9 Oft 5^ =: ^ = n'5 5* u nB ui g-sT ag" Hi's I ao "5 Q s- 5 X a -- o' c* o x> ^ sr 3 -r C --O 9 f"s* .,, CL 9CT 9^ W-- ~93 EM-vr^2~(I 2A9 C9(<91I 2. S' ""S . s s I l-* 323<SO' 92> 5-0 >o3 =:*" : Sd Z "-S s- "ST o3'-33.8 on S o-g- 9 9 m Op <% n sr = s M C9 Aa<' ' 9O o (% *9 ocl 00 e-- sr 9 s o " 3 22o 3. S o. Co' 3 O ?<S' *9-si O2L._<o1 S (2. 2 o_ 3o 3 K'> 3O nc o = I w An =-" ra SR'gJ? ^ - Vw* &o'S=rg 3 * - g itl^w ^s C-* Oo Oo o3o `S. o sor*0tOZ ST --- S-(S 35 S3 ao CL O c< "2 o8 0 c ^ E 2 t! z s c s.M O*T! 2,|S- S 2.- S8.g-s3 o <8 go = 5=; o WS si - o -3 ' So'*" o 3 2.2 s-o^ m o3 9Mis* #orST3 S c .s". 3 g g s> 5 2 50 o a s-iS 0=`8 s -s: e I 2 s o o 732 >3 0A~3' 92?. s. s sfJfli.8 3-- -Sr- a?fO5O 2_- JO.5 0sr 9 ^9-* ^29 =Y9 o2 ^r:o?^ om -o--00^c9 0s0 o*1a3. f'3 2 s' 2. 3 < ~ _ " r> vs<s- == o^ t1at i*e; r32a eoo Scr 5? -g 9 OO 3 1? O Is- 5" 9n 1 n f* ^a 2. o 0=A9 3mO ^w t*Q' ~SM *0.9O)O-^P <2 2 9Ba,3ofl.--Sf23lt.g2"c ?of0f-3sg2P-o-O sn-3o9 l-Q3j. 3 5. O a. o' o9_ o39 ^---0"0?"Aft3MSC:. Sw* O^2v--< _x 9 cr 9 X Om Z? er " g.fi; 23 i 05o0; aQ". 'S-S < 5et<<52 H Ss-f 5 =?< I Is. C9-$? rg2.TnoS "tj e O9y-1 Is-? $ S SS^ sS-'-l mg-- o= a|-S. "H &S-S-! o # o -1 H" S'g'a o i S 3" < i<~fef* = a3 => 5 B * JO .55; 3 9- n^ a 3 o = 2'=5 9> a 3 .5 B 5 ~ 2,g. !'|'3 8?.JJ 5 =3 i ar - - B o SSoJij c* 3 S SilZ o 2JS 3- c S a IP ' IH v< -00 yn a"=* 3-2. - =r S S5' *9 O9 Vs< 3 S.=- A2.,,n9, MW<4lS22 ss? s < " i_Z< * 0yk-- 3oc1n<. Sil ^S-? * 2. # 9 2 - 9< 9f sor n9 ^J? 2^?m 050 n *< sor nw5s ' o=wo c25&<3*r ?ate62r-s=Sosg-(It^:-o'SS-"eI ?Hs;5rgOvO?&*<"ao-*5. 5T_-O2<rSM-aS3n ? sgL-S-s"! g"^ 2. f3;?l =n ^j ?* vT < .g E. n* 9O M- ? A 53.?2.38 - " o s- 5-a-s &fei -o n <b pa ?-! 00 3-g. -3 3. -3 S ri-i*3 Oft* A6 aii a<1 fof* s<1 a -5 " sr |<3 S S.'-S 1 * w o 3-w "e 2-. --ft M_ "s< E:^ . -- 9 f""=- Sg-I S"g g. 5i? s.g E" !25.S<r tC*Os"Ar<13AC5l Q.<9 9 2 3 S 5 2! a 3"-r 2 i.3 O9 *<o(9fSt o 92-Oi? sr. M "A91 i3 !3 i3 aA. Asr *nft y--3ssa grt- -0 X9* 0s3010os*r 3So' -o"B_ S-g? ll 5-2. 5 Sr* -P- S- Oc * o3 _2. '-"O u, o " n .% 8 I?? 55 3 5. S 2 >1 a, "> 5 ^o 3i.^* -r. o ^500 s2r. &sr. ?o ~2 sa o w 2 IT ^ _ Cl r O9- sAr -9- o cO "D NC0OO0J n \/ t=/ V 12 DUP 0832112 M&U.JIBSSSMfcrJi4mitffir tfit!i ES-32S3 REV. M2 DON'T SAY IT-WIUTE IT TO_________Ed U.irvas . :_____ AT___________________________________ FRONT C. F. Richter, .Tr DATE 1/16/74 RETURNING EMPTY CYLINDERS ETHYL ALUMINUM SESOUICHLORIDE TITANIUM TETRACHLORIDE This will confirm our phone conversation of 1-15-74 wherein a procedure for returning empty cylinders noted above was agreed upon. The shipping requisition is no longer necessary for returning these cylinders. When empty cylinders are ready for return, Production is to tag the cylinders "Empty" and the cylinders are ready for Warren Brown's group to pick up and deliver to Stores. When Production tags the cylinders "Empty", they are indicating the cylinders are lmdy for return and no unusual conditions exist. If an unusual condition exists, the cylinders are to be marked accordingly and Purchasing advised of the condition. Implementing this procedure assures a positive means of identifying full and empty cylinders at Stores (full cylinders of each type have been returned to vendors previously). In addition, to eliminating paper work for Production, the procedure assures that Shipping and Purchasing will be advised of any unusual conditions. By copy of this DSIWI Warren Brown is requested not to pick up cylinders noted above unless: 1. An empty tag is tied to each cylinder - or 2. If not empty, the reason for returning the cylinder is explained on a tag tied to the cylinder and signed by Production. DUP 0832113 CFR:ss CC: W. A. Schurtz P. Bean Warren Brown H. A. McLaughlin H. S. Carr W. E. Maurer n\/\ k' * . ** _____ ...r. . > > ~~ 13 DUP 0832114 rrg'-in -Bi^ft-: .ACCOUNTING PROCEDURE ACIDS PRODUCTION 4ny time a fire or gas escape alarm or the Wednesday or Sunday test alarm signal sound, all Acid Production Division personnel will be accounted for following this procedure. All area personnel report to their CCR Operator who will keep a current roster for this purpose. Adipic Acid The Power CCR Operator and the Operation 1 CCR Operator will account for their groups to the Operations 2-4 CCR Operator (phone 502). (Give all initials for any missing.) The Operations 2-4 Operator will make a total accounting for Adipic Acid Area Production personnel by calling Accounting Headquarters (phone 453) NRD-47 The Operations 11-12 CCR Operator and the Operations 13-14 CCR Operator will account for their groups to the Operations 15-16 CCR Operator (phone 533). The Operations 15-16 CCR Operator will make a total accounting for NRD-47 area production personnel by calling Accounting Headquarters (phone 453)(y. GENERAL Adipic Acid and NRD-47 Production Superintendents and Assistant Superintendents report to Bldg. 570 Steno (phone 421), who will account for all Bldg. 570 personnel to Accounting Headquarters. Give the following information to Accounting Headquarters: 1. Reporting area (Adipic Production or NRD-47 Production). 2. Phone number reporting from (NRD-47 - 533 if reporting from Operations 15-16 CCR; 576 if reporting from Avenue B Gate House; 458 if reporting from Acids Waste Area. Adipic Acid - 502 if reporting from Operations 2-4 CCR; 458 if reporting from Acids Waste Area, etc. r \ /> DUP 0832115 - npM'Sn Accounting Procedure - Acids Production ''Continued) 3. Do or do not have missing personnel. 