Document ZJKwMrQRMY5e09XEoxrdMRY1L

CHG 01900 SAFETY PROCEDURES MANUAL DISTRIBUTION .'MANUAL NO. 1 2 3 4 5 6 7 8 9 10 IV 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 ISSUED TO R. P. Pavletic R. A. Arthur C. F. LeRoy H. C. Cazalas T. W. Farnor J. H, Tansey W. B. Duckworth R. A. Loveless P. D. Vrazel N. E. Wittry B. A. Dahm J. E. Bolliger R. W. Frank P. E. Taylor R. A. Koy J. F. Kucera T. N. Coha J. G. Sasara Loss Control C. J. Schulz (Reliability) C. W. Shumate (Engineering) R. C. Rouse K. D. Bosworth (Training) G. W. Smith (E.P. I) D. L. Terry (Maint. Training) F. G. Velasquez (Instrument Shop) J. M.. Snyder D. E. Jarvis (W.P. Maint.) Sal Salinas (Machine Shop) Deep Sea Terminal Terminal S/S Laboratory Main Office Library East Plant Warehouse PERSON RESPONSIBLE Same . Same Same. Same Same SameSame? Same Same. Same Same Same Same-, Same . Same Same Same Same J. W. Mason Same Same Same Same Same Same Same . Same Same Same WV M. Terry J. E. Bolliger J. Garcia C. F. LeRoy L. H. Owen NOTE: The individual listed as "Person Responsible" must ensure that the manuals are updated as new and revised procedures are issued from time to time. -1- L-000208 SAFETY PROCEDURES MANUAL DISTRIBUTION MANUAL NO. 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 5! 52 53 54 ISSUED TO West Plant Warehouse East Plant I S/S HA Platformer Reserved #1FCCU PC Boilers Alky/Cumene BTX/Hydrar East Plant II S/S Main Control Room 20 Block Comfort Sta. 40 Block Comfort Sta. 60 Block Comfort Sta. V. E. Breckenridge G. E. Pakebusch W.P. Main Control Room Coker Weather Sta. Platformer Weather Sta. MDH/SRU Weather Sta. Daniel Safety PERSON RESPONSIBLE L. H. Owen B. A. Dahm B. A. Dahm B. A. Dahm B. A. Dahm B. A. Dahm B. A. Dahm N. E. Wittry N. E. Wittry N. E. Wittry N. E. Wittry N. E. Wittry Same Same U. G. Frondorf U. G. Frondorf U. G. Frondorf U. G. Frondorf J. C. Bailey 5/19/89 -2L-000209 706 706.1 706.2 706.3 706.4 706.5 706.6 706.7 706.8 706.9 706.10 706.11 706.12 707 707.1 707.2 708 708.1 708.2 708.3 708.4 708.5 709 709.1 TABLE OF CONTENTS SPECIAL LOSS CONTROL PROCEDURES Reserved Hazard and Operability Review Procedure Reserved Process Equipment Trip Bypass Procedure Reserved Motor Vehicle Operating Procedure Drains and Vents Removal/Re-Installation of Out of Service Flare Line Relief Valves Blocking In or Removal of In-Service Relief Valves Reserved Use of Motorized Equipment in LPG Storage Areas Reserved FIRE PROTECTION Reserved Reserved INDUSTRIAL HEALTH AND HYGIENE Respiratory Protection Noise Abatement and Hearing Conservation Radiation Safety Program Hazard Communication Program Significant Adverse Reaction Reporting Procedure PLANT EMERGENCY PROCEDURES Reserved 7/31/90 L-000211-2- CHG 01901 TABLE OF CONTENTS 700 700.1 700.2 SAFETY POLICY AND ORGANIZATION Reserved Reserved 701 701.1 701.2 701.3 701.4 INSPECTION, RECORDKEEPING AND REPORTS Incident/Injury Reporting Procedure Reserved Reserved Safety Audit Program 702 702.1 702.2 702.3 SAFETY TRAINING Reserved Reserved Reserved 703 703.1 703.2 703.3 703.4 703.5 703.6 703.7 PERSONNEL PROTECTIVE EQUIPMENT Reserved Safety Shoe Purchase Procedure Reserved Work Clothing Requirements Reserved Reserved Fall Protection 704 704.1 704.2 704.3 704.4 CHEMICAL CONTROL HF Acid Safe Operating Practices Unloading Procedure - Bulk Commodity Chemical Benzene Safe Operating Procedure Reserved 705 705.1 705.2 705.3 705.4 705.5 WORK PERMITS Work Permit Procedure Confined Space (Vessel) Entry Procedure Hot Work Procedure Isolation Procedure For Equipment and Energy Sources Hot Tap and/or Stopple Procedure -1- L-000210 SAFETY PROCEDURES MANUAL TABLE OF CONTENTS SAFETY POLICY AND ORGANIZATION Safety Policy statement Safety Program Implementation Plan INSPECTION/ RECORDKEEPING AND REPORTS IniOTV7`lllness Keoorti'na Procedure 'Accident Investigation Automobile Accident Reporting Safety Audit Program SAFETY TRAINING Safe Use of Ladders Fork Lift Truck Operating Procedure Operation of Aerial Lifts PERSONNEL PROTECTIVE EQUIPMENT Eye Protection Foot Protection Head Protection Work Clothing Special Protective Equipment Nomex Clothing Fall Protection Hand Protection CHEMICAL CONTROL HP Acid Safe Operating Procedure Unloading Procedure for Bulk Commodity Chemicals Benzene Safe Operating Procudure Tetraethyl Lead Handling Procedure WORK PERMITS -'"Safe Work Permit Procedure -'Confined Space (Vessel) Entry -Hot Work Permit Procedure Lockout/Tagout Procedure '-'Hot Tap/Stopple Procedure 700 700.1 700.2 701 701.1 701.2 701.3 701.4 702 702.1 * 702.2 702.3 703 703.1 703.2 703.3 703.4 703.5 703.6 703.7 703.8 704 704.1 704.2 704.3 704.4 705 705.1 705.2 705.3 705.4 705.5 SPECIAL LOSS CONTROL PROCEDURES 706 Safety Regulations for Outside Contractors 706.1 Hazop Review Procedure 706.2 No Smoking Policy 706.3 Flare System Relief Valve Removal 706.4 Equipment Isolation and Blinding 706.5 Scaffolding Use Requirements 706.6 Vehicle Safe Operating Procedures 706.7 Color Coding of In Plant Equipment 706.8 FIRE PROTECTION 707 Use of Portable Fire Extinguishers Firewater System Use 707.1 707.2 a- INDUSTRIAL HEALTH AND HYGIENE 708 Respiratory Protection Program Hearing Conservation Program Radiation Safety Program 708.1 708.2 708.3 PLANT EMERGENCY PROCEDURES 709 L-000213 CHG 01902 CHAMPLIN REFINING COMPANY Safety Policq Champlin Refining Company considers its employees, facilitiea and inventoriea to be ita moat valuable aaaeta. Protection of theae aaaeta are expected to be given high priority by every employee. Champlin'a empioyeea have made significant efforts to reduce injuries and damages, and Champlin ia proud of those efforts. However, ve are committed to a program of neverending improvement. Therefore, Champlin management has the responsibility to maintain employee safety and property protection programs in an endeavor to accomplish the following : 1. Promote safety awareness at all levels of the Company. 2. Reduce personal injuries and property damage by providing safe working conditions. 3. Provide effective training in work procedures and equipment operation, and require employee compliance with established procedures. 4. Complete accident report forms promptly and completely for management review and provide followup with those i nvolved. 5. Comply with all applicable federal, state and local safety and health regulations. 6. Ensure that all work activities are performed with regard for safety in the community. To help achieve these goals, all Champlin employees are expected to use good safety judgement, and to make injury prevention and avoidance of property damage an important part of every job activity. Champlin Refining Company requires the total individual commitment of all employees in support of this policy. A. J. Tomlinson - President A. S. Tepedino - Vice President R. P. Pavletic - General Manager L-000215 CHAMPLIN REFINING COMPANY: SAFETY PHILOSOPHY The following items highlight the safety philosophy of Champlin Refining Company. These guidelines will show all the employees how Champlin intends to conduct its business. Safety is the No. 1 Priority and requires everyone's individual commitment. 1. Safety is a job requirement. Every employee is responsible for his/her work activities and is expected to follow established work procedures and exercise good safety judgement in performing his/her work. 2. Safety is as much a part of organization's responsibilities as production, costs, labor relations, or any other concern. We must make sure that each supervisor is regarded as the source of safety information for the people reporting to them. 3. Management has significant responsibility for preventing personal injuries. The manner in which employees carry out their safety responsibilities should be evaluated when reviewing their performance. The line organization is responsible for every work activity; therefore, each supervisor must accept his/her share of the responsibility for employee safety. 4. Injuries can be prevented by careful work activities and we must work to prevent all injuries. This is a realistic goal-not just a theoretical objective. 5. It is good business to prevent personal injuries on the job and off the job. 6. All personnel are responsible for conducting periodic safety inspections of their facilities. This prevents small problems from becoming bigger. 7. It is essential that all employees be trained to work safely and to understand that working safely is to the advantage of all employees. 8. Safety training for both new and experienced employees is a continuous function. Safety training must stress the reasons behind operating rules and procedures, since employees will reject seemingly arbitrary statements. 9. Management has established a Health and Safety Committee that meets every month to discuss safety related issues. This committee is made up of hourly, supervisory and safety personnel. This is a mechanism for employees to communicate safety concerns. 10. A Management Safety Committee consisting of the Refinery Manager and General Superintendents meets quarterly to review safety programs, safety procedures, and employee inputs from the Health and Safety Committee. It provides feedback to employees on safety issues and establishes new policies to help respond to the changing environments in our industry. L-000216 rtev. \J-1 rtUgUSC .vj, SAFETY ORGANIZATION FUNCTIONAL PROCEDURE PROCEDURE NO. 35 I. PURPOSE A safety movement within a refinery requires an organization comprised of the management and supervisory level. It is here where the decisions are made regarding the extensiveness of the safety activities and where safety policy is established. U. SCOPE The safety policy and compliance with effective safety activities must permeate the particular operation, department or manufacturing process. It includes each individual comprising a specific plant or refinery. XL. SAFETY ACCOUNTABILITY The Champlin Corpus Christi Refinery requires that the safety of its personnel be each manager's and supervisor's responsibility. It is imperative that safety be acted upon and maintained at the same level as the other components of a manager's and supervisor's position; such as, quality, production, service and cost. Safe work conditions are to be provided and each first line supervisor will require that safe procedures are followed. Accident prevention measures will be successful to the degree each member of the refinery organization accepts safety as an indi vidual concept. IV. PRINCIPLES The following principles have been developed to guide the Corpus Christi Refinery in a safety approach designed to control accidents and prevent injuries: 1. Safety is to be continuously stimulated through total staff and line support. 1.1 Tb furnish the initiative and incentives for progress, the department managers will: - Maintain a consistent comprehensive safety program in their operations. - Tate the necessary action to control accidents by correcting unsafe conditions and requiring safe practices. - Employ the use of personal protective equipment in preventing injuries. - Discuss with line supervisory personnel each week the plan for accident ^ reduction activities. - Maintain plantkeeping standards that promote safe work performance. L-000217 -1- SAFETY ORGANIZATION FUNCTIONAL PROCEDURE PROCEDURE NO. 35 2. Provide consistent safety direction regularly. 2.1 The manager of a department, through line supervision with the guidance of the refinery safety department will administer adequate safety activities at all times: - Inform and instruct those in each job assignment on safe work practices and accident control matters. - Develop safe methods with workers, applying safe procedures and as these are formulated or improved, they shall be put down in written form to reflect the existing practices. - Nfeintaln safe working conditions. The department; its property, machinery and equipment is to be safeguarded considering the safety and health of workers. - The MANAGER of a department is held personally and directly accountable \ for the correction of unsafe conditions and any plantkeeping discrepan cies existing in the department. This shall include whatever follow-up may be required. Ibis paramount safety responsibility cannot be delegated. - Investigate, report, and analyze all work inflicted injuries, no-injury accidents as well as the conditions and factors which brought them about. - Enforce the procedures for reporting all work injuries, however slight, iumediately by the injured employee. - Implement the most effective measures to prevent re-occurrence of any occupational case even those first aid case incidents. - Measure and evaluate injury experience and circulate pertinent data widely as a means of making safety guidance and education more meaningful. 3. Train all workers in safety techniques. 3.1 Line supervisors will give safety training to workers concerning their job, work assignment or task to be accomplished. A supervisor has the opportunity, the authority and therefore is accountable for full instructions to clarify the safe efficient conduct of the work assigned.: - Safety instructions must be given, not only to new employees and to those transferred to unfamiliar exposures, but to all members of a group since safety measures, methods and practices continuously improve to meet new techniques and changing conditions. - Each supervisor's leadership action must set an exanple to his people in the area of safety conduct and the use of personal protective equipment \ in particular. - A supervisor must take iimediate action to correct unsafe practices, personal protective equipment violations and rectify improper house keeping. L-000218 -2- SAFETY ORGANIZATION FUNCTIONAL PROCEDURE PROCEDURE NO. 35 Supervisors will require the use of personal protective equipment and clothing prescribed. Accomplishing a state of recordable injury free performance within the refinery is also a function of operations which requires spontaneous cooperation from depart ment managers and line supervisors to ensure proper enforcement of safety activi ties, accident control measures and injury prevention requirements. Necessary action must be taken at management level to see that unsafe practices, unsafe conditions and inadequate housekeeping receives the department manager's consideration for a compatible solution. Ihe Safety Department cannot fulfull the total functions for the various and essential safety requirements without the full cooperation of all refinery personnel. Safety personnel serve in a liaison capacity in directing the safety approach by providing technical instructions and guidance. Department managers and supervisors must be held accountable for the safety of those in their res pective areas. This accountability is in direct proportion to the number of people they supervise. Richard E. Schneck Refinery Manager L-000219 -3- SAFETY PROGRAM IMPLEMENTATION PROCEDURE PROCEDURE NO. 41 I. THE BASIC SAFETY PLAN In order to reach the goal of safe production, manpower, machinery and material must be dealt with effectively. This is the area in which occupational injuries are inflicted. Industrial accidents are preventable since it is possible to control the causal factors. An unplanned event was permitted to develop when an accident results from a method of operating. The accident is the acute symptom that something has gone wrong. Such symptoms have a basic cause which is either the unsafe practice, the unsafe condition or a combination of the two. Loss control studies made by safety practitioners have established that some 95f of all accidents are caused by unsafe practices. Only a very small per cent results from unsafe con ditions. However, the conditions aspect can become more prominent should inadequate attention be given to the control of physical hazards which are created and permitted to exist. One of these two factors is always basic vhile the remainder may or may not be contributing. Emphasis must be placed on safety violation before the accident is a fact and appropriate recognition should be given for safe practices. II. POSITIVE ACCIDENT CONTROL METHODS Supervision has many methods available for use in the constant movement to establish and maintain safe operations. Of these, there are four that are funda mental. In instances, these apply more to line supervisors and in others equally to all management levels. 1. Fhct Finding: The supervisor must know as much as possible about his equip- , ment, its use, the inherent hazards of his operation, the safe method in which the Job may be accomplished and consider the application of these under circumstances of practical human use. 2. Conimnlcations; Accident prevention will not succeed because a supervisor knows what respective safety measures, mechanical safeguards or personal pro tective equipment are essential. Proper safety instruction must be given with the Job assignment. In addition, it is not what the worker is told that counts because what is understood is what will be done. 3. Discipline: Safety in the final analysis must be a requirement of every task undertaken. To attain individual safe performance to a state of practiced accident control, all phases leading to discipline must be exercised - leadership, training, compliance and progressive corrective action. Pro gressive discipline is applicable among those who do not conform during the three basic phases. L-000220 -1- * SAFETY PROGRAM IMPLEMENTATION PROCEDURE PROCEDURE NO. 41 4. Action; Accidents will only be controlled when the entire organization acts for safety uniformly. There is no such state as neutrality - action for safety is either positive or negative. Safety must be developed through the acceptance and execution of safety responsibilities as they pertain to each supervisory level. III. SAFETY RESPONSIBILITY The Refinery ffenager is directly responsible for the safety of all personnel at the refinery operation's location. It is required that a refinery be operated in accordance with corporate policies of accident prevention. Enforcement must be consistent with the basic safety plan in compliance with Federal Safety and Health Regulations. The Operations Ifenager is accountable for fostering those activities essential to an effective operating safety program. He must require that safety is maintained in the proper perspective with the other components of the production requirements. The Safety Department is responsible for the staff functions of directing the proper implementation of the refinery's safety approach, regulations, activities and standards. Steps must be taken to ensure that unsafe practices and unsafe condi tions receive attention by the department involved for correction. Safety engineers cannot successfully assume the total responsibility for the various and essential safety requirements and are in no position to go so far as to actually enforce safety in the jobs of workers. To do so detracts from the supervisor's authority, creates multiple supervision and weakens acceptance of safety by the workers. Line supervision's influence in requiring adherence to safety procedures and regulations on a daily basis is the most positive factor in attaining and maintaining safe production. Department Manager The department manager is accountable for taking that action necessary to correct conditions determined to be detrimental to safety, safeguarding hazards and establishing safety in his department. A manager is to direct the safety approach in his department requiring those who supervise to comply with and enforce all safety regulations. Praipt appropriate progressive corrective measures shall be imposed by the department manager upon recomnendation from the individual's supervisor, subject to review by the Personnel Jfenager concerning safety infrac tions that warrant the final steps of the formal discipline procedures. The Supervisor's influence must be such that safety is a part of every job. He is \ directly and personally responsible to his department manager for the safety of those he supervises. He must be fully conversant with the safety regulations and set the example for all his people. He must make it clear to employees the require ment that they work safely at all times and that safety violations may be the cause for disciplinary action ranging from a censure to separation. L-000221 -2- i SAFETY PROGRAM IMPLEMEJ^TATION PROCEDURE PROCEDURE NO. Ul The Supervisor, Leaderman, Operator and other persons authorized to provide direction to employees in their work are: 1. To train new people with "safe production" the first requirement of the job including adequate familiarization with the refinery's safety rules and follow up for compliance. 2. To educate all employees under his supervision in the acceptance of operating safely. Thinking safety is necessary to practicing safety. 3. To be aware of his operations to the extent he is continuously alert for hazards that develop. Upon detection take action for correction with follow-up to ensure compliance. Housekeeping must be at all times main tained adequately to support safe conditions. 4. To inspect the area for unsafe conditions and be consistently watchful for unsafe acts as well as accident situations that nay be in the develop ment state. Upon detection take corrective action. 5. To require the necessary safety equipment and protective devices be in use regularly as prescribed. He must assure that such equipment is in good condition. 6. To see that tools and machines are in proper repair and adjustment with sufficient safety guards affixed. 7. To require that first aid cases are reported according to procedure. 8. Tb participate in the overall safety program and hold a formal type safety meeting at least once each month. 9. To conduct group safety discussions relating to a particular operation concerning safety matters pertinent to the shift. 10. To contact each employee on his shift concerning safety no less than 1 time each week. 11. To observe the first aid case trend for the purpose of coaching those with repetitive visits to the refinery's medical facilities in the interest of preventing injuries. 12. To accept No unsafe practices and investigate no-injury incidents, report ing each with corrective measures taken. Bnployee Employees are required to work safely. Each must develop the safe way to do the Job and comply with the refinery's safety rules as well as with the depart ment's safety measures. Qnployees are to assist fellow workers and contribute to the safety of an operation. Refinery personnel are subject to disciplinary measures for the violation of safe operating principles. Performance in the area of individual safety accountability is among the factors to be considered in an employee's progress evaluation. L-000222 -3- SAFETY PROGRAM IMPIEMEOTATTON PROCEDURE PROCEDURE NO. ^1 Purchasing Department Purchase orders placed with,vendors for products, merchan dise, hardware, machinery and equipment shall have been processed considering safety factors to include applicable mechanical guards, safety devices, noise control, flammable characterizations and the chemical aspect. Buyers will advise the safety office of any and all chemicals to be purchased which lave toxic, caustic, corrosive or dangerous qualities. Ehgineering Managers in the ares of these respective functions shall insure that the applicable safety factors are provided for during design and construction whether originating within the department or from outside sources. Adequate inter lock, guards, regulators, fire protection and other mechanical or physical devices shall be provided considering the human element prior to use. The safety office shall be advised of projects and proposed installations in writing at the time the plans are first formulated and also in the event of resufcmission. v ffelntenance Supervisors of the maintenance activities shall provide systematic maintenance services which keep the physical refinery in a safe operating condition. Integrated within this, there must be a preventative maintenance emphasis coupled with routine inspections designed to detect conditions, if uncorrected, might result in accidents. A relationship is to be established which expresses the interdependence of maintenance and production in that those who operate are to take care of their machinery and equipment. Work orders regarding safety shall be evaluated and given priority whenever warranted. Personnel Department in their study of the operations and processes are to empha size the safe methods of performing the particular job which is to be reflected in. any training presented. It is essential the written procedures consider the safety of the employee. Job descriptions must be based on safe practices when developed and express the required safety accountability of the individual in work performance. Medical Facility The intent and objective of the medical treatment and first aid approach is to: 1. Accurately evaluate prospective employees from a health and medical point of view to ascertain their physical condition and capability. 2. Properly classify medical injury or illness cases, directing those that are not job incurred to group insurance for the benefits provided by the plan. 3. Positively identify occupational cases through proper diagnosis and prognosis considering an individual's medical history. \ 4. Promptly refer only those occupational cases so determined by the attending physician to competent specialists and/or an approved hospital. Emergencies are subject to immediate appropriate referral. L-000223 -4- SAFETY PROGRAM IMPLEMENTATION PROCEDURE PROCEDURE NO. 41 5. Follow-up occupational injury incidents to prevent loss of time from work that is not warranted. 6. Maintain strict confidence concerning an illness or injury reported in keeping with ethical code practiced between a physician and a private patient. 7. Exercise the essential medical surveillance among employees as required to ascertain the extant of exposure to materials known to be a health hazard and take corrective action as indicated by the clinical results. It shall be established which operators require this routinely and appropriate medical shall be afforded when emergency exposure occurs. Central Safety Conmlttee is comprised of all department heads and has the responsibility to decide matters of refinery safety; such as, general safety policy, safety practices, safety principles or policies, establish disciplinary procedure for safety violators and solve safety natters that are in conflict or suspense. This ccrnnittee will function on a similar basis as a regular staff meeting with the refinery manager and shall meet the second Tuesday of each month. L-000224 -5- 5 champlin REFINING COMPANY CHG 01903 t Procedure No Issued. Revised. Page l of 4 701.1 7/29/88 INCIDENT/INJURY REPORTING PROCEDURE I. PURPOSE To establish a program for the reporting and recording of incidents and injuries that occur at the Corpus Christi Refinery. II. SCOPE This procedure applies to all Champlin employees that work at the Corpus Christi Refinery and associated facilities. HI. DEFINITIONS A. Injury/Dlness - An injury/illness is a medical condition which arises from an event which occurs at the refinery during the performance of work. B. Incident > An event which has the potential for injury and/or property damage. Incidents could involve either Champlin personnel and/or contract employees and could include any of the following: - Fires Near Miss Material Losses Property Damage C. Incident/Injury Fact Sheet - A document which provides a mechanism for the reporting and investigation of refinery injuries and/or incidents. (Attachment #1) IV. PROCEDURE A. On the job injury/illnesses, regardless of the extent, must be reported immediately to the employee's supervisor in order for proper medical treatment to be administered and for an investigation to be completed. L-000226 EchamplinREFINING COMPANY Procedure No Issued. Revised. Page 2 of 4 701.1 7/29/88 INCIDENT/INJURY REPORTING PROCEDURE IV. PROCEDURE (Cont'd.) A. Whether an employee must seek medical attention immediately or if there is a delay in the onset of pain or discomfort following an injury which prevents prompt notification then he/she must report the incident to his/her supervisor as soon as possible. If the employee is off work when he/she realizes that an on-the-job injury occurred and he/she is not able to contact their supervisor then notification to the on-duty shift supervisor or plant nurse is required. B. The employee's supervisor must then complete the * Incident/Injury Fact Sheet* before the end of the work shift on which the injury occurred or as soon as he becomes aware of the injury if there is a delay in reporting by the employee. The supervisor should'involve the injured employee in the entire investigation whenever possible. C. Any employee who observes an incident within the refinery that has the potential for injury or property damage should complete an * Incident/Injury Fact Sheet" in order for corrective action to be taken to prevent a recurrence. Once the form has been completed then the employee should send it to his/her supervisor for his/her review and routing to the appropriate management personnel. D. The person completing the "Incident/Injury Fact Sheet* must: 1. Enter the name, department, and job classification of the person who was injured or otherwise involved in the incident. 2. List any other person(s) who was involved in the incident/injury. 3. Note the date, time of day, and day of week that the incident/injury occurred. 4. List the exact location where the incident/injury occurred (i.e., E.P. II, 30 Block, base of #2 FCC reactor). 5. If the incident involved an injury, so indicate and describe the nature of the injury and the body part affected (i.e., bum (R) forearm, laceration (R) index finger). Also indicate the medical attention that was received. L-000227 champlin REFINING COMPANY Procedure No issued: Revised: Page 3 of 4 701.1 7/25/8 INCIDENT/INJURY REPORTING PROCEDURE IV. PROCEDURE (Cont'd.) D. 6. Describe in detail exactly what occurred to the best of your knowledge. Also indicate the employees involvement who is noted on the top of the form. If it is necessary, talk to witnesses in order to obtain all details so that proper corrective action can be taken. If statements by witnesses are too long to incorporate into the description then attach them to the final report. 7. Describe how this job could be done without incident such as a change in procedure, equipment, or more careful preparation by the person involved. Be sure to include the injured or involved employee(s) in this portion of the investigation so as to obtain all alternatives for corrective action. 8. Indicate what corrective action you are taking or are recommending to be taken to eliminate the cause of the incident/injury. 9. If the incident involved an injury then the injured person must sign the report next to "involved employee" and any witnesses should also sign the report. If the incident did not involve an injury then the person who observes the event should sign next to "witnesses". 10. The report is then signed by the employee's supervisor and forwarded to the appropriate management personnel noted on the form. All copies of the form must stay attached during the routing process in order for all comments to be included in the final document. E. Report Distribution 1. Once the "Incident/Injury Fact Sheet" is completed by the employee or supervisor it must be routed to the Area Superintendent, Department Head, and Refinery Manager. During their review they will include any comments into the section titled "Supervisory Remarks" and affix their signature before forwarding it to the next person on the list. L-000228 champlin REFINING COMPANY Procedure No Issued. Revised: Page 4 of 4 701.1 7/29/88 INCIDENT/INJURY REPORTING PROCEDURE IV. PROCEDURE (Cont'd.) E. 2. When all designated personnel have reviewed and signed the document the Refinery Manager will distribute the final copies. 3. The original will be forwarded to the Safety Department where the bottom portion of the form will be completed by Health Services and filed. F. Notification 1. On the reverse side of the "Incident/Injury Fact Sheet" there is a diagram indicating the required action should an injury occur. It prescribes that all injuries must be reported before the end of the work shift and that the report be completed by the supervisor before he/she leaves the refinery. In addition, it requires that should an ambulance be called to render aid to an injured person that the department management and the safety department be notified immediately so that an investigation can begin. Other action required by the logic diagram must be taken as dictated by the situation. Refinery Mairoger Attachment O &~ i L-000229 ~ l '-rV^; - ev* r- omtaniBfimir a fiMwarc [gAEfr aiKiitirn- (Supervisor - complete by end of shift) Employee Name:__________________________________________ Department. Job Classification:________ ________________ ___________ Other Employees Involved In Incident:________________ -_________ Incident/lrjury Date.___ __________________ Time pm Day Of Week Plant / Unit Location Where Incident Occurred.____________________________________________________ --^ Did Incident Cause Any Injury ? YES MO 4 Describe Type Of Injury & Part Of Body Injured:___________________________________________________ What Medical Attention Was Received (You can check more than one) None In-Unit First Aid Describe Incident and Emplouee's Part In It: Nurse Sent To Doctor Hov Could This Task Have Been Done Without Incident ? ---------------- :------------------ :----------What Action Did You Take To Eliminate The Cause Of This Incident ? Signatures - Involved Emoloueefs)j_________ _______________________________________________ Signed - _______________________ - Witnesses :;:. am Date____________________ Timepm V" ( Supervisor ) ....... Supervisory Remarks_________________ : Area Supt. / Mgr-1:' '.......... Dept. Head Ref. Mgr. TO BE COMPLETED BY HEALTH SERVICES | OSHA RECORDABLE Injury Type: First Aid Mo Restriction Restriction Lost-Time Treatment / Disposition: injury Coding: CAUSE - ^ Nurse Signature- Orig.. Safety RESULT - . Yellow: Dept. Head BODY PART - Date: Pink : Refy . Mgr. L-000230 c champlin A Subsidiary of Union Pacific Corporation AUTOMOBILE ACCIDENT REPORT PROCEDURE NO. 23 -ev. \ -- 1 -tTiS 2, -L-yC- I. PURPOSE This is to establish a uniform plant wide procedure of reporting automobile accidents while on canpany business or in a company owned vehicle. II. SCOPE This procedure shall apply to every (employee) individual working in the Corpus Christi Refinery. m. GENERAL The procedure shall be followed in the event an employee is involved in an auto mobile accident' while on company property or company business in a company-owned vehicle. These instructions shall, be followed regardless of who is at fault. An automobile accident is defined as a collision of a company vehicle with another vehicle, or object, which results in loss or damage to either vehicle, property or equipment. Report all accidents by phone: A. Office hours B. After hours Safety Department, East Plant Safety Department, West Plant Braxton D. Routh Jim P. Kucera (512) 887--333^ (512) 289-3441 (512) 991-^153 (512) 991-5032 On Plant Site Driver: Stop and keep calm. Do not leave scene. Notify supervisor and Safety Department Immediately. Render first aid or call Health Services (Ext. 320/355) for assistance. Complete the Champlin Automobile Accident Report Pom. Off Plant Site Driver: Form SFT-10 (8-77) Stop and keep calm. Do not leave scene. Notify the appropriate law enforcement official Immedi ately advising them should an ambulance be required. Render first aid where necessary. Do not discuss accident (except with supervisory or authorized Champlin employee or representative of our insurance carrier, or police). L-000232 -1- AOTCMOBILE ACCIDENT REPORT PROCEDURE NO. 23 Off Plant Site Driver: (Cont'd) Complete the Champlin Automobile Accident Report. Do not admit liability in any manner; assume any costs, or admit violations of any laws. Secure names and addresses of available witnesses where necessary. Complete forms necessary to report accident to the state in which it occurred. State forms may be obtained from the investigating officer the State Highway Patrol, local Police Department, or the State Department of Public Safety. Imnediate Super visors of Driver: Insure that reports are submitted within 24 hours to the Safety Department. Responsibilities listed above as belonging to the driver become those of his inmediate supervisor in the event the driver is unable to perform these require ments. Distribution of Report: Original and copy to the Safety Department. -2- L-000233 e cnampun -----------!T___ Company Location Name Address AUTO ACCIDENT REPORT Location (H* Street dry. Sum. ZJ# Cede) Time & Place of Accident Oats of Accident . Place ol Accident (wenei. Oar. ... _ .f ^ A.M ( WhIIW = pm `fisr Company and Oriver Information Driver's Full Nam# Onver's Home Address Unit No. jMaks ol Vthiels (Ne., tweet City. SUM. Zip Ceee) Age Type (Coupe. Seat*, rr>**| Year Sex Description ol Damage Police O.ept Agency Name 4 Address Owner 4 Address <* s***1- c*iy. $**>. Codei (Me. Street. city. Sum. Zi* Cede) Other Vehicle and Oriver Information Orivar's Name G l same as owner check boa Driver's Address G il same as owner check box Make ol Vehicle (Ne. Street City. State. Zip Ceee) Typo ICmM. Uil, tn| Insurance Company Name A Address Description of Oamege (Ne Street. Oiy. Sum. Zip Ceee) Persons Injured Nature ol iniury Nsmi a Address (Ne. Street. Off. SUM. Zip Ceeer Witnesses Nature of Injury Name A Address Vanre a Address (Me. Street, C?y. State. I.e Ceee) (Me. Street City. Sum. Zip Ceeej The Accident Describe Whet Happened -- ' OeM 1 on.ca# Name | p i1 i I mtene c Mumper ) Q Hemp 1 Ajs S 1 ***oe Mumper J Z teem 3 Nni j Yf , V.nicls LiCSOSS 1 i rear State | | A Mumper i ^*e# Mumper I 0 Worn j C Nome ! - j Ce van i ott ' 3*^r-r Q Meme Ape Ce Van j om ,, --------- 1 pmoa* Mumeer Q wora C Home Pepee Mumoer C tvora C Heme Other Property Damaged cDwner 4 Address Cmd ol Property (Ne. Street City. State. Zia Ceee) | Extent of Damage ORAW ROUGH OlAGRAM OF ACClOENT; Show your car at ; other cor at; 2 ) at the collision occurred. Show direction and distance *'aveied before crash by solid line thus: Than at point of crash: third, positions and distances traveled after coliii'Cr ow distanca and diraction travaiad after crash by dotted line thus: Reported By Data Reported Distribution: Original and on# copy to: ins. Oapt. Ft. Worth t Copy to Salary Dept iMt*n (ta> da AoomoMAi spacc nccocd usa sack) 1 Copy lor Onvar L-000234 champlin REFINING COMPANY Procedure No, j Issued; I Revised; Page i of 3 701.4 8/10/87 5/26/88 SAFETY AUDIT PROGRAM I. PURPOSE To utilize a safety audit program which encourages participation and effectively addresses safety practices and conditions within the Corpus Christi Refinery. II. SCOPE This audit program applies to ail facilities at the Champlin Corpus Christi Refinery. III. RESPONSIBILITIES A. Area Operations Supervisors 1. Responsible for prioritizing and insuring the completion of all work following each inspection tour. 2. Initiate any follow-up action necessary on incomplete work to insure completion. 3. Accountable to the Management Safety Committee for status of work completion. B. Area Maintenance Supervisors 1. Responsible for prioritizing, directing, and scheduling of maintenance work needed following the inspection tours. 2. Initiate any follow-up necessary on incomplete work. C. Team Leader 1. Establish audit schedule and notify team members and area supervisors of proposed date. 2. Conduct orientation with team prior to inspection to review scope and previous inspection items. 3. Schedule wrap-up meeting with area and maintenance, supervisors following the inspection. 4. Follow-up on inspection items as necessary to insure work completion. L-000235 5 champlin REFINING COMPANY Procedure No. Issued: Revised: Page 2 of 3 701.4 8/10/87 5/26/88 SAFETY AUDIT PROGRAM IV. PROCEDURES The refinery is to be divided into eleven (11) areas which are as follows: 0 #\ Terminal, also the Blender Building and #1 Pump House, Waste Water Treatment 0 Maintenance Shops, Truck Shop, Tool Room, Welding Shop, Operations Building, Carpenter Shop, Terminal Truck Loading 0 #2 and #3 Terminals, PPG Dock, and Southwestern Dock 0 Cumene, BTX, Hydrar, Alky and Boilers 0 West Plant - Platformer, MDH, SRU, Boilers, Coker, Wastewater, Tank Farms, Control Room, Maintenance Buildings, Offices 0 Areas 30, 40, 50 0 U Terminal 8 #1 Cat Cracker, #1, 2, 3 Crude Units, #3 Vacuum Unit, HA Platformer and MTBE 8 Areas 60, 10, 20 and Control Room 8 Laboratory, Safety,Environmental, Warehouse and Main Offices 8 HI, #2, & #3 Docks, 90 & 91 Areas, ButaneTruck Rack B. Each area will be inspected during the last month of each quarter. C. Audit teams for each area are to be comprised of four personnel staffed as follows: 1. One hourly Operations/Terminal/Laboratory 2. One hourly Maintenance 3. One Process/Project engineer 4. One process supervisory representative L-000236 3 champlin REFINING COMPANY Procedure No Issued: Revised: Page 3 of 3 701.4 8/10/87 5/26/88 SAFETY AUDIT PROGRAM IV. PROCEDURES (Cont'd.) D. Audit Format 1. The Team Leader will: a. Contact the hourly operations representative and schedule date and time for the inspection tour, at least one month ahead, then contact remaining group members and area supervisors. b. Conduct a training session prior to the first inspection tour in hazard recognition and safety manual updates. c.. Meet with supervision following the tour and discuss findings and establish priorities. d. Collect all reports and data, so as to initiate all necessary work. 2. The attached inspection checklist is to be used as a guide format for each audit. Attach. L-000237  c ctiamplin A Subsidiary of Union Pacific Corporation LADDERS, FIXED AND PORTABLE PROCEDURE NO. II PURPOSE Ladders are within the scope of safe working surfaces regulations as defined in 29 Code of the Federal Register 1910. Both fixed and portable ladders shall conform to the design standards, be properly maintained and safe procedures must be applied by those who use them. SCOPE Ladders, whether fixed or portable, shall meet safe design, construction and installation requirements. Personnel in the refinery are held accountable for applying safe practices in the proper use of any ladder and shall inspect the ladder to determine that it is in a.safe condition for use. PROCEDURE A. Design and installation of fixed ladders must meet the following requirements: 1. Be designed to withstand a single concentrated load of at least 200 pounds. 2. Have rungs of a minium diameter of 3A inch for metal ladders or lV8 for wood ladders. | 75*-90* PREFERRED ' PITCH UMUMiOmu, T^T V V METAL 1-1 /r* WOOD MIN. OIA. CLEARANCE S= 15" MIN. 254* 1. | CLEARANCE ICLEARANCE Ev ^U! \ 12" MAX. BETWEEN RUNGS ift-- 1 j1"min I -- MIN Clearance /or Unavoidable Obstruction at Rear of Fixed Ladder F9o-rrmn SFT-10 -1- L-000240 c champlin A Subsidiary of Union Pacific Corporation LADDERS, FIXED AND PORTABLE PROCEDURE NO. 11 3. The maximum spacing for the rungs is 12 inches apart and the minimum inside width between side rails is 16 inches. ft. When of a metal construction that is subject to rust and other such corrosion, shall be painted, and if of wood, treated with a nonirritating clear preparation which resists deterioration. 5. Installation for a safe ascent or descent is preferably a pitch of from 75 to 90 inclusive. 6. Body clearance for climbing a ladder with a 90 pitch must be a minimum of 2% feet and 3 feet when the pitch is 75 unless a safety cage is provided. 7. Clearance for toe space in back of the ladder shall be at least 7 inches. 8. Rungs must be clear of obstructions in front and in the rear. Unavoidable obstruction to the rear must be inches above a rung and lh inches below the next upper ring so that there is no interference when placing the foot. 9. Cages are required when the length exceeds 20 feet. 10. The climbing side of the ladder clearance shall be at least 36 inches for a pitch of. 75 and 30 inches for a pitch of 90. 11. Landing platforms are necessary when the length is over 30 feet.. A platform is required for ladders with cages for each 30 foot section and every 20 feet when unprotected. 12. The side rail at the top end is to be at least 3^ feet above the upper most rung which must be at the same level as the landing whether a single ladder or a number of sections of ladders. 13. A clear width of 15 inches on each side of the center line of the ladder is required (unless with cages or walls). B. Safe use of single and extension ladders: 1. ladders should be positioned so that the horizontal distance from the base to the vertical plane of the support Is approximately one-fourth the ladder length between the ladder and the support. (For example, place a 12-foot ladder so that the bottom is 3 feet away from the object against which the top is leaning.) 2. Ladders are not to be used in a horizontal position as runways or scaffold boards, etc. Greater horizontal angles than prescribed in Rule 1 above should not be used. form SfT-10 (1-77) L-000241 e chomplln A Subsidiary of Union Pacific Corporation LADDERS, FIXED AND PORTABLE PROCEDURE NO. 11 ' 3. Ladders should not be positioned In front of doors that open toward the ladder unless the doors are secured to prevent opening. Ladders should have suitable feet for the flooring type on which they will be set. Example: Concrete floors require rubber covered feet, loose soil requires pointed type feet, etc. 5. ladders should be lashed or tled-off prior to performing any type of work from the ladder. A second man.must hold the ladder in position at the bottom while it is being securely fastened at the top level. 6. Ladders should extend at least three feet above a roof level, pipeline, I-beam, etc., when exit is to be made from the ladder.' 7. Ladders should never be positioned against a fire water sprinkler or the sprinkler water line. 8. Ladders should never be positioned against or near (within reach) \ electrical power lines. 9. Ladders should never be modified or spliced together. 10. Portable ladders should never be occupied by more than one person at a time. 11. Ladders should be kept clean of grease, oils, and dirt that may conceal defects or cause it to be slippery. 12. Ladders that are defective should not be used, but should be tagged or marked so they will be repaired or destroyed. 13. Do not climb higher than the third rung from the top. 14. Always face the ladder when ascending or descending the ladder. 15. Always use both hands on the ladder when ascending or descending. 16. Always obtain help when positioning long ladders that could become unbalanced and fall. 17. After each use of a ladder, clean. Inspect, and properly store it away. If defects are noted, promptly remove it from service for appropriate disposition. 18. Always inspect a ladder prior to usage for loosened, weakened, or damaged side rails, rungs, feet, pulley ropes, catch latches, etc. Do not use the ladder if there is evidence of damage until it has been properly Inspected and tested. 19. Ladders should never be set on top of unstable objects such as 'tables, boards, boxes, barrels, etc. Focm SFMO L-000242 c champlin A Subsidiary of Union Pacific Corporation LADDERS, FIXED AND PORTABLE PROCEDURE NO. 11 20. Extension ladders should always be erected so that the upper section side rails lay on the top side of the lower section side rails. 21. Adjustment of extension ladders should be made only when standing on . the floor at the base of the ladders. 22. Ihe top section of an extension ladder must not be substituted to serve as single ladder. 23. Metal ladders are not approved when working on or with electrically powered systems. 2M. Extension ladders shall not be taken apart for usage. 25. Do not skip ladder rungs when going up or down. 26. If you stand on a ladder to perform a work function, you are required to be tied-off with a safety belt and life line. S C. Safety precautions for step ladders: A step ladder is defined as a portable ladder which is self-supporting, nonadjustable in length and consists of one section. The size of a step ladder is determined by the length of .the side rail. Step ladders considered to be the industrial type range from 3 to 20 feet in length and are designed heavy duty. Use of a step ladder longer than 20 feet is not permitted. 1. Step ladders should never be used as straight ladders. 2. Step ladders should never be climbed past the second step from the top. If higher access is needed, get a taller ladder. 3. Step ladders should never be repositioned while standing on them (by walking the ladder). *. The back side of a step ladder should never be used to climb on or stand on. 5. Step ladders should not be used for braces, skids, guys, or for other than their intended purpose. 6. Damaged or defective step ladders should not be used. 7. Step ladders should never be set on top of boxes, barrels, or other unstable bases to obtain additional height. 8. Step ladders should not be positioned in front of unguarded doorways. 9. Step ladders should always be fully opened and locked in the open position when in use. 10. Cnly one person should be on a step ladder at a time. Form SFT-10 (1-77) e champlin A Subsidiary of Union Pacific Corporation LADDERS, FIXED AND PORTABLE PROCEDURE NO. 11 11. Step ladders should be faced while ascending or descending. 12. Oil, grease, dirt, etc., should be cleaned from step ladders prior to usage. 13. Only approved type step ladders should be used - homemade and modified ladders are not permitted. 14. Step ladders should always be promptly stored when not being used. 15* Step ladders should be inspected before and after use. Damaged or defective ladders should be tagged and removed from service. 16. Step ladders should not be painted with colored paint. 17. Metal ladders shall not be used when working on or near electrical power sources. 18. Do not skip ladder rungs when going up or down. D. Fixed ladder safety procedures: 1. Both hands shall be free of tools and/or materials when climbing or descending. 2. Both arms and hands shall be free of ailments or injuries that affect the safety of climbing up or down. (One must be capable of supporting body weight by holding onto a rung with one hand.) 3. Feet and legs mast be free of ailments and/or injuries that would affect the safety of climbing up or down ladders. If you have a dis ability or injury, check with your supervisor before climbing. 4. Only one person at a time is permitted on a straight ladder section. 5. The ladder cage shall not be used to rest against when moving up or down a ladder. 6. Electric power cords, air hoses or tag lines, welding, oxygen, acetylene lines, etc., shall not be routed inside the ladder cagewells. 7. Ladder rungs, side rails, and cages are not desired for supports or tie-offs, and shall not be used for such. 8. Ladders shall be maintained safe for climbing at all times unless barricaded off at all entrances. E. Care and maintenance of ladders: 1. Store when not in use - ladder should be stored in proper place in unit. Form STT-IO (77) L-000244 FORK LIFT TRUCKS OPERATING PROCEDURE PURPOSE To establish parameters for safe fork lift operations. The operators of fork lifts shall have training in driving skills and operating techniques coupled with safe performance testing. SCOPE OF POWERED INDUSTRIAL TRUCK TRAINING AND INSTRUCTION The operator's training course shall include such requirements and principles as: 1. A visual acuity examination. 2. An audiometric test. 3. Safety instructions. 4. Training in driving the truck. 5. Techniques of operating (working) the truck. 6. Preventative Maintenance accountability. 7. Written examination (safety, maintenance, driving, operating). S. Performance demonstration. 9. A valid State Vehicle Operator's License in the event public roads are used for transporting. 10. The instructor shall have completed a qualifying formal Fork Lift Training Course. SAFETY GUARDS AND WARNINGS Fork lift rider trucks shall be fitted with an overhead guard manufactured in accordance with ANSI B56.1. Should operating conditions not permit; a load backrest type guard shall be used to contain the load minimizing the possibility of any part of it falling into the mast. Overhead guards should be such to offer protection from the impact of small packages, boxes, loose parts, bagged material, hardware sections, etc. applicable to a representative job or material handling situation. The standard overhead guard is not to be construed as adequate to withstand the impact of the falling total load capacity of a truck. If battery-operated equipment is used, the battery charging area is to be designed with adequate ventilation and a NO SMOKING sign posted since hydrogen gas is emitted during the charging process. L-000245 FORK LIFT TRUCKS OPERATING PROCEDURE IV. SAFETY PRECAUTIONS FOR OPERATING 1. The forks are to be fully lowered when the operator dismounts from the truck. 2. When a fork lift truck is left unattended in that the operator is more than 25 feet from the truck, the control lever must be positioned in neutral, the power shut off, key removed and the brakes set. 3. Fork lift trucks must be examined before each use for any conditions adversely affecting the safety of the vehicle. Lift trucks used around the clock must be inspected at the beginning of each shift by the on-coming operator. 4. When unloading or loading from carrier vehicles, trailers or railroad cars with fork lift trucks, the operator must secure the truck, trailer or railroad car by setting the brakes and placing the wheel chocks under the wheels properly. Also, it is an operator's responsibility to safely place the portable dock boards in position securely with the devices which prevent their slipping during loading and unloading. 5. If the Toad being carried obstructs the forward view, the operator is required to travel with the load trailing. The Ipad shall always be upgrade in ascending or descending grades in excess of 10%. 6. Should a powered fork lift truck be operated on public roads, the operator will display a slow moving equipment emblem at the time this occurs. V. DRIVER-OPERATOR SAFETY PROCEDURES 1. Know and follow all safe operating practices. 2. Only trained and authorized employees are to drive and operate powered fork lift trucks. 3. Operators shall not permit anyone to become trapped between the fork lift truck and a fixed object. 4. No riders (passengers) on a fork lift truck. 5. No persons shall be allowed on or under elevated forks, empty or loaded. 6. Speed limit is 8 MPH for fork lift trucks. 7. Traveling side by side with another fork lift truck is prohibited. 8. Allow three (3) truck lengths when overtaking another fork lift truck. L-000246 FORK LIFT TRUCKS OPERATING PROCEDURE V. DRIVER-OPERATOR SAFETY PROCEDURES (Cont'd.) 9. The driver is required to slow down for wet or slippery floors. 