4. For each missing person, give: a. Name, including all initials b. Name of persons immediate supervisors c. Person's last known location 5. Report any Victoria Plant employee from another work group that have reported in at your area - identify as "Extra Personnel" and give name, including all initials, and area person normally is assigned to (reporting area). 6. If phones are inoperative, give above (1 through 5) information directly to Emergency Director by radio or messenger. a Operations 2-4 and Operations 15-16 OCR operators report to Patrol-('phone 261)- anyoff-plant visitors, giving visitors' name, location, and escorts if any* If phones--are inoperative, radio information-to Base Station. 9 NOTE: If an area has not reported in to Accounting Headquarters * within 10 minutes, the Accounting Headquarters will followup with a phone call to the unaccounted area. e Alternate assembly points are: Adipic Acid For Power and Operation 5 1. Adipic Acid OCR (502) 2. Avenue B Gate House (576) For Operations 1-4 1. Adipic Acid Power OCR (457) 2. Acids Waste Area (458) NRD-47 For Operations 11-16 and Waste 1. Acids Waste Area (458) 2. Avenue B Gate House (576) DUP 0832116 &Z&/-76 DV fgjltE 14 DUP 0832117 cc: NRD-47 Foremen (10) Safety Guidebooks (5) July 6, 1976 TO: D. C. HOPMANN FROM: T. N. MARTIN T. C. McNUTT INSTRUMENT OPERATION DURING POWER FAILURE During a total loss of power to the NRD-47 Plant, emergency power to the critical circuits will be supplied by batteries located in the CCR. These batteries were designed to give 30 minutes power supply but should last much longer. The Adipic emergency batteries have been tested and shown to supply adequate power for 3.75 hours. The normal battery voltage should be 132 volts. Instruments should function normally down to about 120 volts. With no power at all, the instruments should fail to the safe position. However, between 120 volts and 0 volts, the operation of the instruments is not predictable. Operation under these conditions is hazardous and should be avoided. The action recommended by the I & E Department (M. G. Higgins) is to monitor the battery output voltage during a power failure and plan to have the plant shutdown by the time the voltage drops to 120 volts. TNM/TCM: dm DUP 0832118 jfcsa 15 DUP 0832119 TO: NRD-47 FOREMEN FROM: TOM McNUTT May 20, 1976 COVERALL POLICY I have reconsidered the use of coveralls in Operations 15-16 and Waste Treatment. Coveralls should be considered as optional (not required) protective clothing on the following jobs: Waste Treatment: Mixing filter aid and cleaning operation of the DBW pit. Operation 15: Sampling nitric-containing streams. Operation 16: During shutdown or startup of the building or during warehouse operations such as mixing boric or urea or boxing NRD-47. Use in conjunction with the Coverall Policy (Section 10-4-1) in the Supervisory Manual. TCM/dw DUP 0832120 16 DUP 0832121 Facts About Microwave Safety Characteristics of Microwave Energy Microwaves are a form of radiant energy. Other common forms are radio waves, visible light, infra-red heat and electricity. All forms of radiant energy are a part of the "electromagnetic spectrum." To distinguish between the forms, they are classified according to the wave length which may vary from miles to thousandths of an inch. Microwaves are located in the'"non-ionizing" portion of the energy spectrum between radio waves and visible light. Their first application was in radar during World War II. Today they are widely used in communication relay systems, radar and many other commercial and industrial applications. Large segments of the population are exposed to infra-red rays, visible light waves and microwaves every day. One characteristic of microwaves is their ability to bounce or reflect off of metal surfaces, a characteristic basic to its use in radar. Another is its thermal or heating effect utilized in microwave cooking. Microwaves heat by penetrating non-metallic surfaces where energy is absorbed by the moisture content of the subject matter. By increasing the activity level of the molecules, the microwave energy heats and cooks food through internal molecular friction. Heat in a microwave oven is created by invisible microwaves. The body can feel the heat created by the microwaves at levels far below the levels necessary to cause injury even during short exposures. The difference between R.F. energy and other forms of ionizing radiation, such as X-rays, Alpha, Beta and Gamma rays, is that microwave energy is non ionizing. It does not alter the molecular structure of the item being heated. The effects of microwave energy are strictly thermal and do not cause cellular change as with ionizing radiation. Research is being conducted into the long-term effects of exposure to microwave energy. Results to date indicate no adverse long-range effects due to exposure to low level microwave electromagnetic radiation. Menu master Safety Design Features The Atherton Division of Litton Industries has, for many years, concentrated its entire research and development program on microwave oven technol ogy. This specialization .has placed Litton in the un challenged position of leadership in the microwave oven field. Product design efforts have been focused on maximizing product safety, for the protection not only of the operator but the product itself. Litton's own standards of safety and reliability are the most rigorous in the industry, and all Litton products are designed to meet and surpass those standards. To minimize radio frequency emission, your Menumaster microwave oven has an advanced door seal which