10. Body members shall not be extended beyond the running lines of the fork lift truck or within the mast area. 11. The driver must not operate the mounted type fork lift truck from the floor. 12. The driver shall walk around a fork lift truck that has been parked to note the surroundings before starting it. 13. When traveling, the forks of the truck must be within 2 inches to 6 inches off the floor or ground. 14. The driver is required to keep a clear view of the path of travel and also, avoid running over loose objects. 15. Operators shall set brakes, lower forks to the floor, shut off power, remove key and place all controls in neutral when truck is left unattended. 16. Grades are to be ascended or descended with the load upgrade. 17. Fork lift trucks are to be kept under control at all times and oniy loads within the rated capacity are to be handled. 18. Operator shall not enter an area with prohibitive posted floor capacity limitations. Reference: OSHA 29 CFR 1910.178, Articles (m) (n). 'v L-000247 FORK LIFT TRUCKS OPERATING PROCEDURE PURPOSE To establish parameters for safe fork lift operations. The operators of fork Jifts shall have training in driving skills and operating techniques coupled with safe performance testing. SCOPE OF POWERED INDUSTRIAL TRUCK TRAINING AND INSTRUCTION The operator's training course shall include such requirements and principles as: 1. A visual acuity examination. 2. An audiometric test. 3. Safety instructions. 4. Training in driving the truck. 5. Techniques of operating (working) the truck. 6. Preventative Maintenance accountability. 7. Written examination (safety, maintenance, driving, operating). 8. Performance demonstration. 9. A valid State Vehicle Operator's License in the event public roads are used for transporting. 10. The instructor shall have completed a qualifying formal Fork Lift Training Course. SAFETY GUARDS AND WARNINGS Fork lift rider trucks shall be fitted with an overhead guard manufactured in accordance with ANSI BS6.1. Should operating conditions not permit; a load backrest type guard shall be used to contain the load minimizing the possibility of any part of it falling into the mast. Overhead guards should be such to offer protection from the impact of small packages, boxes, loose parts, bagged material, hardware sections, etc. applicable to a representative job or material handling situation. The standard overhead guard is not to be construed as adequate to withstand the impact of the falling total load capacity of a truck. If battery-operated equipment is used, the battery charging area is to be designed with adequate ventilation and a NO SMOKING sign posted since hydrogen gas is emitted during the charging process. L-000248 FORK LIFT TRUCKS OPERATING PROCEDURE IV. SAFETY PRECAUTIONS FOR OPERATING 1. The forks are to be fully lowered when the operator dismounts from the truck. 2. When a fork lift truck is left unattended in that the operator is more than 25 feet from the truck, the control lever must be positioned in neutral, the power shut off, key removed and the brakes set. 3. Fork lift trucks must be examined before each use for any conditions adversely affecting the safety of the vehicle. Lift trucks used around the clock must be inspects at the beginning of each shift by the on-coming operator. 4. When unloading or loading from carrier vehicles, trailers or railroad cars with fork lift trucks, the operator must secure the truck, trailer or railroad car by setting the brakes and placing the wheel chocks under the wheels properly. Also, it is an operator's responsibility to safely place the portable dock boards in position securely with the devices which prevent their slipping during loading and unloading. 5. If the Toad being carried obstructs the forward view, the operator is required to travel with the load trailing. The load shall always be upgrade in ascending or descending grades in excess of 10%. 6. Should a powered fork lift truck be operated on public roads, the operator will display a slow moving equipment emblem at the time this occurs. V. DRIVER-OPERATOR SAFETY PROCEDURES 1. Know and follow all safe operating practices. 2. Only trained and authorized employees are to drive and operate powered fork lift trucks. 3. Operators shall not permit anyone to become trapped between the fork lift truck and a fixed object. 4. No riders (passengers) on a fork lift truck. 5. No persons shall be allowed on or under elevated forks, empty or loaded. 6. Speed limit is 8 MPH for fork lift trucks. 7. Traveling side by side with another fork lift truck is prohibited. 8. Allow three (3) truck lengths when overtaking another fork lift truck. } L-000249 FORK LIFT TRUCKS OPERATING PROCEDURE V. DRIVER-OPERATOR SAFETY PROCEDURES (Cont'd.) 9. The driver is required to slow down for wet or slippery floors. 10. Body members shall not be extended beyond the running lines of the fork lift truck or within the mast area. 11. The driver must not operate the mounted type fork lift truck from the floor. 12. The driver shall walk around a fork lift truck that has been parked to note the surroundings before starting it. 13. When traveling, the forks of the truck must be within 2 inches to 6 inches off the floor or ground. 14. The driver is required to keep a clear view of the path of travel and also, avoid running over loose objects. 15. Operators shall set brakes, lower forks to the floor, shut off power, remove key and place all controls in neutral when truck is left unattended. 16. Grades are to be ascended or descended with the load upgrade. 17. Fork lift trucks are to be kept under control at all times and only loads within the rated capacity are to be handled. 18. Operator shall not enter an area with prohibitive posted floor capacity limitations. Reference: OSHA 29 CFR 1910.178, Articles (m) (n). L-000250 AUTHORIZATION OF PORK LIFT TRUCK OPERATORS PROCEDURE PROCEDURE NO. 50 PURPOSE The chief objective of fork lift tiuck training is to develop the knowledge and skill of an operator essential for properly working this equipment without damage to property or inflicting accidents. This may be accomplished through a planned experience program coupled with formal instruction periods. Such a training course should be designed to embody operating techniques which include safety, maneuvering, driving, material handling, preventative maintenance and rules of the road. SCOPE OF MOBILE EQUIPMENT OPERATOR QUALIFYING CRITERIA The procedure for properly qualifying which permits the authorization of an employee to operate fork lift truck equipment consists of a number of considerations: I. . Prospective employees for mobile equipment operator assignments should satisfactorily pass a comprehensive eye examination and the results of a hearing evaluation test should be recorded. A. Eye test shall enccmpass visual acuity, depth perception, peripheral vision and color perception. Binocular vision is mandatory. Alterna ting vision must be corrected with side shield prescription safety glasses considering costs to an employee as stipulated in a plant's safety glasses program. B. Hearing ability (threshold level) should be sensitive enough whereby the normal voice does not have to be raised to a shout at a distance of four (^) feet for the Individual to respond under general conditions. Deafness of one ear is a disqualifying factor. C. New placements for fork lift equipment operators are to be scheduled for visual and hearing tests by the personnel supervisor. D. The respective supervisor will arrange for the eye and hearing examina tions for active employees who are candidates for an authorized operator. II. Fork lift equipment operators must be trained in their safety accountability, their job duties, the function of the equipment and must accept this responsibility in their daily performance applying all safety measures. The driver-operator is held directly and personally accountable for safety as it relates to safe practices in operating a fork lift. A. ffenagers of the respective departments will request fork life equipment training for prospective operators by the warehouse supervisor who has been designated to conduct this training. -1- L-000251 AUTHORIZATION OP PORK LEFT TRUCK OPERATORS PROCEDURE PROCEDURE NO. 50 B. The employee's supervisor will certify that the trainee has been qualified and is aware of his safety accountability to the extent it is practiced as normal routine by forwarding the completed operator Evaluation Sheet after implementation to the Safety Office. C. Ihe warehouse supervisor will forward the Fbrk Lift Truck Certification to the Safety Office together with the trainees quiz for recording and the file. D. The Safety Office will then issue a certification card which signifies that the training is complete and authorization is condoned. A license as such is not essential to comply with OSHA. III. The fork lift equipment operators qualify for the authorization to operate by: 1. ffeking a satisfactory visual performance and hearing threshold score. 2. Completing the phases of the driver-operator instruction-demonstration course. 3. Inking a passing grade on the written test for fork lift truck operators and receiving approval of performance as required by the operator evaluation sheet. 4. Ffeintaining a valid State drivers license in the event public roads become involved. 5. Prior training in other employment may be accepted if the prospective operator provides such evidence in the form of a training certificate by submitting a copy for the record. However, the VISION and HEARING test, as well as the written EXAM must be satisfactorily passed and are mandatory. IV. Authority to operate may be revoked for failure to comply with established safety regulations during the final stage of the progressive discipline procedure. Inability to practice safety on the part of the operator is cause for disqualification. Operators are charged with safe performance in operating fork lift equipment to include the safety of pedestrians or employees in the area of any particular operation. Accidents involving fork lift trucks will be thoroughly investigated for personnel failure in safety compliance. L-000252 AUTHORIZATION OF PORK LIFT TRUCK OPERATORS PROCEDURE PROCEDURE NO. 50 Example of employee certification: CHAMPLIN PETROLEUM COMPANY (Clock No.) operate an In-Plant Pork Lift Truck (__ at the Corpus Christi Refinery. Date _____________________ Approved by is certified to Type ) Safety Manager L-000253 AERIAL LIFTS PURPOSE This procedure establishes the precautions which must be observed when operating aerial lifting devices. SCOPE An aerial lift is any device that is not manually operated which is designed to position personnel aloft to perform work. Such devices include extendable boom platforms, aerial ladders, articulating boom platforms, vertical towers, crane line suspended platforms or any combination of such equipment. SAFETY REQUIREMENTS 1. Only persons properly trained should be permitted to operate an aerial lift. 2. Lift controls shall be tested each day prior to use to determine that such controls are responsive and in proper working condition. If any defects in the equipment's operation are noted, repairs shall be made by a trained mechanic and the equipment's operation tested before placing it back into service. 3. Those assigned to work on the lift platform shall always stand on its floor and shall not climb on its edge or sit on its guard rails. Planks or material shall not be extended from its platform to form a work position. 4. A body belt must be wom with lanyard attached to a rail of the platform. 5. Boom and platform limits specified by the manufacturer shall be followed. 6. Aerial lift devices attached to mobile units shall be positioned on pads or solid surfaces with the brakes set and the outriggers in place as required by boom elevation and length. Wheel chocks shall be installed when using an aerial lift on an incline. 7. Mobile aerial lift devices shall not be moved when the boom is extended in a working position with workers in the platform, except for equipment which is specifically designed for this type of operation. 8. Means of control from the platform are required for the operation of aerial lift devices which are designed as mobile units. 9. When operating aerial lifts approximate to, under, over, by or near electric power lines, workers must be warned and the proper clearance maintained. Lines rated at 30 K.V. or less require a minimum clearance of 10 feet away from any part of the aerial lifting device. L-000254 AERIAL LIFTS SAFETY REQUIREMENTS (Cont'd.) 10. Aerial personnel lift devices consisting of platforms suspended from cranes are subject to additional safety requirements: * The rated capacity of the crane at the radius at which the lift will be made should be divided by four, and this limit must not be exceeded. * A full cycle operational test should be made prior to lifting employees. The platform should carry twice the intended load during the test lift. * All lifts should be made in accordance with the manufacturer's lifting recommendations. 9 A firm footing, uniformly level within I percent, or one foot in 100 feet, should be provided for cranes. Outriggers for cranes should be appropriately used during hoisting. The stability of the footing should be verified during the full cycle operational test. 9 The load line on which the platform is suspended should have control load lowering. A "free fall option" should not be used with suspended work platforms. * Work platforms suspended from cranes shall be designed with a lifting bridle so attached to its four legs in a manner that the stability of the platform is ensured. The platform shall be enclosed with standard guard rails. * The attachment for work platforms suspended from cranes shall be secured with a shackle or by a closed hook. A tether must also be applied between the platform bridle and crane cable above the ball type weight or at the lower block. * The number of employees to be hoisted shall be kept to a minimum and shall never exceed tour. Workers using the platform should be considered as weighing 250 pounds each. 9 A platform shall not be used during high winds, electrical storms or other adverse weather conditions which could endanger those on the platform. 9 Standard hand signals visible to the crane operator at all times shall be used. L-000255 champlin REFINING COMPANY CHG 01905 Proceaure No. Issued: Revised: Page j of 4 703.1 5/24/88 11/29/90 EYE PROTECTION PROGRAM I. PURPOSE To establish a program for eye protection in an effort to reduce eye injuries. II. SCOPE This procedure applies to all employees, contractors and visitors on Champlin Refining and Chemicals, Inc. property. III. PROCEDURE A. Definitions 1. Non-Prescription Safety Glasses Protective eyewear that conforms to ANSI Z87.1 and does not incorporate lens correction. 2. Prescription Safety Glasses Protective eyewear that conforms to ANSI Z87.1 and incorporates a corrective prescription manufactured for the individual wearer. B. General 1. ANSI approved. protective eyewear shall be worn at all times when working in or visiting the refinery or terminal operating areas, maintenance shops and laboratory with exception of the following: a. Control rooms, offices, change rooms, lur.ch rooms. b. Inside of vehicles. 2. Eye protection is required in any case if the work being performed creates an eye hazard. 3. With the exception of tasks requiring welding lenses, the wearing of dark lens safety glasses is not permitted within the refinery or terminal areas at night or in confined spaces because visibility will be impaired. L-000257 S champlin REFINING COMPANY Procedure No. | Issued: Revised: Page 2of 4 703.1 5/24/88 11/29/90 EYE PROTECTION PROGRAM III. PROCEDURE (Cont'd.) C. Non-Prescription Safety Glasses - Shall be furnished to all Champlin employees and may be obtained from the warehouse. Damaged, lost, or unserviceable glasses must be replaced immediately. D. Prescription Safety Glasses Each employee is entitled to one free pair of prescription safety glasses every two years or upon a change in corrective prescription. New prescription safety glasses will be authorized due to damage (if unrepairable) or loss, with the approval of the Department Superintendent when the time period is less 1 than two years. This replacement need not be accompanied by an updated prescription if it occurs within the two year period. 1. Ordering Procedure To obtain prescription safety glasses, a current prescription not more than two years old must be presented to Health Services; a request form will be completed and given to the employee. This form will be taken to the vendor selected for safety eyewear, who will perform the service as set forth in the prescription. All examination, prescription, and/or fitting fees will be paid by the employee. E. Contact Lenses 1. Contact lenses afford insufficient protection to the eye and therefore are not acceptable as eye protection devices in the occupational environment. 2. Contact lenses are prohibited in those work areas that present a hazard of chemical vapors, liquids, or particulate exposure to the eye. These areas include all Operating areas. Terminal areas. Maintenance shops, and Laboratory facilities. L-000258 champlin REFINING COMPANY Procedure No. Issued: Revised: Page 3 of 4 703.1 5'24/88 11/29/90 : i EYE PROTECTION PROGRAM III. PROCEDURE (Cont'd.) E. Contact Lenses (Cont'd.) 3. Contact lenses WILL NOT BE USED while wearing respiratory equipment. Exception: Any known medically diagnosed condition requiring the continual use of contact lenses shall be brought to the attention of the Safety Department. Such a situation shall justify the wearing of contact lenses in the above operating areas only to the extent that properly fitted chemical splash goggles shall be worn over the contact lenses. F. Additional Eye/Face Protection Additional eye/face protection as listed below is mandatory when performing the following tasks: Obtaining samples Chemical splash goggles Catalyst handling Chemical splash goggles Depressuring gas or liquid Chemical splash goggles (except HF Acid) Handling corrosive chemicals Chemical splash goggles HF Acid handling Class "C" or "D" clothing Burning operations Burning goggles Welding operations Welding hood Grinding/chipping Faceshield and safety glasses Concrete breaking Faceshield and safety glasses Lighting furnaces Flash hood NOTE: Splash goggles shall be worn during any other tasks not mentioned above whenever an eye hazard is created which cannot be controlled by safety glasses. L-000259 a champlin REFINING COMPANY Procedure No. Issued: Revised: Page 4 of 4 703.1 5/24/88 11/29/90 EYE PROTECTION PROGRAM III. PROCEDURE (Cont'd.) G. Eye Protection for Contractors, Sub-Contractors and Visitors Contractors and Sub-Contractors are required to wear eye protection while in the refinery. They shall be responsible for procuring their own safety equipment. Questions concerning this equipment should be discussed with the refinery representative who is sponsoring them. If visitors need to go into areas which require eye protection, their host is responsible to see that the appropriate eyewear is made available and wom. Refinery Manager L-000260 U ' V.- 'v > SAFETY HAT PROCEDURE PROCEDURE NO. 2 ''r ~~ O V . I. PURPOSE This is to establish a uniform, plant wide regulation for the wearing of safety hats, and to establish a color code plan for identification. II. SCOPE This regulation shall apply to every individual working in the plant compound. III. PROCEDURE Safety hats will be issued to all employees through the Safety department. Wear ing of safety hats is mandatory and they are to be worn at all times in every area of the refinery when on the job, with the following exception: A. Inside office type buildings and designated shops excluding the warehouse high bin areas. All supervisors will be responsible for the enforcement of this regulation. IV. COLOR IDENTIFICATION This rule is not mandatory but is suggested. White Engineers and office personnel Green Laboratory personnel Gray . ffeintenance personnel Orange Welders and welders' helpers Blue Operations Tan Terminal Division Red Safety and visitors Yellow Electricians and instrumentmen Gold Supervisors V. PLANT VISITORS Safety hats, if necessary, will be issued by the person being visited. VI. SAFETY HAT USE AND REPLACEMENT 1. The employee and his supervisor are responsible for the replacement of the safety hat should it become damaged or unsafe for use. -1- L-000261 SAFETY HAT PROCEDURE PROCEDURE NO. 2 2. Each employee is responsible for possession and proper care of his safety hat. 3. Safety hats and caps stall be worn to take full advantage of their design. The bill or wide brim should be forward to take-advantage of their con struction. Head protection used for welding service may be turned around to fit the welding hood during actual welding. 4. Federal safety standards stipulate that the head protection shell or sus pension system shall not be altered or modified. No part of the suspension shall be removed, holes or notches shall not be cut into the shell nor shall the shall be painted. 5. The shell and suspension system of head protection is only to be cleaned with soap and lukewarm water. Each employee is responsible for the clean liness of his or her head protection. 6. Should solvent chemicals, adhesives, gasoline and like substances cane in contact with the protective helmet or shell, replacement may be necessary. Contact your supervisor. Use it, but don't abuse it. You take care of it - it will take care of you. L-000262 -2- champlin REFINING COMPANY Procedure No. 703.2 Issued: 1/15/90 Revised: Page j of 3 SAFETY SHOE PURCHASE PROCEDURE I. PURPOSE To establish an effective program which allows employees a simple means of acquiring protective footwear. II. SCOPE This procedure applies to all Champlin employees who work at the Corpus Christi Refinery. III. RULES 1. The Company will contribute up to $65.00 toward employee purchase of one pair of ANSI-approved protective footwear per employee per calendar year. Because the Company is not the end user, the Company's contribution toward the purchase must be pre-tax only. 2. Protective footwear may be purchased at any time during the year. 3. Tennis-type shoes, "deck" shoes and boots having riding-type heels are not approved for purchase for wear in the refinery. 4. Protective footwear may be either a) ordered from catalogues of recognized manufacturers,' or b) purchased at any local area footwear supplier. Remember, the Company contribution will apply only if the shoes are ANSI-approved, and this must be indicated on the receipt. IV. PROCEDURE 1. For catalogue purchases: a) know your shoe size. b) select your preference from the catalogues in the Safety Department. Safety Department personnel will order your shoes for you. L-000263 champlin REFINING COMPANY Procedure No. 703.2 Issued: 1/15/90 Revised: Page 2 of 3 SAFETY SHOE PURCHASE PROCEDURE IV. PROCEDURE (CONTD.) 1. c) when you are notified that your shoes have arrived at the warehouse, try them on in the warehouse. 1) If they fit satisfactorily, you made a good choice. 2) if the shoes do not fit, they will be returned, and you can re-order, d) If you take the shoes home from the warehouse, they will not be returnable. 2. Area shoe store purchases: a) select a pair of shoes which meet the above rules. b) find out from the shoe store exactly what is involved if it becomes necessary to return a pair of shoes. c) pay for the shoes and bring the receipt to the Safety Department. The receipt must state that the shoes are ANSI-approved safety shoes. d) Safety Department personnel will prepare a check request for the pre-tax price of the shoes, up to $65.00 maximum. e) Accounting will prepare the refund check and mail it to the employee. 0 it is the employee's responsibility to personally deal with the shoe store in case of dissatisfaction with the shoes purchased. V. QUESTIONS AND ANSWERS 1. Q: If I buy/order a pair of shoes in December, can I buy/order another pair the next month, in January? A: Yes. 2. Q: If I do not need a.new pair of shoes this year, can I order two pair next year? * L-000264 champlin REFINING COMPANY i Procedure No. 703 2 Issued: 1/15/90 Revised: Page 3 of 3 SAFETY SHOE PURCHASE PROCEDURE QUESTIONS AND ANSWERS (Corn'd.) 2. A: You may order as many pair of safety shoes as you feel you need. However, Champlin is willing to pay up to $65.00 toward the pre-tax purchase price of only one pair of protective footwear, per employee, per calendar year. If you order two or more pair of shoes, the reimbursement will apply to the most expensive pair. 3. Q: If Champlin does not require ANSI-approved footwear on the job. why can't I be reimbursed for any other style shoe? A: Although not every job in our refinery needs the use of protective footwear. Champlin feels those employees who elect to wear safety shoes should be reimbursed for doing so. L-000265 m champlin REFINING AND CHEMICALS. INC. p'ccedure No issued Revised. Page i of 4 701.4 5/31/88 2/8/91 WORK CLOTHING REQUIREMENTS I. PURPOSE To establish minimum requirements for work clothing in order to afford selected personnel working within the Champlin Corpus Christi Refinery some degree of protection against personal injury. II. SCOPE This procedure applies to all Champlin employees, contractors, visitors, customers or any other person performing work within the Corpus Christi Refinery. HI. PROCEDURE A. Pants and Shirts 1. Work pants and shirts (other than Nomex) should be made of cotton material to afford some injury protection from fire. Nylon or polyester fabrics are not recommended due to their susceptibility to melting when exposed to heat. 2. Long sleeve shirts or long sleeve jackets with collar and cuffs are required to be worn by ALL personnel while in the following areas: - Inside all refinery operating area battery limits (excluding control rooms and comfort stations) - Laboratory testing and bottle wash areas - In all outside terminal and wastewater treatment area battery limits. Temporary sleeves may be worn by visitors. 3. Short sleeve shirts are allowed in all other areas and while walking to and from your work area at the beginning and ending of the work shift. Tank tops, sleeveless shirts or shirts constructed of mesh materials are not allowed at any time. L-000266 m champlin REFINING AND CHEMICALS. INC. Procecure No Issued. Revised: Page 2 of 4 703.4 5/31/88 2/8/9! WORK CLOTHING REQUIREMENTS HI. PROCEDURE A. Pants and Shirts (Cont'd.) 4. Short pants are not allowed in any area of the refinery including office buildings. 5. Clothing must be worn in such a manner as to not create a potential hazard. B. Special Clothing 1. Nomex clothing provides improved employee protection from fire as compared to other materials used in general work clothing construction. Employees should therefore consider the use of Nomex while working within production areas of the refinery. In an effort to encourage its use, Champlin will subsidize the cost of Nomex coveralls. 2. All new hourly Operations employees wili be issued four (4) pair of ERT Nomex coveralls or pants and shirts. All other new employees who would normally enter operating, areas will be issued two (2) pair of Nomex coveralls or pants and shirts. 3. Employees working in areas or performing functions that, in the opinion of management, require the use of Nomex will have the coveralls or pants/shirts provided at company expense. Areas/functions requiring Nomex clothing are: (1) Coker personnel (2) Laboratory personnel (designated areas) (3) Maintenance welding personnel (4) Regularly assigned E.R.T personnel (issued by Safety Department) 3. (a) Replacement of protective clothing will be provided at company expense when, in the opinion of the respective superintendent or Safety Department, the article is "unusable" and turned in for replacement. (Limit: 4 pair/year). L-000267 EchamplinREFINING AND CHEMICALS. INC. Procedure No J Issued. Revised: } Page 3of 4 703.4 5/31/88 2/8/91 WORK CLOTHING REQUIREMENTS III. PROCEDURE B. Special Clothing (Cont'd.) 4. Employees not working in areas or performing functions that, in the opinion of management, require the use of Nomex clothing (which are listed above) may at the option of the employee elect to wear or not wear Nomex clothing. (a) In order to encourage the use of Nomex, the company will subsidize 75 % of the purchase price of approved Nomex clothing and allow up to two (2) pair per calendar year. The employee's 25% portion will be paid through payroll deduction. ) (b) Replacement of damaged Nomex clothing at company expense will be determined on a case by case basis by the department superintendent. This would not include normal wear and tear deterioration. 5. Employees may purchase other Nomex products at 100% of cost (stock list available in department office). This will be done through payroll deduction; either one lump sum deduction or over a two month period (i.e., 1/2 one month and 1/2 the second month). C. Shoes 1. . It is recommended that all employees wear steel-toed safety shoes while in all operating, terminal, laboratory, and maintenance areas in order to afford the maximum amount of protection against foot injuries. To encourage the use of safety shoes Champlin has established a program to subsidize the purchase of such equipment for employees. Details concerning this program can be found in Procedure #703.2 - "Foot Protection". 2. It is a minimum requirement that all personnel including contractors and } visitors wear a good quality work shoe that is compatible with his/her job while in the aforementioned areas. L-000268 m champlin REFINING AND CHEMICALS. INC. issued j Revised | Page 4 of 4 703,4 5/31/88 2/8/91 WORK CLOTHING REQUIREMENTS III. PROCEDURE C. Shoes (Corn'd.) 3. Tennis shoes and canvas shoes are not allowed except when walking to or from your work area at the beginning and end of your shift or while visiting refinery offices. 4. Sandals and/or thongs are not allowed at any time within the refinery. D. Other Equipment 1. Other specialized protective clothing and equipment such as hard hats, safety glasses, gloves, etc., are outlined in the applicable safety procedure found in Section 703. L-000269 EchamplinREFINING COMPANY Procedure No. issued. Revised: Page of 703.7 4/15/88 FALL PROTECTION I. II. ^ III. PURPOSE This procedure is to establish requirements for the use and inspection of fall protection equipment. SCOPE This procedure applies to all Champiin Corpus Christi Refinery employees and contractors working at heights of 10 feet or more without the protection of standard guardrails, walls or nets. PROCEDURE A. Use of Fall Protection Devices 1. Approved body belts with rope lanyards shall be worn when: a. Working from boatswain's chairs, powered platforms (J.L.G.). Electrician's high lift, guarded fork lift platform and crane suspended platforms or baskets. b. Working from incomplete scaffolding. Exception: Qualified scaffold builders are exempt from this during scaffold construction only. c. Working in pipeways or on elevated surfaces, platforms or walkways which are not completely decked and guardrailed. d. Working outside any protected platforms. e. Working from extension or fixed ladders when it is impossible to maintain one hand hold at all times. 2. Safety body belts must be worn and used in the following manner or as prescribed by the manufacturer. a. The circle "D" ring must be in center of the back for waist body belts. L-000270 EchamplinREFINING COMPANY Procedure No. ; issued: Revised: Page -of , 703.7 4/15/88 j FALL PROTECTION III. PROCEDURE (Cont'd.) A. _ Use of Fall Protection Devices 2. b. The rope lanyard shall be secured to a substantial.structure. When in a suspended work basket, the lanyard shall be attached to the siderail. c. The lanyard is to be attached at waist or chest height (same level of circle "D* ring). B. A body harness shall be wom when a worker must descend into or ascend out of a process vessel where the vertical distance exceeds 10 feet. A waist safety belt will not be allowed for this purpose. 1. The body harness is also subject to the same safety procedures as those for the waist belt. 2. A body harness attached to an approved personnel grab and lifeline, retractable lifeline, or other suitable fall protection device as deemed appropriate by the Safety Department will be required while climbing rope ladders which exceed 10 feet in length. C. Inspection of Safety Belts and Harnesses 1. Safety belts, harnesses, lanyards, personnel grabs and lifelines shall be inspected on a 3 month basis by the Maintenance Department. 2. Each employee will visually inspect his/her safety belt and lanyard or body harness before each use. Fall protection devices with damage or suspected of damage shall be turned in to the individuals respective supervisor. a. Safety waist belts and body harnesses will be visually inspected for the following: 1. Stitching 2. Rivets 3. Webbing (Frayed, cut, or abraded) L-000271 5 champlin REFINING COMPANY Procedure No. Issued: Revised: Page 3 of 3 703.7 4/15/88 FALL PROTECTION PROCEDURE (Cont'd.) C. Inspection of Safety Belts and Harnesses 2. a. 4. Buckles 5. Buckle Tabs 6. Circle "D" ring b. Safety lanyards will be examined for: 1. Frayed or broken strands 2. Overhand knots in lanyard 3. Abrasions 4. Cuts 5. Proper snap type hook 6. General appearance finery L-000272 champlin REFINING COMPANY Procedure No. Issued: Revised: Page lot 704.1 7/1/87 i 11/29/90 H.F. ACID SAFE OPERATING PROCEDURES I. PURPOSE To establish safety precautions for the handling of H.F. Acid and equipment in H.F. Acid service. II. SCOPE This procedure applies to all Champlin Refining and Chemicals, Inc. and contract employees who perform work where the exposure to H.F. Acid is possible. HI. GENERAL REQUIREMENTS 1. It is essential that those employees who perform work in an H.F. Acid area be familiar with the hazards and know the location and use of the safety equipment in the area. This includes safety equipment such as protective clothing, neutralizing solution, water hoses, breathing air connections, eye wash fountains and emergency showers. H.F. Acid areas are designated by the yellow striped line on the pavement bounding the area. 2. Any person wishing to enter an H.F. Acid area is to obtain written permission from the unit operator for entry. All personnel must receive an H.F. orientation before entering the Alky unit. The operator in charge of the unit is responsible to insure that maintenance work to be done is authorized by the issuance and display of an Alkylation Unit Work Permit or Hazardous/Routine Work Permit. The operator is also responsible for determining and ensuring what is the proper level of protective clothing to be wom within the unit. 3. Supervisors assigning work within the H.F. Alkylation Unit, whether Operations or Maintenance, will instruct employees in the hazards of specific jobs. Special instructions regarding safety may be provided during unit maintenance turnarounds. L-000274 champlin REFINING COMPANY Procedure No. Issued: Revised: Page pf 8 704.1 7/1/87 11/29/90 H.F. ACID SAFE OPERATING PROCEDURES GENERAL REQUIREMENTS (Cont'd.) 4. H.F. Acid is a hazardous chemical with properties peculiar to itself which call for specific handling and treatment. With improper handling, it can be extremely dangerous. Accordingly, it is essential that these safety considerations be thoroughly understood and strictly followed. Under these conditions, but only under these conditions, the use of H.F. Acid will be no more hazardous than that of common acids. Refer to the HF Acid MSDS for specific handling instructions. 5. Water reacts rapidly with HF, generating heat and creating elevated pressures. Equipment which has contained it and/or hydrocarbon acid mixtures must be emptied, purged, vented and drained before neutralizing with soda ash solution and/or water washing. 6. It is the responsibility of the Area Supervisor and the Unit Operator to ensure that all people entering the H.F. Alky area understand this procedure. 7. This procedure will be reviewed by the unit personnel periodically under the direction of the Shift Supervisor and the Unit Operator. PERSONNEL PROTECTIVE CLOTHING 1. Any person entering the unit must wear protective clothing based on the following criteria: a. TYPE "A" PROTECTION WORK TASK 10" Face shield or chemical Routine operating and maintenance splash goggles, neoprene work during normal operating con gloves, neoprene overshoes ditions. Examples are: or boots, acid resisting a. Reading meters and pressure coat. gauges. L-000275 champlin REFINING COMPANY Procedure No. Issued: Revised: Page if 8 704.1 7/1/87 11/29/90 H.F. ACID SAFE OPERATING PROCEDURES PERSONNEL PROTECTIVE CLOTHING (Cont'd.) 1. a. TYPE "A" PROTECTION WORK TASK b. Assembly of equipment that has been neutralized, washed and dried. c. Visual inspection of area by other personnel. d. Washing down equipment in an acid area when there are no leaks. b. TYPE "B" PROTECTION WORK TASK 10" face shield, acid All phases of routine and resisting coat and overall non-routine work during normal pants, neoprene gloves, operating conditions except those neoprene boots. under TYPE "C" protection. Examples are: a. Starting up or shutting down sections of the plant in an acid area. b. Greasing valves. (Note: If high pressure gun is used Class "C" must be used.) c. Adjusting packing. d. Routine switching of pumps and opening and closing valves in closed systems. e. Draining Acid Regenerator and Polymer Surge Drum. f. Taking samples which do not contain acid. L-00027 6 Procedure No. 704.1 Issued: 7/1/87 Revised: 11/29/90 I Page 4of g H.F. ACID SAFE OPERATING PROCEDURES IV. PERSONNEL PROTECTIVE CLOTHING (Cont'd.) l.c. TYPE "C" PROTECTION WORK TASK Air supplied hood, acid In all operations or during resisting coat w/attached maintenance where it is possible neoprene gloves and to have H.F. leaks to the overall pants, neoprene atmosphere. Examples are: boots. a. Taking H.F. Acid-containing samples. b. Removing plugs from open-ended valves either during operation or during clean-up for a shutdown. c. Changing pressure gauges. d. Breaking unions or flanges or tightening fittings. e. Connecting and disconnecting transfer hose for delivery of acid. f. Working on flare line where access to flare line is necessary, as in removing or installing relief valves. NOTE: When performing work that requires "C" clothing, at least two operators must be present, dressed in "C" clothing to take care of emergency situations. d. TYPE "D" PROTECTION Acid resistant encapsulated suit with suitable air pack or air line. WORK TASK Extreme emergencies where it is necessary to enter areas having a high concentration of acid vapor or where there is an acid spray. L-000277 champlin REFINING COMPANY Procedure No. Issued: Revised: Page 8 704.1 7/1/87 , 11/29/90 H.F. ACID SAFE OPERATING PROCEDURES PERSONNEL PROTECTIVE CLOTHING (Cont'd.) I. d. TYPE "D" PROTECTION WORK TASK NOTE: There will always Examples are: be two (2) persons a. Pump or valve packing failure. completely suited in any b. Large leaks where it is situation requiring necessary to shut off equipment. Type "D" protection. 2. H.F. Acid contact with protective clothing must be washed off at once and then neutralized. Protective clothing is acid resistant and is not to be considered totally acid proof. Gloves should be dipped frequently in neutralizing solution without being removed from the hands. The soles of everyone's boots must be neutralized by stepping in a soda bath upon leaving the unit. Protective clothing must be inspected before each use by person using clothing. 3. The following procedure is suggested for the removal of protective clothing: a. Neutralize boots and gloves. b. Remove face shield and hard hat. c. Remove boots (if they are going to be removed). d. Remove outer clothing. e. If any of above clothing is suspected of contacting acid, neutralize it. MAINTENANCE REQUIREMENTS 1. All maintenance personnel who are to work in the acid area must wear the protective clothing as specified on the safety permit issued for the job. The following presents the recommended type of safety clothing classes for the type of work to be done. You will note that the maintenance clothing classifications parallel those of the unit operator. L-000278 champlin REFINING COMPANY Procedure No. j Issued: I Revised: Page pf 8 704.1 7/1/87 11/29/90 H.F. ACID SAFE OPERATING PROCEDURES MAINTENANCE REQUIREMENTS (Cont'd.) 2. Maintenance Clothing Requirements: a. TYPE "A" PROTECTION WORK TASK 10" Face shield or chemical a. Repair of equipment which has splash goggles, neoprene been opened, dissembled and gloves, neoprene boots or neutralized by dumping into overshoes, acid resisting neutralizing tub which cannot coat. have acid trapped in it. b. Work on non-acid equipment in area if there is no other acid area work going on nearby. c. Visual inspection of equipment by supervisors and visitors. d. Welding on lines that have been properly prepared for welding. e. Reassembling thoroughly cleaned acid equipment. b. TYPE "B" PROTECTION WORK TASK 10" Face shield, acid a. Opening additional side or top resistant coat and overall manways on vessels. pants, neoprene gloves, NOTE: "C" Clothing required for neoprene boots. all manways on bottom of columns. b. Reboiler work (after the bottom manway on the column has been opened). c. Pumps after blinding completely and cover plate removal. d. . Dismantling safety valves. e. Hot bolting equipment which has been purged and blinded. L-000279 champlin REFINING COMPANY r I Procedure No. Issued: Revised: Page pi 8 704.1 7/1/87 11/29/90 H.F. ACID SAFE OPERATING PROCEDURES MAINTENANCE REQUIREMENTS (Cont'd.) 2. c. TYPE "C" PROTECTION WORK TASK Air supplied hood, acid a. AH blinding and other openings resisting coat w/attached of lines. neoprene gloves, and b. All work on any piece of acid overall pants, neoprene equipment which is not blinded boots. at the first flange. This includes work on heat exchangers, etc., not individually blinded even though a section of the plant including them is blinded off. c. Work on small piping manifolds even though isolated (disconnected) from system. Includes all work involving opening of meters and meter manifolds until certain no HF is trapped and all repair work on valves in place. d. Disassembly of equipment, whether or not it has been removed from the operating area, which may contain pockets of trapped acid. All pocketed items (pumps, etc.) must be thoroughly cleaned up. Includes exchanger or reboilers which have plugged tubes, until the tubes are unplugged. L-000280 champlin REFINING COMPANY r i Procedure No. Issued: Revised: Page Sf 8 704.1 7/1/87 11/29/90 H.F. ACID SAFE OPERATING PROCEDURES VI. MISCELLANEOUS 1. Maintenance tools used for repairs of equipment in H.F. Acid service must be neutralized before returning them to storage. Crews using electronic equipment are to: 1) neutralize all probes that come in contact with process equipment; and 2) wipe down electronic enclosures with disposable neutralizing towelettes before returning them to storage. 2. Process components exposed to H.F. Acid must be neutralized, and identified with a special green and yellow HF Caution tag upon removal from the unit. 3. Contaminated material, such as cloth, wood, pipe covering, packing substance are to be placed in special cans marked "HF Trash" for removal. 4. Alkylation unit employees will draw samples requested by the laboratory. ]n such instances a standby employee who is properly clothed is required. Sample container fittings are to be neutralized before transporting to the laboratory and neoprene gloves must be worn. 5. The Alky Unit's operator shall complete a Bulk Chemical Receiving Report at the time of hydrofluoric acid delivery which in turn is forwarded to the operating department office. Refinery Manager L-000281 champlin REFINING COMPANY CHG 01906 Procedure No issued Revised Page 1 of 7 704.2 10/8/87 8/10/88 UNLOADING PROCEDURE FOR BULK COMMODITY CHEMICALS I. PURPOSE Bulk chemicals whether they be caustic, acid, process chemicals, or additives present certain hazards during unloading. This procedure is designed to provide safety measures that prevent adverse effects when handling these substances. II. SCOPE This procedure applies to all Champlin employees, suppliers, and transport carriers involved in the unloading of bulk chemicals. IH. PROCEDURE A. Pre-Unloading Preparations 1. When the transport carrier of bulk chemicals arrives at the gate the guard will notify the respective shift supervisor in the area in which the material will be unloaded. 2. The shift supervisor or unit operator will verify the truck contents from the Bill of Lading, initial it and direct the truck to the proper area. 3. Operator's Responsibilities a. The Bulk Chemical Report (attached) MUST be completed and signed by the Operator and forwarded to the Area Supervisor's office with the Bill of Lading following the transfer. b. MUST insure that the storage facility CAN TAKE the delivery, and the MATERIAL on the Bill of Lading corresponds with the material to be LOADED in the tank. c. MUST show the shower to the driver and INSURE its proper operation. d. MUST place appropriate warning signs near the transport to indicate that unloading is in progress. L-000282 champlin REFINING COMPANY '0C3dofS "JO issued Revised age 2of 704.2 10/8/87 5/31/88 UNLOADING PROCEDURE FOR BULK COMMODITY CHEMICALS PROCEDURE (Confd.) A. 3. Operator's Responsibilities e. When unloading FLAMMABLE materials, the Operator MUST verify that the trailer is properly grounded. f. MUST insure that the driver is properly clothed as specified in attached Receiving Report. g. MUST verify that the Air/N2 regulator is properly operating. Blocked in regulator should not exceed 22 psi*. Also insure that the maximum full scale pressure range of the pressure gauge does not exceed 100 psig. 4. Driver's Responsibilities a. MUST observe the SAFETY precautions required herein and is responsible for his/her own unloading operation. b. MUST be properly clothed as specified in attached Receiving Report. c. When unloading FLAMMABLE materials, MUST have the track and trailer properly grounded. B. Unloading Operation 1. Operator's Responsibilities a. MUST visually inspect hose and connections and if acceptable, have the driver connect both ends of hose. b. MUST properly purge all water/material from any air/nitrogen line and hose PRIOR to completing the connection on the tank track to prevent foreign material entering the system. *Exceptions: Sec III. B.l.c. Note 2 on Page 3 of 7 L-000283 champlin REFINING COMPANY 3roceoure i'jc =ssued =<evisea Page 30I 7 704.2 10/8/87 5/31/88 UNLOADING PROCEDURE FOR BULK COMMODITY CHEMICALS PROCEDURE (Cont'd.) B. Unloading Operation 1. Operator's Responsibilities (Cont'd.) c. MUST NOT exceed 20 psi regulated pressure in the off-loading operation of the chemical when using air/nitrogen. NOTE 1: When the carrier supplies his/her own off-loading air/nitrogen, a MAXIMUM of 20 psi will be allowed. NOTE 2: EXCEPTIONS: HF ACID at the ALKY Unit (90 psi) and CAUSTIC AND ACID at the 60 BLOCK (40 psi). d. MUST be present or in visual sight of the unloading lines and/or storage tanks being used in the off-loading. e. MUST stand clear of, and at a safe distance from the unloading lines and/or storage tanks being used in the off-loading. f. MUST inspect hoses and connections when the off-loading begins to insure there are no leaks. 2. Driver's Responsibilities a. MUST not use more than 20 psi pressure when off-loading chemicals either with air/ nitrogen or pump pressure except at the 60 Block and Alky Unit. b. MUST inspect hoses and connections with operator, and get operator approval to make the connections to CHAMPLIN's line. c. MUST be present during the off-loading operation and if he/she needs to leave the unloading area for any reason, the unloading line MUST BE SHUT DOWN and depressured until he/she returns. L-000284 champlin REFINING COMPANY 3'oceOw<'S -No issued Revised Page 40f 7 704.2 10/8/87 5/31/88 UNLOADING PROCEDURE FOR BULK COMMODITY CHEMICALS PROCEDURE (Cont'd.) B. Unloading Operation 2. Driver's Responsibilities d. MUST check the hoses and connections frequently to insure no leaks. e. MUST stand clear of the unloading lines and/or tanks while off loading. f. If problems arise during the off-loading, SHUT DOWN and depressure the operation then contact the operator and/or shift supervisor for further instruction. g. MUST clear the unloading line of all chemical before disconnecting the hose. Any residue is to be drained to a SAFE location for neutralization and disposal. NOTE: DO NOT DISCONNECT any hoses or lines UNDER PRESSURE. L-000285 EchamplinREFINING COMPANY -'oceaure \o issued Revised Page 5 of 7 704.2 10/8'87 5/31/88 UNLOADING PROCEDURE FOR BULK COMMODITY CHEMICALS III. PROCEDURE (Cont'd.) C. Special Considerations I. Unloading Caustic a. Portable warning signs placed during the unloading shall read: DANGER UNLOADING CAUSTIC b. Permanent signs at the unloading point shall read: LIQUID CAUSTIC DANGER! CAN CAUSE SEVERE BURNS OR BLINDNESS Follow safe procedures and protective measures Do not get in eyes, on skin or on clothing Do not take internally and avoid breathing mists Test safety shower and eye wash Wear goggles with plastic hard hat and face shield, rain-chemical suit, rubber boots and gloves In case of contact, immediately flush eyes and skin plenty of water for at least 15 minutes Skin and eye bums - get medical attention Remove contaminated clothing under deluge shower Flush leak or spill area thoroughly with water L-000286 champlin REFINING COMPANY 3'ocec,,re No issued Revised Page 6of 7 704.2 10/8/87 5/31/88 UNLOADING PROCEDURE FOR BULK COMMODITY CHEMICALS PROCEDURE (Cont'd.) C. 2. Unloading Sulfuric Acid a. Portable warning signs placed during the unloading shall read: DANGER UNLOADING ACID b. Permanent signs at the unloading point shall read: SULFURIC ACID DANGER! CAN CAUSE SEVERE BURNS OR BLINDNESS Follow safe procedures and protective measures Do not get in eyes, on skin or on clothing Do not take internally and avoid breathing mists Test safety shower and eye wash Wear goggles with plastic hard hat and face shield, rain-chemical suit, rubber boots and gloves ... In case of contact, immediately flush eyes and skin for a minimum of IS minutes Skin and eye bums - get medical attention Remove contaminated clothing under deluge shower Flush leak or spill area thoroughly with water L-000287 EchamplinREFINING COMPANY Dr ocedure \o ssoed Revised Page 7 of 7 704.2 10/8/87 5/31/88 UNLOADING PROCEDURE FOR BULK COMMODITY CHEMICALS III. PROCEDURE (Cont'd) C. 3. Unloading Process/Water Treating Chemicals a. Portable warning signs placed during the unloading shall read: CAUTION UNLOADING CHEMICALS 4. Unloading HF Acid a. Refer to HF Acid Safe Operating Procedure. L-000288 BULK CHEMICAL RECEIVING REPORT Complete the report by providing information pertinent to the product being received. Attach to Bill of Lading. Forward this report for file upon completion to Area Supervisor. Unit and Vessel Accepting DeliveryDate Chemical Name of Substance_______________________________________________________________ _____________ Vendor____________________________________________________________________________________ . Trucking Firm;____________________ ___________________________________________________________ ________ Truck Number;Trailer License Number Driver's Name__Badge Number Is chemical flammable? Yes___ No___ If Yes. is truck properly grounded? Yes Pressure Rating of Tank Truck _________________ P.S.I. Relief Valve Setting of Tank TruckP.S.I. Storage Tank Capacity Adequate: Opening Tk Gauge(Gal)Available Capacity(Gal) Unloading Method: Air___ N2____ Pump___ Other MINIMAL CLOTHING REQUIREMENTS FOR UNLOADING MUST INITIAL EACH ITEM Caustic & Sulfuric Unloading HF Acid Unloading ProcessAVater Treating Chemical Unloading Wheels chocked Hose/Couplings satisfactory Warning Sign displayed . Safety Shower & Eyewash tested Hard Hat with Faceshield Splash Goggles Rain/Chemical Suit worn Rubber Boots and Rubber Gloves Actual Unloading Pressure Wheels chocked Hose/Coupiings satisfactory Warning Sign displayed Safety Shower & Eyewash tested Class "C" Suit Actual Unloading Pressure Wheels chocked Hose/Couplings satisfactory Warning Sign displayed Safety Shower & Eyewash tested Hard Hat with Faceshield Rain/Chemical Jacket Rubber Boots or Overshoes Rubber Gloves Actual Unloading Pressure Should driver decline to comply with any safety precautions, do not unload and contact shift supervisor. I have checked the documents for this shipment and verify that connection has been made to the proper storage facility and above precautions have been taken. Operator's Signature Time Started____________________________ Time Ended_____________________________ Unloading Driver's Signature Closing Tk Gauge (Ga!)_ Quantity Unloading(Gal) Comments: ________ _________________________ __ ___________ ' 704.2 L-000289 champlin REFINING COMPANY Procedure No. Issued: Revised: Page j of 5 704.3 1/7/88 5/26/88 BENZENE SAFE OPERATING PROCEDURE I. PURPOSE To establish procedures for the safe handling of benzene and to safeguard the health of personnel working in areas of the refinery where potential exposures exist. II. SCOPE This procedure applies to all Champlin employees and contractors performing work within the Corpus Christi Refinery and associated facilities. III. PROCEDURE A. Description: 1. Benzene (C5H5) is a colorless, volatile and flammable liquid with an s aromatic odor. It freezes at 43F and boils at 176F. Its flammable limits in air are 1.3 to 7.1 percent (voiume) and the autoignition temperature is 1044F. Benzene vapors are about 2.8 times heavier than air and will tend to settle in low areas. 2. Inhalation of benzene vapor may result in acute or chronic poisoning depending upon the concentration of the vapor and the length of exposure. The Threshold Limit Value (TLV) is 1 ppm and the Short Term Exposure Limit (STEL) is 5 ppm. 3. Skin contact with liquid benzene should be avoided, as it dissolves the natural oils of the skin, leaving it dry and possibly irritated. w L-000290 EchamplinREFINING COMPANY Procedure No. Issued: j Revised: ! Page ^ of 704.3 1/7/88 5/26/88 I i J BENZENE SAFE OPERATING PROCEDURE III. PROCEDURE (Cont'd.) B. Labelling: 1. Signs meeting the following specifications will be posted in benzene areas. DANGER Benzene Cancer Hazard Flammable - No Smoking Authorized Personnel Only Respirator May Be Required 2. A label having the following wording will be placed on all tanks and containers of liquids which contain benzene in excess of 0.1 percent volume: DANGER Contains Benzene Cancer Hazard C. Exposure Control: 1. Remember that benzene will present minimal hazard to personnel if proper handling procedures are followed. L-000291 EchamplinREFINING COMPANY oroceCu'e No. I issued: ; Revised: j Page j of 5 704.3 1/7/88 5/26/88 BENZENE SAFE OPERATING PROCEDURE III. PROCEDURE (Cont'd.) C. Exposure Control: 2. Pump seal and line leakage shall be kept to a minimum. When preparing equipment for maintenance, benzene should be drained to a closed aromatic sewer with minimal spillage to the slab or ground. When pipelines containing benzene are disconnected, spill containment of the product is mandatory. Material must be returned to the aromatic sewer. 