combines a choke-type construction with a capacitive' seal plate. The door latching mechanism incorporates two concealed interlocks which insure an automatic electrical cutoff when the latch is opened. The latching mechanism and door hinge have been designed to withstand the most rugged use over an extensive period of time, and have been subjected to and surpassed rigorqus door-slam tests of over 200,000 cycles. The door itself is intrusion-proof with glass on the inside and outside of the metal screen, prohibiting any manner of entry into the oven cavity while the oven is operating. To insure a long, useful product life, your Menumaster incorporates several component protection features. The oven has a thermal sensor to protect the magnetron tube and shelf from unintentional no-load operation. The magnetron is further pro tected by an automatic ten-second warmup of the oven before use. An automatic shutdown after sixty seconds insures a longer life of all electrical components, and internal fusing protects all control circuitry. The Menumaster microwave oven has been approved by Underwriter's Laboratories, the Federal Communications Commission, the National Sanitary Foundation, and the Canadian Standards Association. It has been designed to comply fully with the new standards of the U.S. Department of Health, Education, and Welfare, effective October 6, 1971. DUP 0832122 DV1 6451736 21 Operator Preventive Maintenance To enable your Litton Menumaster microwave oven to give you efficient and dependable service, a well planned preventive maintenance program carried out on a regular basis is very important. Listed below are the proper cleaning procedures which should be performed. NOTE: DO ~NOT USE SCOURING PADS, POWDERS, OR OTHER ABRASIVE MATERIALS ON ANY OF THE OVEN SURFACES. Regularly During the hours of operation, these cleaning procedures should be performed as needed: 1. Wipe up all spillage as it occurs. 2. Do not allow food particles or grease to collect on the plastic stirrer and light cover or on the inner door and oven cavity front surfaces. A build-up of food or grease in these areas can result in damage to the materials and surfaces as well as a loss in cooking power. Daily 1. Turn the main ON-OFF switch to OFF. 2. Wipe the plastic stirrer cover and oven light cover with a cloth or sponge dampened in a mild detergent solution. 3. Wipe all surfaces in the oven cavity with the dampened cloth or sponge and then dry with a clean cloth. 4. Wipe the inner door surface and oven cavity front with a mild detergent solution, making sure to remove all food particles. Weekly 1. ' Remove the air intake filter and wash it in hot water or in the dishwasher to remove grease and dust that collects and obstructs the air flow. 2. Visually check the door seal plate surface for scratches or dents. . 3. Check the door assembly for hinge tightness. 4. Check the interlock switch operation visually: a. Idle condition, door open -- "Ready" light and "Cook" light should be off. All pushbuttons should be released with door open. b. Idle condition, door closed -- "Ready" light should be o."Cook"light should be off. c. Cook condition -- "Ready" light should be off. "Cook" light should be on. If an abnormal condition is noticed during the preventive maintenance checks, contact your nearest Litton Authorized Service Agency. . DVI U4517.J7 cO -O o 00 MW rWo SAFETY PRECAUTIONS The following Safety Precautions should be read care fully and strictly followed: 1. Do not operate if you have a pacemaker. 2. Stay at least an arm's length away from the front of an oven while it is on. 3. Do not look directly into the cavity while the oven is in operation. 4. Do not operate oven if any of the following conditions exist: Door does not close firmly against oven front. Door has a broken or damaged hinge. Door gasket is damaged. Door is bent or warped. Any visible damage to the oven. 5. Never attempt to operate oven with an object (such as a towel draped over the edge) between the closed door and the oven face. 6. Never tamper with or attempt to defeat the safety inter lock switches. 7. It is important to keep the oven clean. All spillages should be wiped up as they occur. Wipe all surfaces in *the oven cavity with a dampened cloth or sponge and then dry with a cloth. The air filter should be cleaned weekly according to the following procedure: Pull out the air filter below the door. Gently tap on the floor to remove dust. If grease has accumulated, wash in a detergent solution. Replace air filter. 8. Do not warm eggs in the shell. 9. CAUTION: Large, solid foods such as shelled eggs, whole potatoes, apples, sausage, etc., must be cut into pieces to release excessive heat and minimize burn potential to the mouth. DUP 0832124 HCG:bjr 8/3/76 64517.38 TO: ALL SUPERVISION - 11 ST "A" FROM: J. R. McSPADDEN - CHAIRMAN OF INVESTIGATING COMMITTEE VICTORIA PLANT INCIDENT REPORT NO. 55 WHAT: 2nd Degree Burn to Inside of Employee's Mouth WHERE: 530 Building Lunch Root WHEN: , Thursday, July 22, 1976 at 11:30 INCIDENT: .An employee heated a (hard) boiled egg in the microwave oven while preparing to eat his lunch. He had removed the shell per written instructions taped to the top of the oven. The injured bit into the egg approximately 4 minutes after removal from the oven when it "burst" in his mouth burning the inside of his upper lip. The employee immediately filled his mouth with ice water to soothe the pain and to minimize possible tissue damage. No after effects were noticed until the following morning when the injured awoke with a swollen lip. He reported to medical for treatment after returning to work. CAUSE: Sudden release of- heat frcm center of egg. INVESTIGATION: 1. Food heats from the "center out" in microwave ovens and food temperature will depend on the heat capacity for that particular food and heating time. It is important, therefore, that items such as eggs, -potatoes, apples, weiners. etc., be cut before eatine to release-excessive heat and minimize burn potential. These foods can be cool to the touch and yet hot inside. 