3. During sampling and gauging operations, employees should try to stand at tank hatches or sample points so that the wind is from their side in order to reduce exposure. In addition, full face dual cartridge air-purifying respirators must be wom during these operations. 4. Obtaining samples which contain benzene requires the use of chemical resistant gloves. 5. Where skin contact with liquid benzene is likely, chemical resistant clothing such as gloves, pants, jacket, and/or boots will be wom to eliminate exposure. 6. To reduce personal exposure, clothing which becomes contaminated with benzene should be removed and placed in a closed container. Cords used to hold benzene tank sample containers should be placed in a closed container or in the open portion of the sampler's truck in order to reduce the likelihood of employee exposure. D. Respiratory Protection: 1. Personnel who are required to wear negative pressure air-purifying respirators will receive a qualitative fit test utilizing irritant smoke when subject to working with benzene. The protocol for this procedure will be in accordance with 29 CFR 1910.1028 Appendix E. L-000292 champlin REFINING COMPANY . Procecure No : Issued: j Revised: | Pa9e 40f 5 704.3 1/7/88 5/26/88 BENZENE SAFE OPERATING PROCEDURE III. PROCEDURE (Cont'd.) D. Respiratory Protection: 2. Negative pressure dual cartridge air-purifying respirators can be used when potential exposures to benzene have been determined to be less than 50 ppm (i.e. tank sampling, barge loading/unioading, transmitter draining, certain ciean-up operations). 3. Where benzene concentrations exceed 50 ppm, self-contained breathing apparatus (Scott Air Pak) in the pressure demand mode or positive pressure air line respirators with egress bottle will be required. E. Spills, Leaks, Ruptures or Other Benzene Emergencies: In the event that benzene is released to the atmosphere from a spill, leak. rupture, or other means the following action should be taken: 1. Don the appropriate respiratory protection device to determine the extent of the emergency. 2. Barricade the area and post signs in accordance with III. B. I to the extent that personnel exposures will be below 1 ppm. 3. Approach the scene from the upwind direction. 4. Use water spray to disperse vapors if feasible. 5. Control source of benzene release and eliminate potential ignition points. 6. Absorb benzene with sand, earth, or other absorbent material or flush with large amounts of water into the oily water sewer. 7. Notify supervisor in order that he/she may contact Environmental Affairs. L-000293 EchamplinREFINING COMPANY Procedure No. 704.J ' issued: 1/7/88 | Revised: 5/26/88 i Page 5of 5 ii BENZENE SAFE OPERATING PROCEDURE III. PROCEDURE (Cont'd.) F. Reporting of Benzene Exposure: If an employee is exposed to benzene either by skin contact, inhalation, or eye contact he/she should report such exposure to the Health Services Department. L-000294 .-'Z> TETRAETHYL LEAD HANDLING PROCEDURE I. II. III. ) PURPOSE This procedure is designed to reduce the possibility of exposure while handling tetraethyl lead compounds at the blending facility. SCOPE This procedure is applicable to all blending personnel or maintenance personnel working in the lead blending plant. PROCEDURE A. Personnel 1. Special personal protective clothing and equipment will be worn while unloading lead containers or performing maintenance work on the lead system. The special clothing is to be the disposable type and must be white or light colored so that spots or stains can be easily seen. Such clothing is to be disposed of after each use, white chemical boots and gloves must be rinsed in kerosene before re-use. 2. Personal protective clothing, rubber gloves and boots must be used to avoid skin contact. The use of self contained breathing apparatus prevents inhalation of lead vapors. These items are required when: Blending from open drums. Opening the tank car and making the proper connections. Disconnecting a tank car after unloading. Making repairs on lines which have carried concentrated fluid. Gearing up leaks or spills. 3. Exposure Treatment a. Inhalation TH Report to your supervisor or Health Sendees as soon as exposure is recognized or suspected. (2) Be prepared to describe all the conditions related to the exposure. j L-000295 TETRAETHYL LEAD HANDLING PROCEDURE PROCEDURE (Cont'd.) A. Personnel 3. b. Skin Contact XT) Stop work immediately, wash the area with kerosene followed by soap and water. (2) Disposable clothing stained by lead should be removed at once, properly discarded and exchanged for new garments. c. Swallowing XT) Swallowing is unlikely, however if lead is accidentally splashed into the mouth, you should seek medical attention immediately. (2) Never eat or drink from a container which has been contaminated with a lead compound. B. Bulk Storage Installation 1. Personnel working around tank can and lead storage tanks should be aware of tripping and slipping hazards. 2. The lead oiant has been designed to minimize the possibility of injuries resulting from lead exposures; however, failure to follow proper operating procedures will compromise these safety features. 3. Upon receiving a railroad tank car of lead, i; shall be properly spotted, grounded, chocked and the blue sign displayed. 4. Leaks are to be reported immediately and only personnel equipped with proper clothing and self contained breathing apparatus shall repair the leak or clean up fluid. 5. Safety precautions must be exercised when decontaminant chemicals are used due to their own toxic characteristics or heat may be generated by chemical reaction with lead compounds. 6. Tools used during maintenance should be washed with kerosene. 7. Waste or cloth used in clean-up of lead compounds must be placed in closed containers to eliminate health hazards. The containers must be identified. Contact the Environmental Affairs department for disposal. L-000296 TETRAETHYL LEAD HANDLING PROCEDURE PROCEDURE (Cont'd.) C. Lead Blending Operation Change Room (Lead Decontamination Building) 1. The Change Room must be used for no other purpose. a. It was provided for donning the proper protective clothing. b. Those using this facility are accountable for housekeeping conditions that reflect cleanliness and orderliness to the extent that hazards to health do not develop. c. Posted instructions shall be followed. L-000297 e chomplin A Subsidiary of Union Pacific Corporation .<$5u6CL; /.ay y i z Rev. (1) December 7, 19 SULFUR LOADING PROCEDURE FOR RAILROAD TANK CABS PROCEDURE NO. 55 PURPOSE Employees who load molten sulfur must be aware of the characteristics of the material as it relates to the conveying and transporting facilities. There are safety measures that must prevail to assure that the system and the methods are canpatible. SCOPE Tto maintain safe practices in loading molten sulfur, definite procedures nust be followed in proper sequence. PROCEEURES 1. The temperature of molten sulfur must be in the 270F to 310F range to flow freely. At either lower or higher temperatures its viscosity is such that it becomes too dense to pump. 2. The operator of the sulfur plant is to be notified prior to starting the loading of cars. 3. The blue flag must be posted at the gate entrance to show that loading will be in progress. fJ. A railroad tank car must be inspected by the terminal or operations employee to ensure it is in a condition for loading sulfur. The bottom valve must be closed, all open lines on the car must be plugged or blinded and both the belly cap and dome cap must be free including the bolts for securing them. The interior of a car is to be inspected from the dome opening for water and debris. Cars containing foreign material are not to be loaded. Water and molten sulfur in the 270 to 310 degree Fahrenheit range creates steam, therefore, the water must be drained from the car before loading. 5. Inquire about the temperature of the sulfur and make sure that there is enough in the pit to load the cars on the track. The Area 4, Block 50 sulfur recovery facility's pit dimensions are such that 1 foot of molten sulfur will load one 12,000 gallon tank car and the pit must NOT be pumped below 1 foot 6 inches. The sulfur recovery ccnplex in Area 5 can load one 12,000 gallon tank car per 21 inches in the pit and a minimum of 1 foot of sulfur must be retained at all times. These levels will ensure that the dip legs in the pit remain sealed. Farm SFT-10 (*77) L-000298 -1- e champlin A Subsidiary of Union Pacific Corporation SULFUR LOADING PROCEDURE FOR RAILROAD TANK CARS PROCEDURE NO. 55 6. Make sure that the sulfur pump discharge line to sulfur storage tank nea" the dock and the railroad tank car rack line valves are both closed. The Stop-Start switch for the transfer pump must be locked in the stop position at both the tank car rack and at the pump location. This is necessary to - prevent molten sulfur fran being pimped before loading is ready. 7. The tank car must have been properly spotted under the loading arm at this time. Tank car wheels must be chocked and the ground cable connected. Extend sulfur loading arm down spout at least 8 inches into the car's top hatch and secure it fran four sides to prevent surging. 8. Tank car is now ready to start loading. The sulfur unit operator must set the Stop-Start switch at the pump in the neutral position. Tank car rack line valve at the discharge of transfer pump must be opened. Use the StopStart switch at the tank car rack during loading. Load the tank car to ) approximately 10" outage. Extreme care must be exercised to make sure punping is stopped when the hose down spout is 1 to 2 inches above the" t sulfur in the car. This level prevents overloading of the car and the air ' space permits the sulfur in the line to drain back to the pit. 9. After the line has been drained, the discharge valve at the sulfur pit pump is to be closed and the Stop-Start switch locked in the Stop position. This is necessary to prevent sulfur from being punped when the riser hose is being removed in preparation for closing the tank car. 10. After the car has been sealed, complete the Tank Car feck Loading Report in full. Molten sulfur placards must be placed in placard holders at both ends and on each side of the tank car. 11. Remove the chocks and disconnect the ground cable from the tank car loaded with sulfur. Both loaded and empty tank cars to be moved or spotted shall be relocated using suitable equipment. A tractor such as a trackmobile or other such powered equipment shall be attached to the R.R. cars by means of a draw bar. Cables are prohibited and equipment boons must not be used. Manually operated jack type rail car movers are also approved. 12. The Blue Flag is to be removed when the tank cars are ready for shipment by rail. This signals the switch engine crew that the cars can be safely pulled away. 13. The assignment to load sulfur requires that there be an experienced atten dant present at all times at the rail facility during the loading operation. t* L-000299 form SFT-10 (77) champlin REFINING COMPANY CHG 01907 Procedure No. Issued: Revised: Page i of 13 705.1 3/2/89 1/17/90 WORK PERMIT PROCEDURE I. PURPOSE To establish a procedure for writing, approving, and executing work permits. II. SCOPE This procedure applies to all personnel performing work within the Champlin Refining and Chemical Company, Corpus Christi Refinery. III. GENERAL 1. It is the responsibility of Champlin management to insure that these procedures are enforced in compliance with Federal Regulations (OSHA). 2. Supervisors and operators in the Operating, Terminal and Laboratory areas are responsible for establishing conditions of safety when issuing Hazardous and Routine work permits. Operations and Maintenance supervisors and their personnel are jointly responsible for safety while the job is in progress. They must monitor and stay abreast of the job in progress throughout the permit period. 3. The authorized Operating department signee of the permit must discuss at the jobsite the scope of work, method of equipment isolation, and detailed conditions of the work permit with the authorized Maintenance Department signee. This must be done before the permit is signed. 4. The authorized Maintenance department signee of the permit must receive the above information and convey this information to the craftsmen. All conditions of the permit must be met throughout the progress of the job. Additionally, he/she must insure that all techniques being used to perform the work demonstrate conservative safe practice and good judgment L-000301 champlin REFINING COMPANY Procedure No. Issued: Revised: Page 2 of 13 705.1 3/2/89 1/17/90 WORK PERMIT PROCEDURE III. GENERAL (Cont'd.) 5. Throughout this document reference will be made to the following safety procedures which must also be complied with in order to safely perform work. #704.2 - Unloading Procedure - Bulk Commodity Chemicals #705.2 - Confined Space (Vessel) Entry Procedure #705.3 - Hot Work Procedure #705.4 - Lock-Out/Tag-Out Procedure #705.5 - Hot Tap and/or Stopple Procedure #706.5 Equipment Isolation and Blinding Procedure #706.7 - Drains and Vents #706.11 - Use of Motorized Equipment in LPG Storage Areas Mobile Crane Operating Procedures Maintenance Memorandum -"Coordination of Construction Move-In and Tie-Ins with Operations" - C. W. Shumate - 6/6/89 IV. DEFINITIONS A. Area Craftsman These craftsmen consist of electricians, mechanics, instrumentmen, and machinists who are assigned to an operating unit or area. These personnel routinely check equipment in their respective areas. These routine area monitorings may be made without a maintenance work plan or the issuance of a work permit; but only with the operator's approval. It is the responsibility of the area craftsman to notify the area operator if, after routine checks of equipment, more involved repairs are needed. If so. work plans and permits will be issued accordingly. B. Area Operator - Specifically, the Area Operator, Step-up Operator, or Laboratory Leaderman designation excludes Area Technicians. The Area Operator must satisfactorily complete a training program conducted by the Champlin Safety Department and be knowledgeable of all Champlin safety rules and regulations to be authorized to sign permits. L-000302 3 champlin REFINING COMPANY Procedure No. Issued: Revised: Page 3 of 13 705.1 3/2/89 1/17/90 WORK PERMIT PROCEDURE IV. DEFINITIONS (Cont'd.) C. Authority to Halt Work - Any employee that has a sincere concern that an imminent danger has or is developing has the responsibility to halt work and request a management review. D. Battery Limits - Operations - All areas within operating units excluding adjacent streets. E. Battery Limits - Terminal - Tanks and pipelines within earthen dikes, pump pad locations, pump pits and dock facilities. F. Champlin Construction Department - In the case of work being done by the construction department, the Champlin construction manager will designate an authorized contract construction coordinator or foreman for signing permits. The designated contract construction coordinator must satisfactorily complete a training program conducted by the Champlin Safety Department and be knowledgeable of all Champlin safety rules and regulations to be authorized to sign permits. G. Confined Space - Is any space which has any one of the following characteristics: 1. Limited access for entry and exit. 2. Inadequate ventilation. 3. Equipment which is not designed for continuous worker occupancy such as towers, boilers, pits, sumps, storage tanks, process vessels, cooling towers, heaters, etc. 4. Any congested area where egress is restricted. H. Confined Space Entry - An entry which results from the head or body penetrating the opening of the confined space. * t L-000303 E champlinREFINING COMPANY Procedure No. issued: Revised: Page 4 of 13 705.1 3/2/89 1/17/90 WORK PERMIT PROCEDURE IV. DEFINITIONS (Cont'd.) I. Contractors - Contractors are subject to the same provisions as described herein. The Champlin sponsor is the person who arranged for the contractor to enter the Refinery. The Champlin sponsor is responsible to see that the work of the contractor is controlled by permits and also monitored. The Champlin sponsor may do this personally where he is authorized or he can turn the contractor over to other authorized Champlin personnel. J. Hazardous Work - Work performed by personnel where there is a risk of exposure to injury from one or more sources. Some examples include: 1. Hot work. 2. Confined space entry. 3. Work on PRV's in service. 4. Hot Taps and Stopples. 5. High voltage electrical work. 6. Critical Instrumentation/Electrical work (shutdown related circuitry). 7. High Hazard Chemicals - Chemicals that are highly flammable and/or pose a serious health hazard in high concentrations: Examples include: Cl^, HF, H2S, LPG, Caustic, H2S04, H2, Benzene. Specific determinations as to hazard level will be made at the time of permit issuance by the operator. K. Hot Tap/Stopple - In order for a hot tap and/or stopple to be performed a "Authorization for Hot Tap/Stopple" form must be completed by the assigned Project Engineer. He must coordinate the information gathering process described therein and obtain the necessary signatures prior to the request for a "Hazardous Work" permit. See details for this in Champlin Procedure #705.5 Hot Tap/Stopple. L-000304 EchamplinREFINING COMPANY Procedure No. Issued: Revised: Page 5 of 13 705.' 3/2/89 1/17/90 WORK PERMIT PROCEDURE IV. ) DEFINITIONS (Cont'd) L. Hot Work - Any operation in which the heat generated is sufficient to cause the ignition of any flammable liquid or gas. Following are some examples of hot work: 1. Work involving torches or other open flames. 2. Electric welding and cutting. 3. Hot forging. 4. Portable electric tools. 5. Grinding. 6. Drilling, chipping or soldering. 7. Sandblasting. M. Leaderman A Champlin Maintenance Craftsman who has been designated as a Leaderman. For those areas not having a Champlin Leaderman, the Champlin Maintenance, Manager will authorize an area contract foreman to fill this responsibility. The contract foreman so authorized must be fully knowledgeable of the operations of the area. In addition they must satisfactorily complete a training program conducted by the Champlin Safety Department and be knowledgeable of all Champlin safety rules and regulations. N. Operating Areas - The battery limits of process/terminal areas including the immediately adjacent roadways. O. Permit Re-Issuance There are three situations which require the re-issuance of a work permit. They are as follows: 1. A new Maintenance/Construction crew starts to work, even if it is on the same activity. A new permit must be written and signed in order to assure proper communication. 2. A scope change is made which changes the complexity of the activity that was defined on the previous work permit. L-000305 EchamplinREFINING COMPANY Procedure No. Issued: Revised: Page 6 of 13 705.1 3/2/89 1/17/90 WORK PERMIT PROCEDURE IV. DEFINITIONS (Cont'd) O. 3. If the previous permit expires, new permits must be written. A work permit expires when: a. A plant emergency occurs in which the fire whistle is sounded, and/or in case of a spill or release of any flammable product in the area of work; b. In the case of Hazardous or Routine work, if work does not commence within one hour, the work permit is void and must be re issued; or c. The expiration time entered at the top of the permit is reached. P. Routine Work - Activities which are considered to be of minimal hazardous nature. Some examples include: 1. Painting. 2. Pipefitting. 3. Pump and compressor repair. 4. Scaffolding. 5. Non-Critical Instrument/Electrical work (no shut down circuitry). 6. X-Ray. 7. Valve Removal. 8. Vehicle entry into battery limits Q. Status Board - A status board will be provided for the posting of all complete and incomplete work permits. These will be installed in high visibility areas in the control rooms, comfort stations and terminal operations building. The purpose of the Status Board is to insure that all personnel are aware of all work activities in their areas of responsibility. L-000306 champlin REFINING COMPANY Procedure No. Issued: Revised: Page 7 of 13 705.1 3/2/89 1/17/90 WORK PERMIT PROCEDURE IV. DEFINITIONS (Cont'd) R. Time Limits - A permit can be in effect (active) for a maximum of 12 hours. Permits will be issued for the maintenance shift. To extend the permit, the Area Operator must initial the permit at the site and on the status board, noting the new expiration time. S. Training - All personnel must successfully complete the required course of instruction and skills demonstration prior to being authorized to sign work permits. The training program will include minimum standards of performance. Those personnel having authority to sign permits are: 1. Trained Operations, Terminal, Laboratory Operators or Leadman for his normal work area only. 2. Trained Maintenance Craftsman, Leaderman or Construction Foreman for only their normal work activities. 3. Supervisors for his area of responsibility. T. Turnaround Permits * Turnaround permits (Hazardous) will be handled by a Turnaround Safety Coordinator assigned from the operating unit/area where T/A work is in progress. Routine permits will be initiated by operating personnel. During turnarounds additional personnel will be authorized to approve work permits. U. Turnover Responsibility - Maintenance responsibility does not begin and end with performance of their work activity alone. It begins with the preparation of equipment and does not end until the equipment is returned to normal operation. Operations responsibility continues throughout the maintenance activity as a quality and safety check. Jointly with Maintenance personnel. Operations audits completeness in accordance with drawings and mechanical specifications. L-000307 champlin REFINING COMPANY Procedure No. Issued: Revised: Page go/ 13 705.1 3/2/89 1/17/90 WORK PERMIT PROCEDURE IV. DEFINITIONS (Cont'd) V. Work Permit - Posting - There are three copies of both Routine and Hazardous work permits. The first (original) copy must be posted in a plastic envelope by the craftsman at the job site. The second copy will be posted by the Area Operator on the status board in the appropriate Control Room or comfort station. The third copy will be retained in the permit book. Empty permit books will be returned to the Safety Department. W. Work Permit - A work permit is a formal safety checklist that must be completed before maintenance work can begin in the operating areas of the refinery. A separate work permit issued by Maintenance, Safety or Shift Supervisors may be required for work outside the operating areas. Different crafts each need separate work permits to perform their part of an approved work plan. One permit may cover more than one task per craft if it involves the same risk source. A Work Permit will also be issued to other contractors such as hydroblasters, leak repair services, and vacuum trucks before they perform any work in operating areas. An example of work that does not require a Work Permit is bulk chemical deliveries such as caustic, acid and process chemicals which are covered by Procedure 704.2 "Unloading Procedure for Bulk Commodity Chemicals". X. Work Plan - The description of work to be performed by Champlin employees and contractors. The work plan will be developed by the Champlin planning department through work requests submitted by all areas of the refinery. Y. Work Scope Changes - It is the responsibility of the craftsman to notify Operations if the work scope changes during the course of a job. Work permits (both hazardous and routine) are issued for specific work activities. If additional work not described on the permit becomes necessary, then a new permit must be issued. L-000308 champlin REFINING COMPANY Procedure No. Issued: Revised: Page 9 of 13 "70571-- 3/2/89 i/17/90 WORK PERMIT PROCEDURE PROCEDURE A. When the craftsman receives an approved work plan, he reports to the Area Operator for a work permit. The proper safety precautions must be defined by the operator and verified by the maintenance craftsman or supervisor. Work cannot start until the job site has been thoroughly checked, the permit completed, signed and issued by the appropriate personnel as designated in Table I, II or III. B. Work permits for the Operating/Terminal/Lab areas are always initiated by personnel in those areas. Jobs in non-operating areas such as the maintenance shop, office buildings, etc. may require a separate permit to be issued by Maintenance or Safety. The Maintenance Supervisor must approve work without a permit in non-operating areas. In the Terminal department, routine work permits issued in outlying areas such as the 90/91, BTX Gauger areas, and all dock facilities can be issued and approved by the technician in charge of that facility through verbal permission from the Terminal Operator as outlined in Table III. C. The Area Operator must determine which permit must be filled out for each work activity. Some minor preparatory work such as covering drains or delivering tools can be done at the discretion of the Area Operator. No written permit will be needed for the preparatory work. The permit should be filled out according to the following procedure: 1. Record the work plan number on the work permit in the space provided. This will help provide reference if needed at a later time. 2. Fill out the "issued to" spaces. Write the specific name of CRC craftsman, or contract craftsman and company name. L-000309 champlin REFINING COMPANY Procedure No. Issued: Revised: Page (oof 13 705.1 3/2/89 1/17/90 WORK PERMIT PROCEDURE V. PROCEDURE (Cont'd.) C. 3. Note the date and time of expiration. Permits will be set to expire at the end of the maintenance shift. If a particular maintenance crew continues to work longer than originally quoted, the permit may then be extended by the Area Operator by changing expiration time and initialling. 4. Fill out equipment information, noting unit, equipment number, and name. Also, log the date the permit is being issued. 5. Fill out the 'job description/material involved' portion, in as much detail as possible after discussing the scope of the work with the Maintenance personnel. Be sure to specify the chemical which could be involved and discuss hazards - refer to MSDS if necessary. On multi-activity jobs, the craftsman will have to verbally indicate which part of the sequence (activity) he wants to do in order for the Area Operator to write it on the permit. Be specific. Define the limits of the work to be done so that the craftsman doesn't work on equipment which is not prepared. Work activity is limited to what is specifically defined ;n the permit. A separate work permit is normally required for each craft, but there will be instances where more than one craftsman will be able to work from the same permit. 