2. Numerous "near misses" with microwave ovens have not been reported in the past. The ovens can be "booby traps" and we must benefit from experience gained with their use on the plant. N'e encourage reporting all incidents associated with these ovens. DV! 6451739 DUP 0832125 0. A simlai' incident occurred in .'lay of 19.5 causing a minor injury. REOJ-MEMDATION: 1. This incident should be publicised in all plant safety meetings and the above points emphasised. 2. Operating and safety instructions attached to ovens should be more explicit. Investigating Committee J. R. McSpadden - Chairman A. B. Cordell G. V. Gauthier T. E. Rnipling J. A. Janak DVI 6451740 DUP 0832126 aiaaiatL. 17 DUP 0832127 11_L_7i AC ITS LIVES IIN THE FAT FT ITG T ' T TAG TS C-ETE3AL i:rr:?MA?ION . II Section 20 of the Emergency Manual provides general plant information for threatening contacts, and this should he reviewed. The purpose of this, procedure is to provide additional guidelines for action to be.taken by field personnel if the Acids Division receives or is included in a threatening contact (tomb thr OUTLINE C? ECME THREAT PROCEDURE i Plant reaction to a bomb threat will vary depending on time (days versus shift) and type of threat received (defined below1). Per E.M. 2C-2, if the threat.is received on days (Monday - Friday) notification and decisions will be made by plant staff. Cn shift, the Chief Shift Supervisor will have primary responsibility. Communication to appropriate supervision will follow E.M. 20-2. Reaction to a bomb threat by field personnel in the Aciis Eivisicn will be in two phases: A. Bomb Threat Alert 3. Bomb Threat Emergency A.. 3crab Thr'eat Alert A comb threat alert, exius cn receipt of a threatening call which dees not designate a specific plant, area as the target, or if cuts ice of the critical time oeriod ^clus cr ui'-us <c chutes' DUP 0832128 r'-iwaMwwwawwf';MBwr--" :~nw8fwn Page: lt-P-2 rate: 11---71 ' A considered assessment of the available facts by supervision will govern whether any Acids Area operations will be evacuated or shutdown. Information should be relayed by phene to these involved. Personnel should assemble in the CCR or other designated areas to receive information and to minimize exposure. yechanical and Technical personnel should be evacuated to a remote area (shop or office building) for safety, cut should be available to assist if requested by area supervision. People not involved with area operation should be evacuated by a safe route to a remote area. A systematic search ever a predetermined path will be initiated and directed by supervision in all Acids plant operations. Information specific to each process area in the Acids Division is attached. The most qualified--people to conduct a search are these most familiar with the area to be searched. Participation in the search should be on a voluntary basis. Coverall goggles should be worn during a search. If a suspicious object is located leave the area immediately. Do not touch or- handle the object in any manner. The bob disposal squads should be called per E.M. Procedure 2C-}~. 5c 5:mb- Threat Emergency A bomb threat err.erg.mncy will be designated on receipt DUP 0832129 late: fie1, i personnel. The bull ling evacuation should not be sounded unless it is imperative to do so. Field personnel will be instructed to report to the OCR or to a location upwind and at least 1500 feet from the threatened location. Accounting should be dene in the ususal manner. Special accounting locations should be announced over the ?A. System. If the target area contains hazardous materials such as cyclohexane or nitric acid in large quanties it should be shutdown tc a standby status from the CCR. This should be done in an orderly and safe fashion. The area isolation valves should be operated to minimize fire.or fume potential. However, these reisiens should be made by either the .Area Supervisor or Chief hift Supervisor. Adjacent areas, especially these downwind, should be notified of the situation and made aware of potential problems such as fume releases, etc. Judgement should be exercised as tc whether the adjacent areas should continue to run or shutdown. A. search will not be conducted during a Bomb Threat However, after trie critical time period he C 23 O r\ c O ^ the condition should revert to a momb Threat Alert, and a search should be initiated. ''sir.tain communications with the Emergency Director in the normal manner. n v; 1 DUP 0832130 ?r Coera tier. 11 o r* - s ' Page 12-D-^l Revised 11-1-71 1. Check fire extinguisher box north of f"fCn tr rr,'Li'T r-trcue"z. _iL v tr X 2. Oil cabinet by "Aconverter feed punp. 3. Fire extinguisher box east of waste organic tank. 4. Check all tank skirts. 5- Check all trenches (under grating). Operation. 11 Ground Fleer 1. Fire extinguisher box, circulating water flew recorder box, protective clothing box, sample bottle box, and dancer tag box west of the 3d dryers. 2. Maintenance storage cabinet east side of building between Y{ 3- Fire extinguisher box and analyzer house -rest side of builcinc, 4. Protective clothing box and maintenance work cabinet corner of building. 5. Fire extinguisher box on south end of the building. 6. Rag containers' and trash cans. 7. Check all trenches (under crating). 8. Centrifuge water analyzer house. 9- Look up in the pips bridge and in beazis. 10. Check all oumo bases. DUP 0832131 Operation 11 Second Floor 1. Analyzer house at southeast corner of building and under flare stack. 2. Fire extinguisher box on handrail east side of building. 3* Duct work for ICR air conditioning syster. cn east wall outside of ICR.4 4 Ur.d-'" ^ - g -- -- ^ -2" ,1 ^ ^ Operator shelter. - cf 5 -zer e V 1. n 2_j* 2. -- r rp ~ 3. " -r v* -J SU*w.. 5'vti. -ij, "i" h = a"i y' i- Vi r-^ r cox south v:all of ECR 4. Fire extinguisher box on east wall of r.CR and 3HT pur.ps. 5. ECR ana underneath 3rd floor. 6. Duct work for ECR air conditioning system, north wall outside ECR. 7. Operator shelter * 8. Ascend stairway cn south side of Operator shelter to mezzanine between 2nd and 3-d floors and check fire extinguisher box on south handrail and 1HT storage cabinet. Operation 12 third r __kj l 1. r'ire extinguisher box on south handrail. 2# Ssliinc oiTf*-- zs 3. Check top platforms around topper and refiner to top of columns. 4. Exi'l Look in the trench between Operation 11 and Cper Operation 11A. ana Ope ration 11-A 1. Fire extinguisher box northwest of sump pump. 2. Protective clothing box west of dry PDT storage 3. Storage cabinet west of dry PDT storage tank. 4. BTM catalyst unloading house (inside and on top) 5. 3CC# ansul house south of Operation 11A. 6. :rotective clothing boxes (2) south of catalyst circ. pumps. DUP 0832132 OVI * 4 im: -nafeKWMWjfrwiw--mu m i ~aait!^1l> y-. HHM*i!W.'Tl;WK4iiii .r- ^.jHMBasiagia Cz=-. tier. 11 f: zri ^ic:r (Cc-tlrued) - 2 bi e 12-3-5 6. Coeratcr shelter ari^-ol adiabatic r- r 2d decanter and 7. Best Been. 8. Danger tag box -rest side cf Operator shelter. 9- Fire extinguisher box and nainter.ar.ee work and storage cabinets (5) bp- the centrifuge. Coerat_ioun 11 ht'r' -loc-s JL. Chech around nist separator-, ".IFE head and platforr. 2. Check trash can. 3. Check around 'JFE spray condenser. 4. Exit north end of building and proceed to Operation 12 f? Coe ration 12 Tank Farr. 1. Check under CDD receiver tank skirts. 2. Maintenance storage cabinet on east, side of walk-ray by the condensate pur.p. 3. Check trenches. 'deration 12 Ground Floor Circulating -rater flow recorder box at north end of building. 2. Prct active clothing box by the drain tank. 3. Dang er tag box by the topper fe ed tank. 4. Fire extinguisher OCX at northw'sst corner of 5- r ii 8 extinguisher box at scuthv est corner of ` 6. Trash cans and around all pur.p bases. 7. Lock up in all pipe bridges and "I" bears underneath 2nd fleer. 8. Check topper and refiner colum skirts while cn rrcurd fleer. o e>*th end of tuilcina to reczanine. 10. __n DUP 0832133 Cp^i~stier. 11-A (Continued) -7 7. Fire extinguisher box south of catalyst circ. pumps. 8. Maintenance storage cabinet east of UM circ. ourr.os. 9. Behind instrument panel. 10. Up on top of UM, BTM, and dry solvent storage tanks and by N2 dryer or dry solvent tank. 11. Check around maintenanc? DUP 0832134 i i * DVI revised ,4 !4 1. :e and stretch box at scuthwes o corner of building, 2. Danger tag box north of* CDD storage tank. f Operation l4 Tank Fern 1. Check all tank skirts. 2. Fire extinguisher box east of "A" PAK receiver. 3. Protective clothing box south of "3" and "C" PAX receivers. 4. Maintenance storage cabinets south of RDD tank. Operation jh Ground Floor _ ; 1. Fire extinguisher box to left of walkway by east stairway. 2. Maintenance storage cabinet south of WwP tank (if not locked)., 3. Storage cabinets (2) south of extractor. ^ 1T> cO------ ^ - -w* ^4- -W w W ^ building west of extractor. . J__-*______ _____ i uc, c x O Ouu u IJ. 3 _L U, G? U-L 5. Protective clothing., maintenance storage cabinet (if not locked), sample bottle cabinet and fire extinguisher box along south side of building. 6. Pag containers and trash cans and look up into pipe bridge, beans, etc. under 2nd floor. 7* Check all trenches and sump area to W.T. pumps. 8. Check stripper, refiner, and topper column skirts before leaving ground floor. 9- Ascend south stairway to second floor. DUP 0832135 Operation jb Second Floor 1. Duct work for ECR air conditioning system on south wall outside ECR. 2. Fire extinguisher box west of the'ECR. 3- F"`re extinguisher box north wall outside of the ECRT OV 1 II----"1 Operation 1^ Second Flocr (Continued) h. FIR 5. Cpertor Shelter. 6. Protective clothing box east wall outside Operator shelter. 7. Fire extinguisher box on east handrail by stairway. 8. Trash cans and underneath 3rd floor (pipes, etc.) 9. Cn top of :;AK and platform, building decanter, and platforms around the columns. 1C. Platform on tank farm (PAK receivers, ?AK HUT, etc.) 11. Ascent east stariway to the third floor. Operation lk Third Floor 1. Fire extinguisher box on east handrail by stairway. 2, "ndernesth the 3rd flocr (pipes, etc.) anger tag container on south handrail by the tempered star header valves. L. Fire extinguisher box on south handrail by the soutn stariway. 5. Platfern cn the columns. 6. Ascaad south stariway to the fourth floor. Cperatlon 1- Fourth Floor 1. Fire extinguisher box on south handrail by stairway 2. Fireextinguisher box on east handrail by the tempered water coolers. 