6. A gas test will be performed by the operator if specified by the permit. Supervisors need not perform an independent gas test. L-000310 champlin REFINING COMPANY Procedure No. Issued: Revised: Page llof 13 705.1 3/2/89 1/17/90 WORK PERMIT PROCEDURE V. PROCEDURE (Cont'd.) C. 7. The next section of the permit itemizes the precautions which must be taken as a condition of the permit. Ail precautions noted by the issuer must be observed. If a bold heading is not checked, it is to be marked not applicable (N/A). The Shift Supervisor or Maintenance Supervisor/Leaderman should be consulted prior to the preparation of the Work Permit if conditions are not straightforward. NOTE: Other precautions may be added under the comments section of the work permit. The Area Operator and Supervisor issuing the permit must first check the specific Champlin safety procedures corresponding to the type of work being performed. There may be several procedures applicable to a given permit. 8. When the permit is complete, the Area Operator will sign the "prepared by" space. By signing, the Area Operator insures that the following have been accomplished: a. The Area Operator has physically inspected the jobsite with the craftsman, checked equipment conditions, tagged and/or locked valves, and has completed all gas tests. Operations personnel must insure that all permit requirements are met prior to signing the permit. b. The Maintenance/Construction personnel have confirmed to the Area Operator the scope and limits of the work to be done. The Area Operator will show the Maintenance/Construction personnel how the equipment is isolated, the location of locks and tags, special precautions taken, and safety equipment required. c. Once all special precautions and conditions are met and all safety equipment required is on site, then the person required by Table I. II, or III must be called to check and approve the permit. L-000311 champlin REFINING COMPANY Procedure No. Issued: Revised: Page l2of 13 705.1 3/2/89 1/17/90 WORK PERMIT PROCEDURE V. PROCEDURE (Cont'd.) C. 9. When the work activity is complete, or the permit expires, whichever comes first, the craftsman .must return the original copy of the (Hazardous or Routine permit) permit to the Area Operator. a. The Area operator must inspect the job for completion before signing off, (Refer to Item IV. U. Turnover Responsibility for guidelines.) b. Both the Area operator and the craftsman will then sign the permit to verify that it is no longer active. c. For completed work activities the status board copy will be kept on the completed work status board. d. For incompleted work activities the status board copy will be kept on the incomplete work status board. 10. Only "active" permits should be on the status board. Note: It is the Area Operator's responsibility to keep the permit status board up-to-date. If a permit is in effect at the time of the Operations/Terminal/Lab shift change, the oncoming Area Operator must review the permit status board and initial these copies of the permit (board copies). For tasks involving Hazardous Work, the Area Operator will inspect the job sites, and verify compliance with existing permits without interrupting work. This should be done immediately after shift change. 11. When the Work Plan is signed off, the Area Operator shall assure that any outstanding work permits associated with the Work Plan are completed and removed from the Status Board. L-000312 champlin REFINING COMPANY Procedure No. Issued: Revised: Page 13of 13 703.1 3/2/89 1/17/90 WORK PERMIT PROCEDURE VI. SPECIAL CONSIDERATIONS A. Crane Operation - When it is necessary to use a mobile crane for a particular job task, its use must comply with the applicable Champlin Maintenance Department requirements. B. Work in LPG Storage Areas - Work within LPG storage areas which requires mobile equipment must be reviewed by the Terminal Department to insure that proper precautions are taken to prevent contact with tanks, pumps, and piping (Procedure No. 706.11). C. Construction Tie-ins - When tie-ins to existing equipment are made special procedures as prescribed by the memorandum "Coordination of Construction Move-In and Tie-Ins with Operations" dated June 6, 1989 and authored by C. W. Shumate will apply. Attach. Appendix A Appendix B Attachment C Attachment D Attachment E Attachment F Attachment G Routine Work Permit Specifics Hazardous Work Permit Specifics Routine Work Permit Hazardous Work Permit Table I - Hazardous Work Permit Approval All Areas Table II - Routine Work Permit Approval All Areas Excluding Terminal Table III - Routine Work Permit Approval Terminal Area L-000313 ROUTINE WORK PERMIT SPECIFICS APPENDIX A Once the above information is completed then the "work to be performed" is checked on the permit. If none of the work categories apply, indicate the type of work in the "Job Description" or "Comments" section. The method of Isolation of Equipment and/or Energy Source is then to be specified and the appropriate tags (i.e. "Caution" or "Do Not Operate") and/or locks must be affixed to the equipment. The operator and each craft working on the job must attach their tag and lock. Refer to Safety Procedures #705.4, #706.5 and 706.7 for details. The appropriate Respiratory Equipment and Protective Clothing necessary must be specified if a hazardous chemical is involved. Remember to instruct the craftsman as to the hazards of the material and make reference to the MSDS where applicable. If work involving LPG Area Entry is to be performed then refer to Procedure #706. i 1 for details concerning special precautions to be taken to prevent contact with equipment. If the task involves Opening of Process Equipment/Valve Removal then the energy source must be isolated and the equipment drained and purged. Excavations less than five feet will require a Routine work permit whereas an excavation greater than that depth in most cases will require a Hazardous work permit. Attention should be directed to the depth of the excavation, presence of underground lines, shoring/sioping, and barricading of the area for personnel protection. Permits for Vehicle Entry/Vacuum Truck can be issued on either a Routine or Hazardous work permit. Vacuum truck work will require a Routine work permit when the material is picked up and another permit when it is received at its destination within the refinery. A separate permit for disposing of the material will not be necessary when it is delivered within the same operating area or it is delivered to an offsite disposal facility. It is extremely important to convey to the vacuum truck driver the hazards of the material that is being handled. For X-Ray of Equipment it is required that radiographers have posted barricades around the exposure area. In addition, they must post signs stating "Caution Radiation Area" on or near the barricades. The radiographer will in both cases determine where barricades and signs are placed. Any routine work which requires _> 15 Ton Crane Operation will need to be addressed on the permit. Particular attention must be directed to placement of outrigger pads, area of boom travel, and overhead electric or process lines. In addition, cranes which are either operating with a load or traveling where the vision is obstructed must have a lookout person accompany the crane to prevent contact with equipment. Finally, the lead craftsman, contract foreman or non-bulk chemical truck driver must always sign the permit. By signing the permit, the maintenance personnel acknowledge that they approve of how the equipment is prepared and isolated and agree to comply with ail permit conditions. Additionally, he/she must insure that all techniques being used to perform the work demonstrate conservative safe practice and good judgment. L-000314 HAZARDOUS WORK PERMIT SPECIFICS APPENDIX B 1. The method of Isolation of Equipment and/or Energy Source should be specified and the appropriate tags (i.e. "Caution" or "Do Not Operate") and/or locks must be affixed to the equipment. The operator and each craft working on the job must attach their tag and lock. Refer to Safety Procedures #705.4, #706.5 and 706.7 for details. Blinds must be installed and marked according to the Blind List and identified with streamers. 2. If Hot Work/Vehicle Entry is to be performed then the appropriate means of draining, purging, and isolation of equipment must be accomplished. Other items which are applicable to the hot work being performed should be checked and verified by both the operations and maintenance representatives. Should entry of a vehicle into the operating area be necessary to perform the task described on the Hazardous work permit then all sewers should be covered and a gas test completed in and around the work area. Refer to Safety Procedure #705.3. 3. Tasks involving Hot Tap/Stopple must be accompanied by the "Authorization For Hot Tap/Stopple" form. The completed form must be presented to the operator prior to the issuance of the permit. The form will specify line thickness, service, operating conditions, flow or liquid head established, etc. all of which will-be necessary prior to starting work. Details concerning these requirements can be found in Safety Procedure #705.5. Following the verification of this information the provisions established in the Hot Work/Vehicle Entry section of the Hazardous work permit must be completed. 4. Work involving Confined Space Entry will require completion of the section entitled "Isolation of Equipment and/or Energy Source". The confined space entry requirements are then checked and must be in place before the permit is issued. When hot work is to be performed within the confined space it will be necessary to thoroughly examine the vessel to eliminate or otherwise separate residual oil or other combustible materials from the area of hot work. This could involve removal of the material or utilizing wet fire blankets to separate combustib<es from potential ignition sources. 5. Work on In-Service Pressure Relief Valves or the installation of battery limit flare line blinds will require close coordination with the affected operating area(s) to verify unit stability prior to starting work. This work will require personnel flash suits and air line respiratory equipment to reduce the potential for personal injury should an upset occur. Personnel removing relief valves which are isolated by a blind such as a battery limit flare line blind need only wear an air line respirator and are not required to wear a flash suit. Where the relief valve is isolated with a block valve it will be necessary to wear both the flash suit and air line respirator. 6. Any hazardous work which requires _> 15 Ton Crane Operation will need to be addressed on the permit. Particular attention must be directed to placement of outrigger pads, area of boom travel, overhead electric or process lines, and other equipment considerations. In addition, cranes which are either operating with a load or travelling where the vision is obstructed must have a lookout person accompany the crane to prevent contact with equipment. L-000315 -1- 00 H Ztu S1 3 O' 3 a. 00 a "*o oo >55 C >- a^s uCuj QUJ w> gi5a5li or*i (H_Z v> </ .--3 8-a.s **T*3* c Oa un 0r%* o\ 8 r- . *s c 8 13 to Or-* IC8WU 8r%* as0 1 c8w vn* 2 <N woi > =>t g. 3*?*>. aa.. = s i/i O ** g VO 8 "GCQ Ss S. a . t- > 7g3 joC 0U 7T 8V) * -, O8Q 8 Stl? '> -oc 8r O%r* 8 A. w S !Q U. r~ Ujo:, ~cn 3 w a .f s-a 5 Ss 8. ra j W S Q. O IP uu 5 x 5e 3 g 2g *!* 13 s * I8s lag. u 5<o .w2 _ &3 In V5 Co --<0 '23-2gc| OPS i G UO u 8 Ov iH G 2 e^ gJ &_ OHStfl *! S is O^w & il GS uS 3" = a 1S W o <u85. O 3 * i3 o Ills 5<j 8< L- 000316 o WORK PERM IT APPROVAL >ns/ 1 Super or Area sor * Refer to G enera Note I Refer to General Note 11 1vO5 <QS. ss fciut '(J g *2 S.s iss "ss a.f a 8 Q. OO "8a ae <3 *w a > o 33 i is 1a3 & U -I ^a s "c '3 .2 a *5 |S I-S aV* G_ PO 9 C Uw 'r II APPROVAL odUDING TERMINAL w gS O5' i aOm CO is *Q gg oo 55 Qh m 8r* o c <0 Orw*-v a, 5 1 3 2 j i * e 1 w% u .2 "S. s J(S9 u o <W5 o& s * m s a acj s 8 8 3 & & (S * (a30 (Se0 *S s `QC I>Soyo lUwU3l O. Jouu<w0Q300* '*g w `QCs ! CJ <2 > oCw8l .U22 e "5. "<S5. 6u a _uo lua > * Shift Supervisor to be verbaily notified o f these permits by operator when issued. Refer to G E N E R A L N O T E WORK ^ . AREAS o &I Bu 3 i? 3O s.s u (S u 2 s I81fPD 8 " `*a2 1- oo i'iu s aU > 0s0 ;s S s.O 3 1 "I1e \ g s a > O 3 wX oJ3 s o * o 0 1 Me is 3 e"*3 00 3 S.` al E</) 5s .2 wc SU 030 V *2 > s 5 o".*SSoB iisS1 2oc H *33 a 3 <3 I 3O(0 3o X * ow is u V) u *> .i<s0 ? . 8 uu t/s & 3 O ^3 . >3 5o *3 u u O >M e W " o2 *o A 3 3 </> *3s -- 1c u j O c* > L-000317 j3 Hn 38 w 2 g a 1 U5 I w>a*s asQ oo S* 55 o Oh <o s cs 3 c <0 J4 u-j o 38 Ow3 a8. 8 32 J 3O s? 8P w S H3O3 <U"/) uEc & uo. e* CQ J ^ `5v5 * # cao 6 *<e0 s c (0 S <<w2 u a. (9 3 U u> *Qw *u 2 >u <2 <9 CO <9 JUS U . a. 290 .2 i Q -1><o25j * .s *a <o JS O 51 v J* -35fc JS > fJ 3 3 3 0U 33 Q ^ O <c> 8 J.2 o u u *5 w * C 1u5 > .ri* o 2 * * * # w O <5 w 8. 0 1 c* | *e L-000318 ^ot U|)J .*25 <3v/ i0as0 .v3> `5 JS ag Is 6vU.SMs & o. .2 o (cOo uB cu*^u rs 3 tl 1 inw 2 flo OS uo aaS. 3o 35 3.uae3 1 s jss i&'<sc a ^ sl i 1^ Sg-a 19 C oo SG S..JSS (Ss 0c0 3.a s .a i 6 ) O&5 w '3> S8 ^8 gi Is '-So EI A3 .M5 uJuS3 == S *co3 5 wgK O * Jurf H S 33 t$ *oG3 oo *a3 </) i*8 ui oeeS <coso 3 3 is 8*1 CJ V) X^ CQ < ai I * 2 ss. ,SE* II 90 .2 5< 3O3ao wtf 2 3co g M -3J * 3 5 s *> 3u<0 (C90 3S I < JS C* - I 3 U 3M a <A .2 I u 3M o ue o *u 2>u (S | >* 3 3 S >1 f |S ia-8 Q C<o - J<0 a *w -- a 5>i c S CO *** K3 Refer lo G ENERAL NOTE HAZAJRDOUS work permit specifics APPENDIX B 7. Work Involving Hazardous Chemicals listed in the procedure will require special protective clothing considerations. Clothing should be selected based on the hazards of the material involved and can be referenced in the MSDS or "Chemical Safety Handbook". In addition, it will be necessary to properly depressure, de-inventory, and lock and tag the equipment prior to commencing work. 8. Tasks involving Critical Instrument Work as defined by the items listed on the permit must be properly coordinated to prevent malfunction or unit shutdown. The applicable items listed must be checked and comments noted and reviewed with operations and maintenance supervision. 9. Tasks involving High Voltage Electrical Work must also be coordinated with operations in order to insure proper communications take place, that tags and locks are in place, and what special equipment is necessary to perform the job safely. 10. Work Near Power Lines means any task which involves personnel or equipment coming within 10 feet of an overhead power transmission line. Examples could include scaffold construction, use of a crane to hoist personnel or equipment, use of a manlift, or any other task which can endanger personnel from contact with power lines. Many of the tasks performed may, in fact, be routine in nature; however become extremely hazardous when performed in close proximity to overhead lines. A spotter on the ground is required for these tasks. Before work begins, ' call the Electrical Department to see if the section of power line could be de-energized while the work is done. 11. The Champlin Operations/Terminal Supervisor or Superintendent noted on Table I must then go to the job site for Hazardous Permits. When he/she arrives at the site, the Supervisor must review the work plan and work permit. He must then require the Area Operator to give him an in-depth review, showing him or telling him about equipment conditions (valves, blinds, bleeders, as applicable). Then he will approve the permit by signing in the "Operations/Terminal Approved" space. The Supervisor will not normally perform gas tests. His main purpose is to double-check equipment preparation and safety conditions. The Safety Department will always make an independent review and co-approve initial confined space entry permits. The Safety Department will be available for consultation on specific jobs. 12. The lead craftsman, appropriate Maintenance/Construction Supervisor or Leaderman (per Table I) must then sign the work permit. The craftsman will already be at the job site. The Maintenance/Construction Leaderman or Maintenance/Construction Supervisor must also go to the site to sign Hazardous permits. By signing the permit, the Maintenance/Construction personnel acknowledge that they approve of how the equipment is prepared and isolated and agree to comply with all permit conditions. It is preferable that the Maintenance/Construction/Supervisor/Leaderman report to the site at the same time as the Operations/Terminal Supervisor. On larger jobs, this practice will help to ensure good communications between supervisors. ) L-000319 -2- Echamplin | routine work permit vm <* aucu. stc lssued:_am/pm it:_____------------------- . Expires:----------------------- am/pm Issued to: ___________________________________________ Equipment 1,0.: Job Description / Material Involved:_____________________________________________ Dote: . W .PM / %LEL. /OXYGEN H2S ppm Thlt PERMIT it VOID If the Mr* alarm sounds, Thlt PERMIT bcomt VOID at expiration tlm. Work To B PTformod PERMIT It VOIO tf work do** not b*gin within on* hour of Usuanc* or If wofk c*as*t for ov*r on* hour. Procoutlong To Bo Takon ;___ General Mechanical Work ____ Pump or Compressor Repair ___ Boil.rmaklng ____ Pipelining '___ Scaffold Erection/Dismantling ____ Excavation ____ Painting ____ Chemical 0liv*rit __ Imulation __ Non-Routine Impaction ____ Generol labor t Cleanup ___ _ Hydroblasting ____ low Volt. Elec./lnstr. Work ItolaHon of Equipment and/or Energy Source Elc. Equip. loek/Tog/Try Inlet/ Outlat Valves locked/Tagged Closed Vents/ Oraint Yellow Tagged Open Blinds Installed and Marked Reiptratory Protection Air Purifying Required Type:------------------------------- Fresh Air Supply Required Type:------------------------------- Protective Clothing Gloves (Chemical) Required Gloves (Thermal) Required Goggles Required Paceshlald Required Slicker Suit Required Rubber Boots Required Alky Gear Class A B Other: _____________________ Reviewed Work Proced. For IPG Area Entry Opening Proc. Equip. / Valve Removal See Itol. of Equip. /Ener, Source Oepresture/purge lino Excavation Underground lines Checked Barricodes Needed Depth less Than Five Feet Shoring/Sloping Needed Flammable Gas Present Vehicle Entry/ Vacuum Truck Flammable Gat Present Sewers Covered X-Ray Of Equipment Barricades and Signs Posted _> 15-Ton Crane Oper. Crane Inspection Sheet . Completed lifting Plan Reviewed/Approved large Outrigger Pads Needed Comments:, L-000320 NOTE: A |obsite visit by alt tlgnees as designated In Tables II and III is MANDATORY. Prepored and approved by:__________. Craftsman Approval: WorkStotus: Incomplete Permit Sign-Off: Complete Oncoming Operator's Initials At Shift Change:. Craftsman: ^Qpornto>. champiin irasuoouoaK IHAZARDOUS WORK PERMIT Unit:. Issued:____________ Expires:__ _am/pm am/pm Dote: ______ L W.PJ. Issued to: ' Equipment 1.0,: Job Description / Material Involved:____________________________________________ / %LEL %Qn This PERMIT Is VOID H the (Ire alarm sounds. This PERMIT becomes VOID at expiration time. Isolation of Equipment ____ and/or Energy Source ____ Elec. Equip, lock/Tog/Try ____ Inlet/Outlef Volves locked/Tagged Closed ____ Vents/Oralns Yellow Tagged Open ____ Hinds Installed and Marked ____ Hot Work/Vehicle Entry ____ See Isol. of Equip./Ener. Source ____ line/Equip. Oepressured ____ line/Equip. Blinded ____ Sewers Covered/Steamed ____ Welding llankets Needed ____ Steam or Nj Purge Required ____ Adequate Area Ventilation ____ Area Barrteoded __ Fire Extinguisher On Site ____ Charged Fire Hose On Site ____ Fire Watch w/Red Vest ____ Gas Tests Completed ____ Hot Tap/Stopple __ See Hat Work Items ____ Authorisation Form Verified ____ Confined Space Entry ____ See Isol. of Equip./Ener. Source ____ Gas Tests Completed ____. Vessel Orained. Purged and Vented ____ Hinds Installed At Vessel and Marked ____ Monway Watch w/Vest On Site ____ Radioactive Sources Isolated __ Vessel Drains Plugged ____ Forced Ventilation In Operation ____ Fresh Air Equip. Req'd./Accessible ____ Vessel Below I0SF Reviewed Work Procedure ____ Far IPG Area Entry Work On In-Service ____ Pressure Relief Valve ____ See Isol. at Equip./Ener. Source ____ Coordinate w/Operations ____ Blinds Required ____ Flash Suit Required ____ Breathing Air Required ____ ____ ____ ____ > 15-Ton Crane Operation Crone Inspection Sheet Complete lifting Plan Reviewed/Approved large Outrigger Pods Needed H9$ ppm ppm PERMIT Is VOIO if work does not begin within one hour of Issuance or It work ceases for over one hour. ____ Work w/Hax. Chemicals ____ See Isol. of Equip./Ener. Source ____ Equipment Oepressured ____ Gloves (Chemical) Required ____ Gloves (Thermal) Required ____ Goggles Required __ Foceshleld Required ____ Slicker Suit Required ____ Rubber Boots Required ____ Alky Gear Class A B C D __ Respiratory Protection ____ Air Purifying Required Type: ---------------------------------____ Fresh Air Supply Required Type: ---------------------------------- ____ Critical Instrument Work ____ Control loop In manual ____ Shutdown bypasses required __ Input points turned oH scan in computer __ loop provides signal to shutdown system ____ Control valve used as shutdown device ____ Signal is part of feed-forward to other loops ____ Field Instr. Is Intrinsically safe or non-incendive If not, gas test required. __ This work will cause flammable vapors to be released Into the vicinity of the work ____ Shutdown set point changes HAZOPed and approved by Area Supt. POST-WORK CHECKS _ loops relumed to automatic ____ Points turned on In computer __ Shutdown bypasses lifted jumpers, clamps ____ High Voltaga Electrical Work ____ Affected Units ond Shift Supervisors notified __ Elec. Equip, lock/Tag/Try ____ Critical motor/ No Spare ____ 12.5 KV breaker ____ Hot stick, flash suit and high voltage gloves required Bucket truck required ____ Work Near Power Unas ____ 10-foot clearance (or more) _ Coordinate w/Elec. Dept. ____ Spotter on Ground Required NOTH Equipment Movement Requires lookout When Vision Is Restricted Comments; -------------------------------------:-------------------------------------------------- =------------- L-000321 NOTE: A jobsite visit by all slgnees as designated In Table I Is MANDATORY. Prepared and approved by; Oper./Tenn. Approval: Safety Dept. Approval:_________________ Croftsmon Approvol:------------------------------------------------------ Main!. Supv./leaderman Approvol: Work Status: D Incomplete Permit Sign-Off: Craftsman: rv.ins Complete ''Oncoming Operator's Initials' At Shift Change:. f-insfalof 3 champlin REFINING COMPANY Procedure No. Issued: Revised: I Page j of 7 705.2 2/24/89 CONFINED SPACE (VESSEL) ENTRY PROCEDURE I. PURPOSE This procedure establishes guidelines which allow entry and performance of effective work in confined spaces. II. SCOPE This procedure applies to all employees and contractors who perform work within the Corpus Christi Refinery and/or associated facilities. III. DEFINITIONS A. Confined Space (Vessel) - Any enclosed space which has limited access or restricted entry or exit such as vessels, tanks, drums, pipelines, boilers, tank cars, reactors, receivers, furnaces, etc. Also included are pits, sewers, and cooling towers where employee egress is restricted. B. Oxygen Deficiency - Any atmosphere that has an oxygen concentration of less than 19.5%. C. Immediately Dangerous to Life and Health (IDLH) - This is a maximum gas concentration from which one could escape within 30 minutes without any symptoms that would impair their escape or cause irreversible health effects. D. Confined Space Entry - An entry which results from the head or body penetrating the opening of the confined space. IV. PROCEDURE A. Operations will initiate a "Hazardous Work Permit" for any personnel who are required to perform work in a confined space. L-000322 champlin REFINING COMPANY j Procedure No. ! Issued: Revised: Page 2 of 7 705.2 2/24/89 CONFINED SPACE (VESSEL) ENTRY PROCEDURE IV. PROCEDURE (Cont'd.) B. Confined Space (Vessel) Preparations 1. It will be necessary to isolate, drain, and purge process equipment before entry. In most cases it 'will be necessary to steam out the vessel in order to remove all residual hydrocarbon. It will then be necessary to allow the vessel to cool while ventilating the confined space. At the time that the vessel is opened for ventilation a sign containing the following information will be placed on the manway until a confined space entry permit is issued. danger; TOXIC GASES DO NOT BREATHE 2. ALL lines terminating at the vessel or space shall be blinded at the first flange closest to the vessel. Where this is not practical, blinding can be done at other locations with the approval of the Safety Department. In these cases it will be necessary to install a spacer on the vessel side of the blind in order for the line to free drain should it contain liquid. Double block valves with an intervening bleeder valve are not considered equivalent to a blind where personnel enter the vessel or confined space. 3. Furnace firebox tubes do not terminate at the furnace shell; therefore, for radiant or convection section entry it is not necessary to blind all the tubes where they enter or exit the furnace. If a leaking tube has been detected, then only the inlet and outlet of that tube pass needs to be blinded. L-000323 champlin REFINING COMPANY Procedure No. Issued: Revised: Page 3 of 7 705.2 2/24/89 CONFINED SPACE (VESSEL) ENTRY PROCEDURE IV. \ ) PROCEDURE (Cont'd.) B. 4. For entry into confined spaces such as vaults, API separators, sumps, pits. sewers, etc. where blinding is not possible it will be necessary to take precautions to isolate these areas by other means such as the use of plumbers plugs, etc. When plumbers plugs are used it is necessary that special care be taken to relieve any upstream pressure build-up so that the plumbers plug cannot blow out. 5. Drain lines which penetrate sewers must be either plugged or have the flange/union spread apart and offset. 6. All power-driven equipment in the vessel shall be immobilized (i.e. agitators, mixers, heater draft fans, etc.). Electrical equipment shall be locked out in accordance with the "Lockout and Tagout Procedure", No. 705.4. The power supply to other fixed equipment inside the vessel driven by air, steam, or hydraulic fluid shall have control valves closed, chained, and locked or be blinded. 7. Vessels which employ the use of a radioactive device MUST HAVE the source shutter locked out and tagged by the Safety or Instrument Department prior to entry. The device will be placed back in service only after the vessel has been closed and secured. 8. Controls must be provided that will prevent contaminants from entering the confined space such as open-ended pipes, sewers, or other similar equipment. This can be accomplished by covering the vessel opening or sealing the source from which these materials can discharge. 9. All vessels and/or confined spaces entered will require exhaust ventilation prior to and during entry. It may be necessary to supply forced ventilation by the use of fans, blowers, etc. if natural ventilation is not sufficient. When forced ventilation is utilized the blower should be placed in such a way to pull clean air from the top of the vessel down. L-000324 champlin REFINING COMPANY Procedure No. Issued: Revised: Page 4 of 7 705.2 2/24/89 CONFINED SPACE (VESSEL) ENTRY PROCEDURE IV. ) PROCEDURE (Cont'd.) B. 10. The atmosphere inside the space to be entered shall be tested for flammability, oxygen content, and other toxic materials. Acceptable test levels are: a. Oxygen - Must be between 19.5% and 21.0%. b. Flammable gas content - Must be zero (0). c. H2S content - Must be zero (0). d. Carbon monoxide Maximum 50 ppm. e. Other toxic materials - No entry without respiratory protection will be permitted unless test indicates exposure wilt be at or below the TLV. Lead in air analyses will be required for all storage tanks which have held leaded gasoline. f. Where inert gas entry is performed special procedures will apply. C. Permit Preparations 1. Confined space entry tasks will always require a "Hazardous Work Permit" to be issued by the operations personnel in the area where the work will be performed. The appropriate supervisory and operator approvals as indicated in the "Work Permit Procedure" Table I will be required prior to permit issuance. 