3. Trash cans. h. Around top and support beams of coders. F. Platform cn the columns. 6. Proceed to east end cf Operation 13 tank farm. DUP 0832136 1. 2 3 ~ -> -n ^ -= ' 4 rrotec cm 5 ua 6 o 7 8 revised 1 C or a . .3 i . -- . :j.G r PAX r hex cy h ta ver. ..03 so c n ed er flcv: recorder box north of xalkv:ay at Acir.^. e br 3 east of n ^ r*ra. Ooer _ry 1. Hire exrrr. from east. ox on right upon entering tuilcins 2. Protective cl: of building. :g box to the right of v;al'-r.;ay east end 3. 7"s *r & zr v >aso oi r-m -uT 4. rrccucncn scorage czc-i.-r.ez, sa.v.pue ocoore ccroainer, and trash can at vest er 5. of AID cooler. 6. Protective clothing box, rancr.eter storage cabinet, ar.d trash cans under stairway leading to roe z canine. 7. Fire extinguisher box southeast corner by PDD preheater. 8. Scrap dur.pster and drur.s, trenches, ana underneath 2nd floor. 9- Proceed to Mezzanine. Gcerati 1. Trash can (2 boxes) HID insirunert flush box to each oxidizer iecono door. DUP 0832137 DVI 1 a ~ -i - V.'3 ' ~ U- - . th 1 r y 2. d oor ;5s at southwest corner (check east and north 3- r.sW . r' r a ~ 'container - between the flasher and slurry HUT. 4. Fire 5. Tras: 6. FOR. 7. Duct outs: oo i Oner: 9i. Rest 10. Fire xtinguisher box by the rest room doer. li. Prrcott:ective clothing box east wall outside rest room. St or; ; cabinet on vail north of Hash vacuum pump (if not locked). 13. Maintenance work bench. cabinet space and dar.ge.r tag container along east v:all north of stairv:ay. 14. Fire. extinguisher box on east handrail south of stairway, 15- Ascend east stairv;ay to third floor. Operation 13 Third Floor 1. Danger tag container on east handrail by stairway. 2. Fire extinguisher cox on east handrail south of stairway. 3. Trash cans. Platform on top of flasher condenser, CAii decanter, and on Dec DUP 0832138 H. OJ OVI F, V ) \ i ' ' 18 DUP 0832139 TO: NRD-47 PERSONNEL FROM: T. C. McNUTT June 30, 1976 RELIEF VALVE INSPECTION PROCEDURE To insure removal, inspection, and installation of the proper relief valve, the following procedure should be followed in the NRD-47 area in conjunction with S & F 48: 1. At the beginning of- the month, the Day Production Foreman should give a list of all relief valves to be shopped that month to the Maintenance Foreman. (A Xerox of the computer printout is sufficient.) 2. Prior to shopping the relief valve, the Production Foreman (or his designate) should place the relief-.valve co-.ip-.iter card In a danger tag envelope and hang it on the reiief valve to be shopped. If the relief valve is Inaccessible, the card can be attached after removal. 3. The Maintenance Foreman (or his designate) should check the computer card to insure that the proper relief valve is removed. 4. Production and Maintenance should insure that the relief valve is out of service and properly tagged. 5. A Mechanic should make the first break, wearing the proper protective clothing. He should remove the relief valve, sign the computer card, and send the relief valve and card to the Central Shop. 6. After ..inspection, the relief valve should be returned to the area for installation by Maintenance. The Mechanic will verify that the valve-location is correct. Discharge and suction piping should be checked to insure the absence of any restrictions. Upon installation the Mechanic should sign the card, leave it on the relief valve, and inform the Production Foreman of the completion of the job. DUP 0832140 '1 -.. ~-- 1 iiiiilimM 1 2 Pr^uctioa - CVi. Hi (or his s ?g r ate) should verify ."er ir.stallat 'on o f : Lv e. The in for".: at ion >:n the card should again be clv-cked to insure agreement ith obe relief valve tag-and flange fag. If satisfied, he ai.ouj-d then sign, date, and process the card, "MC/d-nc DUP 0832141 mtm 19 DUP 0832142 May 11, 1977 TO: STAFF FROM: G. L. BRENNAN IDENTIFICATION OF GAS CYLINDERS D.O.T. Regulations 1. Cylinders must be marked with proper shipping name. 2. Name must be on the tag or label. 3. Each cylinder must be imprinted with: A. D.O.T. design specifications B. Pressure rating C. Manufacturer's name D. Date of manufacture E. Date of last pressure test ^ Cylinder Connection The industry has standardized on 16 different cylinder connections shown on the attached pages. The list shows, for example, that there is a unique connection for oxygen, a unique connection for the rare gases, the acetylene connection is common with butadiene, butane, butene, propane, etc., and hydrogen connection is common with carbon monoxide, ethane, ethylene, methane, etc. Looking at the common gases used on the plant, a hydrogen regulator cannot be attached to air, oxygen, nitrogen, helium, acetylene, carbon dioxide or ammonia regulators. However, as in dicated above a hydrogen cylinder could contain several different types of chemicals. Since we fill breathing air cylinders on the plant and because of the uniqueness of cylinder connections, we recommend that no program for analysis of the gases prior to use be established. We do recommend that users be alert to proper cylinder markings, and if there is a doubt as to cylinder contents, the Purchasing Group should be notified. GLB/11 Attachments 4 r- DVI .1 DUP 0832143 Connection Number 110 170 240 290 CYLINDER CONNECTIONS Gases HI, IFs Bromotrifluoroethylene, Methyl Fluoride NH3 Anhydrous, Dimethylamine, Monoethylamine, Monomethylamine, Trimethylamine Vinyl Bromide, Vinyl Chloride, Vinyl Methyl Ether 300 320 326 330 350 510 540 580 590 660 677 678 679 Ethyl Chloride C0, 1,1-Difluoroethylene, Freon 13B1, Freon 14, Freon 21, Genetron 23f Genetron ll^f Methyl Bromide, NiC04, Vinyl Fluoride Nitrous oxide BF3, Carbonyl Sulfide, HBr, HC1 , H2S, Methyl Mercaptan, SiF4, SF4 CO, D2, Ethane, Ethylene, H2, Manufactured Gas B, CH4, Silane 1C, Tetrafluoroethylene Acetylene', Allene, 1,3 Butadiene, Butane, Butenes, Cyclopropane, Dimethyl Ether, 2,2 Dimethylpropane, Ethylene Oxide, Isobutane, Isobutylene, 3-Methyl Butene-1, Propane, Propylene, Silane lx 02 Argon, He, Kr, Ne, N2, Xe Air, SF2 NH3(U.H.P.), Arsine, BCI3, C0F2, Cl2, Chlorotrifluoroethylene(CN)2, CNCl , Freon 13, Freon 22, Freon 114, Freon 116.5, Genetron 142B, 1,1Difluoro-l-Chloroethane, Genetron 152A, Germane, HF, H2Se, CH3CI, Nitric Oxide, N02, N203, NOC1, Perfluoropropane, COCl2, PH3, S02, S02F2 N2, Argon 6000 psig Dichlorosilane F2 g "D O 0wto0 OVl 6 aMaiasiiij CGA COr/:r IESSED GAS CYLINDER VALVE 0L5TL ITS AND CONNECTIONS CGA GAS Valve Outlet end Conn. Acetylene Air Allene Ammonia, Anhydrous Ammonia (U.H.P.) Argon Argon 6000 p.s.i.g. Arsine Boron Trichloride Boron Trifluorid** Bromotrillmv tylene 1-3 Butadir Butana Butenes Carbon Dioxide Carbon Monoxide Carbonyl Fluoride Carbonyl Sulfide Chlorine Chlorotrifluoroethylene Cyanogen Cyanogen Chloride Cyclopropane Deuterium Dichlorosilane 1,1-Diflucoethylene Dimethyl; ine Dimethyl i ner Dimetnylpropane Lecture Bottles only 510 590 510 240 660 580 77 660 660 330 170' 510 510 510 | 320 350 660 330 660 660 660 660 510 350 678 320 240 510 510 CGA GAS Valve Outlet and Conn. Ethane 350 Ethyl Chloride 300 Ethylene Ethylene Oxide 350 510, Fluorine "Freon 12"* 679 (Dichiorodifiuoromethar.e) 050 "Freon 13"* (Chlorotrifluoromethane) "Freon 13B1" 320 (Bromotrifluoromethane) "Freon 14" 320 (Tetrafluoromethane) "Freon 21"* 320 (Dichlorofluoromethane) "Freon 22" 660 (Chlorodifluoromethane) 660 "Freon 114" (l,2Dichlo- rotetrafluoroethane) "Freon 116-.5" 660 (Hexafluoroethane) "Genetron 23" 320 (Fluoroform) "Genetron 115" (Mono- 320 chloropentafluoroethane) "Genetron 1428" 660 1,1-Difluoro-l-Chloroethane 660' CGA GAS Valve Outlet and Conn. "Genetron 1S2A" (1,1-Difluoroethane) Germane Helium Hydrogen Hydrogen Bromide Hydrogen Chloride Hydrogen Fluoride Hydrogen Iodide Hydrogen Selenidt Hydrogen Sulfide Iodine Pentafluoridt Isobutane Isobutylene Krypton "Manufactured Gas B" Methane Methyl Bromide 3-Methyl Butene-1 Methyl Chloride Methyl Fluoride Methyl Mercaptan Monoethylamine Monomethylamine Neon Nickel Carbonyl 660 660 580 350 330 330 660 110' 660 330 110' 510 510 580 350 350 320 510 66Q 170' 330 240 240 580 320 < . CGA GAS Valve Outlet and Conn. Nitric Oxide Nitrogen Nitrogen. 6000 p.ii.g. Nitrogen Dioxide Nitrogen Trioxide Nitrosyl Chloride Nitrous Oxide Oxygen Pertluoropropane Phosgene Phosphine Propane Propylene Silane 1C, 1W Cyis Silane IX, 3P Cyls Silicon Tetrafluoride Sulfur Dioxide Sulfur Hexafluoride Sulfur Tetrafluoride Sulfuryl Fluoride Tetrafiuoroethyiene Trimethytamine Vinyl Bromide Vinyl Chloride Vinyl Fluoride Vinyl Methyl Ether Xenon 660 580 677. 660 660 660 326 340 660 660 660 510 510 350 510 330 660 590 330 660 350 240 290 l 290 ` 320 290 580 Thn* dim.nsioml drawing illustrate cylinder valve outlets and connections. The drawing at the left illustrates the cylinder valve outlet. The one entitled "CONNECTION" illustrates its mating regulator or valve connection. More details are in our pamphlet "Compressed Gas Cylinder Valve Outlets and Connections". Ask us for a free copy. Fractional dimensions shown below are approximate and can be used to identify connections. OUTLET CONNECTION CONNECTION 110 LECTURE BOTTLE OUTLET -CORROSIVE GASES 5/16" -32 RH INT. using Flat Seat with Washer ---------, OUTLET CONNECTION 290 .745" -14 LH EXT. accepting a Bullet Shaped Nipple <Xr7L*T CONNECTION CONNECTION 170 LECTURE BOTTLE OUTLET - NON-CORROSIVE GASES 9/16" -18 RH EXT. and 5/16" -32 RH INT. using Flat Seat with Washer CONNECTION 296 .803" -14 RH INT. accepting a Bullet Shaped Nipple CONNECTION 240 3/8"-NGT RH INT. IPS accepting Tapered ' .825" -14 RH EXT. accepting a Cone Shaped Nipple co 0 ooo CO to 4 cn outlet \y\r coNMtcnoN CONNECTION 320 .825**0 4 RH EXT. urni with Fijt Scat and Waaher CONNECTION 328 ,S25"-14 RH EXT. accepting a Round Shaped Nipple owner 3 i CONNECTION 580 .965"-14 RH I NT. accepting a Bullet Shaped Nipple ^~i-.... 'a CONNECTION 590 ,965"-14 LH INT. accepting a Bullet Shaped Nipple OUTLET CONNECnOM CONNECTION 330 .825--14 LH EXT. used with Flat Seat and Washer CONNECTION .7. J2513/tf CONNECTION 350 .825*'-14 LH EXT. accepting Round Shaped Nipple owner CONMCCTKM 1 CONNECTION 510 ,885"-14 LH INT. accepting a Bullet Shaped Nipple CONNECTION 660 1.030"-14 RH EXT. using Flat Seat with Washer CONNECTION 677 1.030"-14LH EXT. accepting Round Shaped Nipple OUTLET CONNECTION CONNECTION 678 1.030"-14 LH EXT. (Shprt Nipple) using Flat Seat with Washer conntenon CONNECTION 540 .903"-14 RH EXT. accepting a Round Shaped Nipple CONNECTION 679 1.030"-14 LH EXT. using Small Flat Seat with Washer DUP 0832146 Mitem atsMsB-iagihal itt' jfe^xLLJMB iiiii I 20 DUP 0832147 CC: O. A. Sampson G. L. Brennan W. L. Smith H. H. Street August 18, 1977 TO: Division Superintendents Assistant Division Superintendents FR024: Plant Vacuum Truck Committee L. F. Getz W. R. Matthews D. C. Kopmann T. C. McNutt A. C. Vaught VACUUM TRUCK USAGE Beginning 9-12-77, the two Plant owned vacuum trucks will be the primary source of vacuum truck service for the plant. Non-company owned vacuum truck service will be available with approval of Shops and Services Assistant Division Superintendent, or the Chief Shift Supervisor oni\ to avoid