2. Ail vessel preparations previously mentioned will be completed prior to the issuance of a confined space entry permit. In addition, each item listed on the "Hazardous Work Permit" pertaining to confined space entry must be checked during permit completion. It is required that these items be checked at the location where the work is to be performed. L-000325 champlin REFINING COMPANY Procedure No. Issued: Revised: Page 50/ 7 705.2 2/24/89 CONFINED SPACE (VESSEL) ENTRY PROCEDURE IV. PROCEDURE (Cont'd.) C. 3. The INITIAL vessel entry permit on ALL confined spaces will be independently reviewed by the Safety Department and co*signed by one of its representatives. Entry permits which involve work within Immediately Dangerous to Life and Health (IDLH) atmospheres will be co-signed by the Safety Department at each maintenance shift change if work extends beyond the first shift. 4. Confined space entry permits are issued for the time period specified on the top of the permit and expire one hour after the time of issue if work has not commenced. Permits will normally cover the time period of the maintenance shift but will not exceed 12 hours. 5. Where the work extends beyond the operational shift change the new shift coming on will recheck the confined space and initial the permit without interrupting the work. 6. Permits must be posted at the entrance to the vessel/confined space to be entered in a location that is readily visible to personnel. D. Special Precautions 1. Only explosion proof low voltage (12 volts) lights, flashlights, and/or extension cords may be used for confined space entry. The use of ground fault interrupters (GF1) will permit the use of lighting with a higher voltage rating provided the lights are explosion proof. 2. The temperature inside the confined space shall not exceed 100F unless special precautions to prevent heat stress have been taken. 3. If the refinery emergency alarm sounds all permits are VOID and all personnel must exit entered vessels. All confined spaces in the area of the emergency must be rechecked before personnel are allowed to re-enter. L-000326 champlin REFINING COMPANY Procedure No. issued: Revised: Page 6 of 7 705.2 2/24/89 < CONFINED SPACE (VESSEL) ENTRY PROCEDURE IV. PROCEDURE (Cont'd.) D. 4. If exhaust ventilation cannot be supplied and/or natural ventilation is not sufficient then breathing air equipment must be used in the enclosure. 5. The supervisor responsible for personnel entering the confined space will designate at least one person as a "safety watch" who will be positioned at the confined space/vessel entrance. On larger vessels it might be necessary to have more than one "safety watch" in order to adequately monitor the personnel inside. The "safety watch" responsibilities are: a) An accounting of all personnel working in the vessel. b) Visually observe and/or maintain a means or communication with personnel inside the vessel/space. c) The "safety watch" will be required to wear a red vest to so identify him/her as a manway attendant. d) Assure that conditions outside the vessel are not altered or tampered with such that conditions inside the vessel will be affected. e) Have all personnel leave from inside the vessel in case fire alarm sounds. f) The "safety watch" WILL NOT enter the vessel but instead summon assistance in the event of an emergency inside or outside the space. g) The safety watch must not leave the vessel at any time for any reason while personnel are inside the vessel. 6. In certain work situations, it may be necessary to enter vessels/confined spaces that contain an oxygen deficient atmosphere or is not completely purged of toxic materials. Personnel entry can be permitted provided that the appropriate precautionary measures are taken. L-000327 champlin REFINING COMPANY Procedure No. Issued. Revised: Page 7 of 7 705.2 2/24/89 CONFINED SPACE (VESSEL) ENTRY PROCEDURE IV. PROCEDURE (Cont'd.) D. 6. a) The Safety Department must be consulted on all such activities before the work commences. b) Ail personnel entering the vessel/confined space must wear and be trained in the use of the proper protective equipment for the hazard involved. c) Only pressure-demand hose line respirators with self-contained egress bottles will be allowed in confined spaces that contain an oxygen deficient atmosphere or one that is Immediately Dangerous to Life and Health (IDLH). d) Other special provisions will be required as deemed appropriate by the respective Safety Department representative. 7. In some instances it will be necessary for personnel entering a vessel to have additional personal protective equipment such as a safety harness, lifeline, fall protection device, or other equipment as prescribed by the Safety Department. 8. If it is necessary to perform "hot work" inside the confined space then the precautions outlined in the "Hot Work Procedure" will be followed. In addition, it is required that unattended flame cutting torches and hoses be removed from the confined space if work lapses for more than one hour. L--000328 champlin REFINING COMPANY j Procedure No. I issued: Revised: Page 2 of 5 705.3 2/20/89 HOT WORK PROCEDURE III. DEFINITIONS (CONT'D.) 2. Temporary Sources of Ignition: i. Powered sanding j. Sandblasting k. Electrical devices such as electrically powered tools, motors, generators, switches, and test equipment l. Motor vehicles such as trucks, cars, and scooters m. Cameras n. Internal combustion engines. IV. HOT WORK ALTERNATIVES The operating department authorized signee of the hot work permit should assess if the hot work job is really necessary, or if there is a safer alternative method or safer time for the work to be done. For example: 1. Can a support beam be bolted in place instead of welding? 2. Can a section of pipe be disconnected at the flanges and transported to a nonhazardous area for repair? 3. Can you cold cut a line with a pneumatic saw instead of cutting with an oxy/acetylene torch? V. WORK SITE PREPARATIONS 1. The area operator, lab leaderman, or terminal operator must insure the following is complete prior to hot work being performed: a. Shut down, lock out, and tag equipment that is to be worked on. b. Depressure the line and/or equipment. c. Drain, purge, and steam out the line or equipment with the bleeders open. d. The equipment is then blinded, plugged or a spool piece removed. Double block/bleed and plumbers plugs are not positive isolation systems and can only be used with prior approval from Operations and Safety Department personnel. L-0C032 chomplin REFINING COMPANY Procedure No. Issued: Revised: Page 1 of 5 705.3 2/20/89 HOT WORK PROCEDURE I. H. 111. ) PURPOSE To establish a safe, efficient, and reliable procedure for the performance of hot work within the refinery. SCOPE This procedure applies to all personnel who perform hot work at the Corpus Christi Refinery including terminal areas and associated pipelines. This procedure does not apply to the following non-hazardous areas: inside office buildings inside control rooms inside maintenance shops DEFINITIONS 1 Hot Work: Hot work is defined as permitting, under controlled conditions, a temporary source of ignition inside the operating areas of the refinery including tank storage areas, product pipelines, metering stations, waste treatment areas, and dock facilities. 2. Temporary Sources of Ignition: a. Welding b. Torch cutting c. Hot forging d. Soldering and brazing e. Hot tap/stoppling f. Stress relieving g. Gas fired heaters h. Grinding, chipping, or chiselling L-000330 champlin REFINING COMPANY , Procedure No i Issued" I Revised' ! Page 3 of 5 705.3 2/20/89 HOT WORK PROCEDURE V. WORK SITE PREPARATIONS (Cont'd.) 1. e. Cover and seal manhole plates, catch basins and sewers. Introduce steam if necessary. f. Survey immediate area to search for possible hydrocarbon leaks. g. Flammable gas content in the area of the "hot work" must be zero (0)% of the LEL before the work commences. For hot work in a confined space (pipe, vessel, etc.) a gas test must be taken inside the space. h. It may be necessary to introduce steam or nitrogen into the line or equipment before welding commences to further eliminate the possibility of a flammable atmosphere being present. 2. The maintenance crew will complete the following: a. Lock out and tag out controls for equipment which could create a hazard if activated during the job. b. Barricade the area when other personnel may be exposed to hazards such as falling sparks. c. Provide adequate ventilation for the welder and helper in order to eliminate exposure to welding fumes. d. Put a tarp/blanket in place to catch all welding sparks and slag so that they do not reach personnel or combustible material. The tarp/blanket is to be wet down to extinguish sparks. e. Provide a charged 1-1/2" fire hose with nozzle or 1" utility water hose, according to job needs. f. Provide a fully charged 30 lb., BC-rated dry chemical fire extinguisher. g. Provide a trained fire watch with orange vest. L-000331 champlin REFINING COMPANY Procedure No. issued: I Revised: I Page 4of 5 705.3 2/20/89 j HOT WORK PROCEDURE VI. PERMIT PREPARATIONS 1. The area operator, lab leaderman, or terminal operator must visit the job site and complete the Hazardous Work permit. When all permit requirements have been met, the area operator, lab leaderman, or terminal operator contacts their respective supervisor and the maintenance supervisor to request a final permit review. 2. The operations, lab, or terminal supervisor visits the job site and double checks the work site preparations. He/she then co-signs the permit to indicate that the equipment is adequately prepared and that the maintenance workers are complying with permit requirements. 3. The maintenance supervisor/Leaderman and the maintenance craftsman visit the job site, review the Hazardous Work permit, and sign the permit. By signing the permit, the craftsman and the maintenance supervisor are agreeing that the permit conditions are sufficient to perform the job safely. 4. Hazardous Work Permits are completed in accordance with Procedure 705.1. The Safety Department will be available to review permit conditions upon request. 5. Permits will be posted in the immediate area of the hot work. VII. SPECIAL PERMITS A. During the performance of low energy hot work such as vehicle entry or use of a camera in unit battery limits then the operator will issue a "Routine Safety Permit" as described in Procedure 705.1. The area operator, lab leaderman, and/or terminal operator must complete the following tasks prior to permit issuance: 1. Flammable gas content in the area is zero (0). 2. Survey area upwind for hydrocarbon leaks. 3. If necessary, cover sewers and catch basins in the area. L-000332 champlin REFINING COMPANY j Procedure No, Issued: Revised: Page 5 of 5 705.J 2/20/89 HOT WORK PROCEDURE VII. SPECIAL PERMITS (Cont'd.) B. When Hot Tap/Stoppling tasks are to be performed special precautions must be taken as outlined on the "Hazardous Work Permit" and in Procedure 705.5. Precautions as described in A through E of this procedure must also be followed before work begins. VIII. ADDITIONAL PRECAUTIONS A. When hot work is to be performed within confined spaces it will be necessary to comply with the requirements of this procedure in addition to the precautions outlined in Procedure 705.2. B. Oxygen/Acetylene equipment shall be turned off at the cylinder when not in use and the cutting torch removed from any enclosures or vessels. C. A flame arrestor or check valve must be properly installed between the cylinder regulator and hose line when using Oxygen/Acetylene equipment. D. Permits for hot work are void as prescribed in Procedure 705.1. Refinery Manager L-000333 5 champlin REFINING COMPANY ; Procedure No i issued: I Revised: i Page I of 9 705.4 7/28/89 7/10/90 ISOLATION PROCEDURE FOR EQUIPMENT AND ENERGY SOURCES (Lock Out and Tag Out) I. PURPOSE The purpose of this procedure is to establish proper guidelines for the isolation of equipment prior to maintenance and/or vessel entry to prevent possible injury. This * procedure also establishes the means to secure machinery, equipment and ether energy sources to allow safe operations and maintenance functions, it also includes a system for locating and recording blinds. II. SCOPE This procedure applies to all employees, contractors and sub-contractors performing work for Champlin Refining and Chemicals, Inc. Examples of tasks covered by this procedure are: 1. Pump Repair 2. Valve Removal 3. Pipe Replacement 4. Instrument Repair/Removal 5. Confined Space Entry 6. Compressor Repair 7. Electrical Work III. RESPONSIBILITY It is the responsibility of Champlin management to insure that these procedures are enforced in compliance with Federal Regulations (OSHA). The roles of the Area Operators, Craftsmen, Operations Supervisors, Maintenance Supervisors, and/or others are described in the Work Permit Procedure. The Operator is primarily responsible for isolating energy sources, for depressuring and clearing equipment of its process contents, tagging/locking associated valves and issuing and maintaining blind lists. The Operations and Maintenance Departments are jointly responsible for ensuring that prepared equipment is safe for work. L-000334 champlin REFINING COMPANY Procedure No. Issued: Revised: Page 2 of 9 705.4 7/28/89 7/10/90 ISOLATION PROCEDURE FOR EQUIPMENT AND ENERGY SOURCES (Lock Out and Tag Out) RESPONSIBILITY (Cont'd.) A complete blind list must be maintained by the Operations Department. The Unit operator must give approval for the installation or removal of any blind. DEFINITIONS A. Equipment B. Tag-out C. Lock-out D. Isolation Vessels, pits, pumps, exchangers, pressure gauges, D.P. cells, steam turbines, receivers, etc. Attachment of a "Danger, Do Not Operate" tag onto equipment whose inadvertent operation may cause a hazard to personnel during their work performance. Tags will contain the following information: 1. A brief description of the reason for tag placement. 2. Name (signature) and department of person placing the tag. 3. Date of tag placement Physical placement of keyed lock with attached tag or chain/lock for energy source isolation. Each person who is required to isolate or work on machinery, power systems, or other mechanical equipment must have his or her own isolation lock. Operations department locks may be universally keyed; however, only operating personnel shall have access to the keys. The locks must be substantial and durable. Lockout hasps or adapters will be used when multiple locks are required. Effective separation of a piece of equipment from its system. L-000335 champlin REFINING COMPANY Procedure No. issued: Revised: Page 3 of 9 705.4 7/28/89 7/10/90 ISOLATION PROCEDURE FOR EQUIPMENT AND ENERGY SOURCES (Lock Out and Tag Out) IV. DEFINITIONS (Cont'd.) E. Senior Craftsman - The craftsman with the most experience where the work is taking place. F. Area Operator - Includes area technicians. > G. Energy Source - Any source of electrical, mechanical, hydraulic, pneumatic, chemical, thermal, radioactive, or other energy. 1 V. PROCEDURE A. Before equipment work begins: 1. Operations is responsible for shutting equipment down prior to the performance of maintenance work. 2. The Area Operator will decommission and install lockouts and tags on all associated electrical equipment, electric valve operators, air starters, steam turbines and other power drives. a. The electrical start switch, if available for the piece of equipment being worked on, must be activated to insure proper isolation following main switch isolation. If the unit fails to start, it is de energized; now depress the reset and/or stop switch. Note: Prior to lock removal and breaker activation, depress the reset and/or stop switch to prevent premature starting of the equipment. I L-000336 champlin REFINING COMPANY Procedure No. Issued: Revised: Page 4 of 9 705.4 7/28/89 7/10/90 ISOLATION PROCEDURE FOR EQUIPMENT AND ENERGY SOURCES (Lock Out and Tag Out) PROCEDURE (Cont'd.) A. 2. b. For power drives other than electric, such as steam or air, it will be necessary to immobilize equipment through chaining and locking valves, blinding, drop spool, removal of hydraulic or pneumatic pressure, or other effective means. In addition to locking out the motor on large pieces of equipment such as compressors where the crankcase is to be entered by the hands or body, the flywheel or crankshaft may need to be secured to prevent rolling, c. Once Operations have their locks and tags installed and the start switch tried, then a representative of each maintenance craft performing work on that equipment must place their lock and tag in place. 3. Operations will close all block valves going to and from the affected equipment. Double block and bleed, if feasible. 4. The Area Operator must tag-out and lock all associated isolation valves. If valves can not be locked a tag may be installed with a heavy duty tie wrap to prevent operation. 5. Operations must then depressure the equipment. Be sure to confirm that drains and vents are not plugged and use an "angle worm reamer" if necessary. Drain or vent remaining hydrocarbons and dispose of liquids. A yellow "Caution" tag shall be placed on all open vents and drains by Operations. 6. The senior craftsman for each craft on the job or the Maintenance Leaderman verifies that isolation valves are closed and that the equipment is depressured. The craftsman or Leaderman must also place his/her identified lock on isolation valves. L-000337 EchamplinREFINING COMPANY Procedure No. Issued: Revised: Page 5 of 9 705.4 7/28/89 7/10/90 ISOLATION PROCEDURE FOR EQUIPMENT AND ENERGY SOURCES (Lock Out and Tag Out) V. PROCEDURE (Cont'd.) A. 7. The operations or maintenance personnel involved in each job may decide to install blinds, depending on the integrity of the block valves, the hazard of the process equipment and the time of exposure. It may also be necessary to blind the equipment in order to finish clearing it of process material. In this situation workers installing blinds may need to wear special protective clothing and be supplied with breathing air. 8. Operations must clear the equipment of any remaining process liquids or gases by purging with steam, nitrogen or water, whichever is appropriate. Level gauge glasses and instrument taps should also be purged. 9. Verily that all of the isolation procedures have been completed prior to issuing a work permit. 10. Verify the effectiveness of equipment isolation efforts by using the correct meter or device to test the air quality in and around the immediate work area. . 11. After a permit has been issued, no new hoses or tie-ins can be added to the isolated equipment unless a new work permit has been issued. 12. Operations' locks and tags will stay in place until alj work has been completed and all maintenance locks and lags have been removed. Operations will then remove their lock indicating that the equipment is ready for service. (NOTE: The Operations lock and tag is always the first on and the last removed.) \ L-000338 champlin REFINING COMPANY Procedure No. Issued: Revised: Page 6 of 9 705.4 7/28/89 7/10/90 ISOLATION PROCEDURE FOR EQUIPMENT AND ENERGY SOURCES (Lock Out and Tag Out) PROCEDURE (Cont'd.) A. 12. Remember - when blinding, a. Keep personnel in the immediate area to an absolute minimum, b. Make sure those doing the blinding have a clear escape route, and c. If you encounter "surprise" releases, get away from the area, and get operating personnel to specify a new procedure or protection to cope with the "surprise" release. 13. If the job will be completed by someone other than the craftsman who started the job: a. The first craftsmen will remove their identified locks and notify the operator that the work has not been completed. b. The new craftsmen will go to the unit operator and inform the operator that they are taking over the job and verify the location where their identified locks are to be installed. B. Confined Space Entry 1. Entry into confined spaces present special hazards (Refer to Procedure 705.2), therefore the following additional precautions are required: a. Equipment blinding is mandatory for work activities involving confined space entry. Isolation blinds are normally placed at the first flange from the vessel. Blinds should be installed with the proper gaskets on both sides. b. The Operations Department shall supply a "blind list" for the recording of all blinds. L-000339 champlin REFINING COMPANY Procedure No j Issued ! Revised i Page 7of 9 705.4 7/28/89 7/10/90 ISOLATION PROCEDURE FOR EQUIPMENT AND ENERGY SOURCES (Lock Out and Tag Out) PROCEDURE (Cont'd.) B. 1. c. Install all blinds with an obviously conspicuous plastic streamer attached to the blind. During turnarounds, it will be- necessary to attach a numbered tag to the blind. The tag number must be recorded on the master blind list and the duplicate tag placed on the blind board. All blinds for a particular vessel are to be grouped together on the blind list in order to verify proper isolation. d. The Maintenance Craftsman and the Area Operator must initial the master blind list when blinds are installed. When all blinds on the list are installed, the Maintenance Leaderman or senior craftsman for each craft on the job and the Area Operator must sign at the bottom of the master blind list. By signing the blind list, both persons are confirming that blinding is complete per the list. e. When one blind is common to two different jobs, it must be on both blind lists. Each such "common" blind must be specially marked on both blind lists that it is also being used for another job. Obviously, common blinds cannot be removed until both jobs are complete. For blinds which serve two or more jobs, it may be helpful to install two or more streamers on the blind's tab to reduce the likelihood of its being pulled prematurely. f. If blinding is not feasible, a special procedure must be approved by Operations, Maintenance and Safety representatives. g. If a radioactive source is present on the equipment, contact the Instrument or Safety Department to lock out the source. L-000340 chomplin REFINING COMPANY =roceoure No ' issued | Revised ! Page 8 of 9 705.4 7/28/89 7/10/90 ; ISOLATION PROCEDURE FOR EQUIPMENT AND ENERGY SOURCES (Lock Out and Tag Out) PROCEDURE (Cont'd.) B. 1. h. A Safety Department representative must sign the permit form on all initial confined space entries. C. When equipment work is complete: 1. The Maintenance Leaderman or senior craftsman for each craft on the job contacts Operations and notifies them that the isolation devices are ready for removal. 2. After ensuring that all employees, tools and other maintenance equipment have been removed from any confined spaces, the maintenance crafts shall close and secure all vessel manways. An Operations representative must be present just prior to manway closure. 3. The Area Operator and Maintenance Leaderman or senior craftsman for each craft on the job must initial the "OK to remove" space on the master blind list. When the blinds are removed, both the Maintenance Leaderman or senior craftsman for each craft on the job and the Area Operator must again initial the master blind list after visually verifying that the blinds are out. 4. The Maintenance Leaderman or senior craftsman for each craft on the job assures that all maintenance tags and locks are removed. 5. The Area Operator removes all operations tags and locks. 6. The Maintenance Leadermen or senior craftsmen will then sign off the Work Permit. L-000341 champlin REFINING COMPANY a'Qcecure No issued Reused Rage 9 of 9 7C5.4 7/28/89 7/10/90 ISOLATION PROCEDURE FOR EQUIPMENT AND ENERGY SOURCES (Lock Out and Tag Out) V. PROCEDURE (Cont'd.) C. 7. Emergency Removal of Locks/Tags If a lockout device must be removed by cutting, the Shift Foreman and Maintenance Supervisor in the affected area: a. are the only people who can remove a lockout device. b. must assure themselves the owner of the lock is not on the plant property. c. must acquaint themselves thoroughly with the reason for the equipment being locked. d. must acquaint themselves with the status of the job. e. must inspect the equipment completely. f. must satisfy themselves from the above that it is safe to remove the lock. g. must, as soon as practicable, notify the employee who placed the lock that it has been removed. Iw L-000342 CHAMPUN REFINUNG AND CHEMICALS. INC. CORPUS CHRISTI REFINERY BUND UST 705.4 S oo o& s3 13 's(C5 1| 521c iS-sjL 2 gj o Q(0 C ---- 525-81-* HU asa 3Ji--TaJ J4S1-^ .-If)i S " a jj ss Is*Zse-l 5 73 9 StJ9 gl !a*a J3s55'S-a 2s3 60 < V V 11 (2 zSSS L-000343 champlin REFINING COMPANY Procedure No. Issued: Revised: Page j of 7 705.5 8/3/89 HOT TAP AND/OR STOPPLE PROCEDURE I. PURPOSE To establish a procedure for planning and safely performing a Hot Tap and/or Stopple. II. DEFINITIONS HOT TAP A method used to add piping connections to live pressurized equipment. This method includes the welding of a reinforced nozzle or weldolet to the equipment being tapped while the equipment is in service. STOPPLE A method which involves setting one or more temporary plugs in the piping by mechanical means through connections hot tapped onto the piping. These plugs are designed to retain pressure and temporarily stop flow. III. SCOPE This procedure applies to all Champlin employees and contractors performing work within Champlin facilities. It should be used to tie into the equipment only when it is not feasible or not possible to remove the equipment from service. All hot taps/stopples must be approved by the appropriate Area Operations or Terminal Superintendent and the Maintenance Supervisor. In certain cases (defined herein) authorization is required from the Plant Manager. If vessels are to be hot tapped then the National Board Form R-l is required which is obtained from Operations Reliability. IV. FEASIBILITY Prior to obtaining the required permit, the feasibility and HazOp of the proposed hot taps and stopples shall be reviewed by Engineering and Operations Reliability Department representatives. Consideration shall be given to the following: L-000344 EchamplinREFINING COMPANY Procedure No. Issued: Revised: Page 2 of 7 705.5 8/3/89 HOT TAP AND/OR STOPPLE PROCEDURE IV. FEASIBILITY (Cont'd.) A. METALLURGY 1. Base Metal Thickness In general, a thickness reading of 1/4" shall be considered minimum. Hot taps can be made in lamination-free areas only. 2. Alloys and Stress Relieving Stress relieving cannot normally be done while the equipment is under pressure. 3. Metal Temperature Preheating of base metals may be required for proper welding procedures. 4. A weld procedure as described by ANSI B31.3 must be written by Operations Reliability. 