a safety or environmental incident. The Services Group of Shops and Services will be the proprietor of the Plants owned trucks and is responsible for the maintenance and operation of these trucks. In effect. Shops and Services will be providing the service that we currently receive from off plant contractors. Each user Area will continue to have full responsibility for the safe and proper handling of their chemicals. The majority of vacuum truck usage on the plant can be scheduled, and can be accomplished on the day shift Monday through Friday. Requests for vacuum truck service should be routed to the Services Group. This will normally be accomplished by telephone by a member of supervision. Any personal protective equipment required beyond hard hat, safety glasses, gloves, and coverall goggles should be included in the request. Cooperation and negotiation among all groups on the, plant will be necessary since the Services Group cannot set priorities when conflicts arise. Contract labor will be trained to operate the vacuum trucks for day shift rbqui rements, and tney v.ill be available on a scheduled overtime basis. However, all Production Areas must h.avt.- pn -.annul trained to operate n \ 11 V' DUP 0832148 2 these trucks to cover unscheduled vacuum truck needs during off hours. Shops and Services will conduct the training of personnel designated by each area to operate vacuum trucks. These persons must also participate in annual refresher training and check out for vacuum truck operation. The Committee recommends that each area have at least two persons per shift trained to operate vacuum trucks. - Each area that will require vacuum truck service should review S&F Procedure #60, revised 8-18-77 for all safety requirements and procedures for their area. DUP 0832149 4 SAFETY MANUAL SAFETY AND FIRE PROTECTION PROCEDURE NO. 60 VACUUM TRUCKS I. GENERAL Company and non-company vacuum trucks are used throughout the plant handling process waste materials, a number of which may be toxic or corrosive. The consequences of a failure due to error or oversight could be quite high in terms of exposure of people to the materials we handle in vacuum trucks. The purpose of this procedure is to designate areas of responsibility. II. SAFETY REQUIREMENTS 1. When a vacuum truck is used for handling materials requiring special safety considerations, it shall be the responsibility of area supervision to provide adequate procedures for safe handling. This should include specifying and providing the required personnel protective clothing, followup or standby at the job site and disposal area, and decontamination of hose lines and truck tank. 2. Disposal of collected materials shall be in compliance with S&F Procedure No. 17, "Disposal of Plant Waste." 3. It shall be the responsibility of each user area to provide a procedure for cleaning of the equipment and to ascertain that it is adequately done before final release. 4. Procedures for decontamination and inspection of the truck for- final release are to be included in the Area Operating Guides. 5. It is the responsibility of each area to have personnel trained to operate the plant owned vacuum trucks to cover unscheduled vacuum truck needs during off hours. Shops and Services will conduct the training and annual refresher training of personnel designated by each area to operate vacuum trucks. Each area is also responsible for scheduling these persons for annual refresher training and checkout; B-1S-77 DUP 0832150 2 III. REQUESTS FOR VACUUM TRUCK SERVICE 1. Plant owned vacuum trucks are the primary source of vacuum truck service. Requests for plant owned vacuum truck service should be routed to the Services Group of Shops and Services. 2. Non-company owned vacuum truck service is available only with approval of the Shops and Services Assistant Division Superintendent, in an emergency situation, to avoid a safety or environmental incident. All requests for this service shall be routed through the Stores Purchasing Group. This will normally be accomplished by telephone by a member of supervision. During "off hours" the Chief Shift Supervisor has the authority to request this service by contacting the contracted vendor. Upon completion of the work, supervision will enter the cost code on the service receipt. DUP 0832151 8-18-77 -- i + \ V\ \ 1 r DUP 0832152 VICTORIA PUNT MATERIALS LISTED UNDER SARA A CERCLA REPORTABLE QUANTITIES fRQI CHEMICAL NAME AOIPIC ADIPONITRILE AMMONIA ASBESTOS BENZENE BUTADIENE CHLORINE COBALT CRESOLS CYANIDE SALTS (SOLUBLE) CYCLOHEXANE CYCLOHEXANONE CYCLQHEXYLAMINE HYDROCYANIC ACID HYDROGEN CHLORIDE NICKEL NICKEL CYANIDE NITRIC ACID NITRIC OXIDE NITROGEN DIOXIDE PHENOL PHOSPHORIC ACID PHOSPHOROUS TRICHLORIDE PCBs SODIUM CYANIDE SODIUM HYDROXIDE SODIUM HYPOCHLORITE SULFURIC ACID TITANIUM TETRACHLORIDE TOLUENE VANADIUM PENTOXIDE VINYL ACETATE MONOMER Tpq (LBS) 1,000 500 10,000 100 10,000 1,000 10,000 100 500 10,000 1,000 100 100 500 1,000 100 1,000 100 100 1,000 Rq-SARA(1) (LBS) 1 100 1 10 1 1,000 1 10 5,000 1 1,000 10 10 1,000 1,000 10 1,000 1 1,000 5,000 RQ-CERCLA (LBS) 5,000 1 100 1 (10)` 100 10 1,000 10 1,000 5,000 1 10 5,000 (10) (10) 1,000 10 10 1,000 5,000 1,000 10 10 1,000 100 1,000 1 1,000 1,000 5,000 ^Statutory reportable quantity for purpose of emergency noti fication under SARA Section 304(a)(2). ^Statutory reportable quantity under CERCLA Section 102(b). ^Threshold planning quantities under SARA Section 304(a)(2). ^Proposed Limits, 40 CFR117 and 302, March 16, 1987 DUP 0832153 5/4/87 ^463071