3. CHEMICAL In general, hot tapping cannot be performed on equipment in the following services: 1. Air, halogens, or oxygen 2. Vacuum systems 3. Hydrogen or H2-rich streams 4. Flammable vapor/Oxygen mixtures 5. Acids, caustics, amine, sulfur, H2S, acid gas 6. Systems above 500 psig pressure or 500F temperature 7. Flare systems If it is deemed absolutely necessary to initiate hot tap procedures in any of the above services, a complete detailed investigation as to the possible hazards shall be presented to the Plant Manager for his approval of the project. L-000345 champlin REFINING COMPANY ; Procedure No. I Issued: Revised: Page 3 of 7 705.5 8/3/89 HOT TAP AND/OR STOPPLE PROCEDURE IV. FEASIBILITY (Cont'd.) C. SPECIAL CONSIDERATIONS 1. Lined Pipes or Tanks Hot tapping cannot be done on equipment that js cladded or lined with glass, lead, refractory, plastic, etc. Ensure that piping is not jacketed. 2. Rotating Equipment Avoid hot tapping upstream of rotating equipment unless protection is provided for cuttings by filters, traps, etc. 3. Flow Ensure that adequate flow is present in the line to be tapped to help dissipate the heat generated by welding. It may be necessary to introduce an inert gas or steam to accomplish this. 4. Tanks Maintain a liquid level of at least three (3) feet above the hot work area for hot taps on tanks. Pumping in and out of tanks shall be avoided during hot tap procedures. Mixers shall be shut down and locked out. Water drawing and sampling shall be prohibited during the hot tap procedure. 5. Pressure Vessels This procedure is not intended to cover welding procedures on ASME Coded Pressure Vessels. After this review has been completed by the Engineering and Operations Reliability Departments, the "Authorization for Hot Tap/Stopple" Form (attached) shall be completed and the proper authorizations obtained. L-000346 champlin REFINING COMPANY : Proceaure No. issued: Revised: Page 4 of 7 705.5 8/3/89 HOT TAP AND/OR STOPPLE PROCEDURE V. PROCEDURE FOR HOT TAPPING A. The assigned Project Engineer, based on information from the "Authorization for Hot Tap/Stopple" Form, will determine the type of reinforcement required and make detailed drawings specifying all components and procedures to be used. He will also specify the hydrotest pressure of the new connection on the Hot Tap/Stopple Form. Safety precautions shall also be specified. B. The" Authorization for Hot Tap/Stopple" and appropriate drawings must then be attached to a Maintenance Work Request. Each hot tap requires a separate Maintenance Work Request which is to be approved by the Area Operations Superintendent. C. After approval, the Maintenance Work Request can be forwarded to the appropriate Champlin Maintenance or Construction Supervisor via the Planning Department. D. The Maintenance or Construction Supervisor and Project Engineer shall inspect the job site and verify with the appropriate Operations Area Supervisor the proper location and equipment. The Maintenance or Construction Supervisor shall verify that enough clearance for the Hot Tap machine exists and that the job site is properly and safely prepared. Scaffolding, excavation, or insulation removal may be required and the proper work permits for these activities must be obtained. E. Once the job site is properly prepared, the exact location of the hot tap must be marked on the equipment jointly by Operations, Maintenance and Project Engineering, and the Inspection Department notified to ultrasonically test or radiograph the actual hot tap location. The test results shall be recorded and the welder notified of the actual thickness. L-000347 champlin REFINING COMPANY Procedure No. Issued: Revised: Page of "705.5 8/3/89 HOT TAP AND/OR STOPPLE PROCEDURE V. PROCEDURE FOR HOT TAPPING (Cont'd.) F. The Area Operations Superintendent must assess the adverse consequences of performing a hot tap or stopple, and must take the appropriate precautions, such as: 1. Equipment (or unit) isolation - where, how. 2. Firefighting equipment and standby personnel, if warranted. G. In order to weld the hot tap fitting on the equipment, a Hazardous Work Permit must be obtained. The Area Operations Superintendent and Maintenance Supervisor must sign this permit after insuring that flow or liquid head has been established. Ail Permit conditions must be verified. H. The Maintenance Supervisor shall verify the following: 1. The material is as specified or the engineering drawings. 2. The proper welding guidelines governed by OSHA 29CFRI910, Subpart Q, and American National Standards Institute. Z49.1 1967, Safety in Welding and Cutting, are followed. 3. The criteria detailed on the authorization for Hot Tap/Stopple is adhered to. I. After completion of the attachment weld, the hot tap valve shall be installed and the entire system tested for clearance and machine operation. The new weldment shall then be hydrotested, in addition to any non-destructive testing as required by Operations Reliability. If a reinforcing pad is used, it shall be tested separately. J. The Hot Tap machine can now be installed, pressure tested, and purged with nitrogen. Operations and Maintenance Supervisors shall verify that all items on the Hot Tap Authorization are in effect. During the cutting operation, the retraction of the boring bar, closing of the hot tap valve, and the depressuring of the machine, both Maintenance and Area Operations Supervisors, or their representatives, shall be at the job site. L-000348 EchamplinREFINING COMPANY I Procedure No. Issued: Revised: Page 6 of 7 705.5 8/3/89 HOT TAP AND/OR STOPPLE PROCEDURE V. PROCEDURE FOR HOT TAPPING (Cont'd.) K. After the tapping procedure is complete, the valve closed, and the machine depressured, the machine should be removed from the valve. L. The ''coupon" from the cutting operation is to be given to the Inspection Department for evaluation. VI. PROCEDURE FOR STOPPLING A. To initiate a stopple operation, the same feasibility study by the Engineering and Operations Reliability Departments that has been outlined for a hot tap will be performed. B. The assigned Project Engineer must contact a qualified Tapping and Plugging contractor to determine what type of fitting to use, what type elastomer the plug should be made of, and to be sure it is compatible with the commodity in the piping to be stoppled. C. The Engineer shall write a step-by-step work sequence, including drawings and specifications, and the locations of venting and pressure equalizing connections. In addition, the Engineer shall include the necessary safety precautions. This work sequence shall be approved by the Operations and Maintenance Superintendents. The "Authorization for Hot Tap/Stopple" shall then be completed. D. The hot tap fitting can then be installed per the Hot Tap procedure. E. For stoppling, the stoppling contractor's valve is used instead of the Hot Tap valve. The Maintenance Supervisor is responsible to verily the integrity of the valve, the Hot Tap machine, and the plugging machine by pressure testing. L-000349 champlin REFINING COMPANY , Procedure No. Issued: Revised: v Page 7 of 7 705.5 8/3/89 HOT TAP AND/OR STOPPLE PROCEDURE VI. PROCEDURE FOR STOPPLING (Cont'd.) F. After the hot tap is completed and the Hot Tap machine is removed, the Stoppling machine can be installed. The appropriate Operations Representative is to ascertain that, during installation of the plug, there is minimum flow in the line. G. With the plug in place, the isolated section of the pipe can be depressured and drained and the tightness of the plug verified. H. Work can now commence on the downstream side of the plug. This may involve cutting the line, welding on a flange and installing a new valve, or just replacing an existing valve. However, work shall proceed without any interruptions until the line is closed again and the stopple is ready for removal. I. In order to remove the stopple plug, the Maintenance Supervisor is to verify that all work is completed and the line is properly closed. The Operations Shift Supervisor is to verify that the pressure on both sides of the plug is 0 psig, making the plug ready for removal. The stopple plug can then be removed and a completion plug installed in the stopple fitting. When the completion plug is in place, the stoppling machine can be depressured and removed. A blind flange shall be installed over the completion plug. Attach. L-000350 AUTHORIZATION FOR HOT TAP/STOPPLE DESCRIPTION OF THE PROPOSED INSTALLATION Date: Diameter of the principal line:_____________ Line Service:_____ _______________________ Nozzle sue of the HOT-TAP:_^____________ Pipe Wall Thickness at Weld Point:_________ Location of the proposed nozzle: (Be specific) Max Oper. Pressure: Line Temperature: Type of flange:_____ POINTS 1 2 3 4 5 6 PREREQUISITES There are no other alternatives. Written procedures and approved drawings by Project Engineering. The line has a good flow. The level of liquid in the tank is satisfactory. Fire equipment available on site. Stopple rated for proper temperature and pressure. APPROVALS PROCESS/PROJECT ENGINEERING DATE OPERATIONS RELIABILITY APPROVED: 705.5 AREA OPERATIONS SUPERINTENDENT DATE L-000351 e champlin A Subsidiary of Union PacificCorporation nev. / ijune o, o PREPARATION TO CLEAN AND ENTER TANK FOR REPAIRS PROCEDURE NO. 30 I. PURPOSE Ehtry and repairs within enclosures such as a tank or vessel must be coordinated to ensure that adequate preparation has been made to control hazards as they relate to each other and the worker's safety. H. SCOPE This procedure is to be applied to all confined areas In the refinery, vessels and tanks whether or not in active service. It shall be extended to any type of hot work performed under such circumstances. III. GENERAL Those who assign and supervise such work, whether contract or refinery personnel, are accountable for the necessary safeguards while those who enter such enclosures ^ are responsible for following safe procedures. IV. PROCEDURES 1. Safe work permits are required to cover the work to be accomplished. The hazards that are present and their degree of concentration must be deter mined. Safety precautions shall be consistent with the exposures that may b encountered. Generally, petroleum vapors are flamnable from 1% at the lower level (LEL) to 7% at the upper (UEL). An enclosed space is safe for entry and hot work without respiratory equipment under the following conditions: a. Ventilation is adequate using explosive proof equipment and the lnterio is clean. b. The ambient atmosphere has been vapor freed to less than 5% of the lowe explosive limit. c. H2S concentration is found to be no more than 10 ppm. d. Lead-in-air is found to be no more than 2 Ug/ft3 (0.075 mg/m3). e. Oxygen content is at least 19.5%. f. Blinding has been completed. g. Any iron polusulfide deposits which are pyrophoric are kept wet down. h. That the tank is effectively grounded. v i. Added safety precautions for the particular work to be performed have ' been taken. j. Assignments within an enclosure are limited to 8 hours a day. Form SFTO0 (8-77) -1- L-000352 PREPARATION TO CLEAN AND ENTER TANK FOR REPAIRS PROCEDURE NO. 30 2. Consideration shall be given to personal protective equipment and clothing relative- to the possible hazards that may exist in cotimencing and conpleting the work. 3. Blinding of a tank or vessel definitely requires caution in that gas fumes and product are always present. Be extronely cautious that you do not create a spark. 4. After tank is blinded, water wash all lines leading into tank. Steam the tank is steam is available. Initial cleaning is to be performed from outside a confined space. 5. Set stroke-type pump to strip all products from tank. 6. Dig hole approximately 8f x 8' at base of water draw. Remove water draw connection. 7. Fbr floating roof tanks, remove man-way plate on upwind side of tank and use 1-1/2" fire hose to wash excess product from the floor of the tank into the hole and pump to slop line or tank. 8. Remove opposite man-way and insert4a steam Jet to remove the fumes from the tank. 9. When all clear water comes through the water draw, check tank with explosive meter. When you have the tank clear of gas, you may enter the tank wearing fresh air breathing equipment, rain suit, boots, and gloves. Wash the floor of the tank. After the floor and sides of the tank are clean, the floor should be mopped to remove water from the floor. 10. The tank should be allowed to dry.- At least 60% of the floor must be dry and then a lead-in-air analysis must be taken. If results are within allowable limits the tank may then be entered without personal protective equipment. 11. A confined space may be entered for inspection with positive pressure air supplied respirator using dry-cell safety lamps for light; provided the space is drained to the lowest possible level, blinding has been accomplished and general ventilation is sufficient to maintain the vapor concentration below 20% of the lower explosive limit. No work shall be performed until the internal area is vapor free. 12. No artificial lights shall be used within a confined space until it is vapor free. Portable seal beam explosion proof lights with connectors or switches approved for hazardous locations may be used. Enclosed lights equipped with ground fault interrupters are permissible at the entrance to a confined space with the approval of the Operations and Maintenance superintendents. An electrician must confirm the proper operation of the ground fault interrupt* prior to use for each application. -2- L-000353 e chomplin A Subsidiary of Union Pacific Corporation PREPARATION TO CLEAN AND ENTER TANK FDR REPAIRS PROCEDURE NO. 30 13- Check all piping as well as the entire tank for explosive atmosphere and follow hot work procedure. Tank must have a non-explosive atmosphere and proper forced air ventilation before starting to weld. 14. For welding on tank floor you must: a. Build dike approximately 18" high around outside of tank and fill with water. b. Inject water under tank floor with water connection near the center of the tank. c. Have four vents equally spaced with vent lines running outside to atmosphere. d. When water is present in all four vent holes you may proceed to" weld on floor. e. The electric welding machine's ground lead affixed to the exterior must be securely clamped. Hooks create unnecessary arcing and this should ) be controlled to the minimum. 15. In case of lightning tank should NOT be opened. If you are working in a and lightning occurs, shut down welding and remove all personnel until lightning ceases. 16. It is preferable that tank cleaning operations be performed during the day light hours. Visibility presents problems at night which may prompt the creation of ignition sources of any vapors present. } Ffm SFT-tO {8-77) L-000354 -3- c champlin A Subsidiary of Union Pacific Corporation issuec: ,-ecruary _ Rev, (1) April 3C, 1984 INTERNAL FLOATING DECK UTILIZATION POLICY PROCEDURE NO. 52 PURPOSE A definition of policy must be stated for the safe utilization of internal float ing deck tanks in service. Safety precautions for maintenance below the roof on floating decks buoyed by product are complex and more often than not impractical to adequately control the impending hazards. SCOPE Operating and maintenance functions are accountable for coordinating their activities involving maintenance, repair and adjustment of internal floating decks to ensure the safety of employees. POLICY \ 1. Thnk entry is only permissible for tanks that have been taken out of service, are free of gas, oxygen is adequate, the lead content is below the threshold limit value and exhaust ventilation has been provided. 2. Work will not be performed on a product floatation deck. Operations will give preference to transferring the product to another tank in all cases for deck repairs, leg adjustment, seal repairs, preventative maintenance and etc. 3. Inspection of a floating deck may be permitted by conplying with the tank entry procedure to ensure clean ambient air providing 3/4" x 2' plywood walking surface and utilizing a safety harness with line. In addition, two employees must tend the line constantly to ensure it is taut at all times and the employee performing the inspection shall wear a positive pressure air line respirator properly fitted. 4. In the event an emergency arises to the extent work on a floating deck becomes necessary, the matter will be subjected to the joint determina tion of the department heads from maintenance, operations, safety and the refinery manager. Safety precautions that must be exercised will be formulated accordingly at that time. \ Form SFT-10 (8-77) ******* L-000355 i c champlin A Subsidiary of Union Pacific Corporation SAFETY PROCEDURE FOR MAINTENANCE WORK ORDER SYSTEM No. 25 Issued June 15, 1976 Revised Oct. 26, 1979 I. Purpose To provide a procedure to assure the safety of all personnel. The following procedure represents minimum requirements only. Any additional precautions deemed necessary, inconsistent with the pro cedure, should be used as directed by supervision. When in doubt, always consult your supervisor. II. Scope This procedure is applicable to all work being performed within the Refinery and Tank Farm as required by work orders issued during normal operations. Turnaround maintenance and construction is pre-planned taking into account safety considerations, therefore this system is not applied. Ill. General \ The revised maintenance work order form (copy attached) will also be used to assure that safety precautionary measures are in order. All work to be performed within the Refinery will require a duly approved work order. The procedure for the work order system is as follows: 1. The Maintenance Craftsman, or the Contractor,that has been assigned the repair or construction work will receive the green copy of the maintenance work order form. The bottom section of the maintenance work order form serves as the safety audit for the job. 2. The Lead Craftsman (or representative for the Contractor) that is to perform the work and the Operator of the unit in which the work is to be performed, will both carefully review the work to be done at the work site and inspect the work site to assure that the work in question can be accomplished safely. If the work is in the Terminal area, the Terminal Operator for that area will be responsible for checking out the equipment and the site. 3. The Lead Craftsman (or contractor representative) and the Operator will both sign the green copy of the work order form in the proper space under "Work Permit" pertaining to safety considerations. The date and hour portion should also be completed. The total work order is now duly authorized. All work within the Refinery Units or Tank Farm area must have a work order duly authorized prior to the commencing of the work. > L-000356 4. The craft sequence on the work order provides for different types of work to be performed with the same work order. For example, if a' pump and motor driver are to be repaired, they can be done with the same work order. The Electricians and Machinists would be the Form 3FT-10 two crafts involved. In that the safety aspect is somewhat different. m e champlin A Subsidiary of Union Pacific Corporation MAINTENANCE WORK ORDER SYSTEM craftsmen from both crafts (Electrical and Machinists) shall by their signature verify that the safety has been given consideration. 5. If the work Is not completed the same day and the equipment is not operable (but left in a safe condition), the green copy of the work order form must be left in the Control Room or a place that is highly visible (preferably on a clip board). The Operator on shift and the Craftsman must both check the appropriate block of the safety audit permit (including date and hour). 6. If the work is not completed the same day, but the equipment is left operable, the appropriate block should be checked on the green copy of the work order form (with the date and hour) and placed in a highly visible place in the Control Room. It is important that the Operator and the Craftsman both initial the proper block on the form stating the equipment is left operable. 7. When the work is completed, the bottom section of the green copy of the work order should be completed and signed by both the Operator and the Craftsman. This section certifies that the work . has been completed and the area cleaned up, and that the Operator has accepted the work and the clean up. 8. The green copy of the work order is then returned to the Craftsman's Supervisor to be filed by Planning. Supervisors will review this procedure with all personnel at least annually. Form SFT-10 <*77} L-000357 champlin c Number: Equipment #: Title: MAINTENANCE WORK ORDER Location Number Equip. Name: Description of Problem Originator Approval: Craft Sequence Date: Date: # Men R.E. Approval: Accepted 8y: Activity AFE/ACC. Area: CRAFT DESIGNATIO ______ Machinist ______ P.FVB.M. ______ Electrician ______ Instrument _____ Welder _____ Other PRIORITY ___ Emergency ___ Urgent (1) ___ Urgent (2) ___ Routine ___Shutdown ___ Turnaround WORK SAFELY Permit Required: ___ Work ___ Hot Work ___ Entry ___ Protective Clothing ___ Other Date: Date: Equipment Hist. Act. Time Work Permit Equipment Inspected and Considered safe for work CRAFT COMPLETED ANO CLEAN-UP OPERATOR CRAFTSMAN SIGNATURE DATE TIME OP CR SIGNATURE DATE SIGNATURE JOB COMPLETED AND CLEAN-UP date SIGNATURE TIME CRAFTSMAN: OPERATOR: --------------------- L-00 0358 TIME DATE CHG 01908 706.1 7/15/75 2/1/91 15 CONTRACTOR SAFETY PROGRAM I. PURPOSE The purpose of this procedure is to provide protection for both Champiin and contract employees from injury or illness as a result of contracted work. II. SCOPE These guidelines set forth safety and occupational health requirements for contractors who perform various services on Champiin property. Applicable portions of the guidelines should be considered for new construction where Champiin personnel may be less directly involved. These guidelines do not apply to contract operations which are performed off Champiin property. IH. PROCEDURE A. General Requirements 1. Contract personnel shall comply with all applicable OSHA 29 CFR 1926 and 1910 Regulations and other Federal, State, local, and Champiin regulations as well as those established by their own organizations. 2. Contractors are responsible for protecting the health and safety of their own employees and must have an established and written safety program. 3. Contractors shall conduct themselves so they do not constitute a hazard to either Champiin employees or property. 4. Champiin may, at its option, inspect work sites to insure that safety practices are in accordance with applicable regulations and site standards. Such inspections shall not constitute an acceptance of the contractor organization's practices nor will they relieve the contractor organization of responsibility for the safety and health of its employees. L-000360 706.1 7/15/75 2/1/91 25 CONTRACTOR SAFETY PROGRAM PROCEDURE (Cont'd.) A. 5. Apparent violations of the Occupational Safety and Health Act. and applicable Federal, State and local regulations by contractor personnel should be brought to the attention of contract supervision. 6. Contractors will be informed of the hazards of Champlin operations and materials that they may encounter so that appropriate precautions can be taken. 7. The presence of Champlin personnel in the work area of the contractor should be minimal and limited to only Champlin employees who need to be involved. 8. Champlin's management will communicate only with contractor's supervisors with relation to the job goals and job quality standards to be achieved and not with contractor's other employees. 9. Contractors with 50 or more employees on Champlin property at one time must provide an on-site safety representative. 10. Injury Reporting - OSHA recordable injuries involving contractor personnel on Champlin property must be reported to Champlin management according to the following: a. OSHA recordable injuries which do not involve lost time must be investigated immediately and a full report completed by the contract supervisor which includes the pertinent facts and the proposed corrective action. This report must be submitted to Champlin management within 48 hours of the injury. A meeting with the appropriate Champlin management representative will be scheduled so that the contractor may discuss facts and corrective actions. In addition, the contractor must provide a copy of the "First Report of Injury" which the contractor must provide to their insurance carrier on all OSHA recordable injuries. L-000361 706.1 7/15/75 2/1/91 CONTRACTOR SAFETY PROGRAM III. PROCEDURE (Cont'd.) A. 10. b. OSHA recordable injuries which do involve lost time from work must also be investigated immediately by the contract supervisor. An oral presentation concerning the facts of the incident must be made to members of Champlin staff within 24 hours of any lost time injury. In addition, a formal report and "First Report of Injury" as described above must be submitted within 48 hours, c. Failure to meet the above reporting requirements will result in the immediate suspension from Champlin property those employees involved in the incident until such time that the proper reports have \ been submitted. B. Guidelines I. Site Entry Requirements - Before a contractor begins work in the refinery the following must be provided: a. A contractor orientation to include as a minimum: i) Restrictions regarding intoxicants, illegal drugs, matches and lighters, smoking, firearms, ammunition, explosives, cameras, beards, etc. ii) Champlin emergency alarms and evacuation procedures. iii) Pedestrian and vehicular traffic and authorized parking areas. iv) Reporting to Champlin's representatives all OSHA recordable injuries through the contractor's designated supervisory channels. v) Other specific safety precautions that apply to the work performed. See Attachment A. vi) Each contract employee will be given a copy of "Basic Safety Regulations for Contractors and Contract Employees". L-000362 7/15/75 2/1/91 CONTRACTOR SAFETY PROGRAM PROCEDURE (Cont'd.) B. 1. b. Gate control procedures have been established and enforced so that the presence and numbers of contractor personnel can be properly monitored. c. The contractor must possess appropriate protective and safety equipment. i) Contractors delivering, picking up or working with hazardous materials must have and use appropriate protective equipment consistent both with the hazards of the materials being transferred and appropriate for the areas where they are used. Material Safety Data Sheets must be provided to Champlin on all hazardous materials. ii) If contractor does not have appropriate personal protective equipment, Champlin may choose to supply basic equipment such as hard hats, safety glasses and toe guards, subject to prior agreement. The contract employer should provide the required safety equipment for the particular job as soon as possible. Champlin will decide whether it will provide the necessary protective equipment or delay the task until the appropriate protective equipment is provided by the contractor. 2. Responsibilities of the Contractor's Supervisors - A clear understanding as to the responsibilities of the contractor's on-site supervision should be reached before work is started. The following specific duties are required: a. Obtain approval and work permits from the designated Champlin representative before beginning work. b. Be responsible for compliance with all applicable local. State, and Federal laws pertaining to work being performed and any safety requirements in the contract. L-000363 706.1 7/15/75 2/1/9! 55 CONTRACTOR SAFETY PROGRAM III. PROCEDURE (Cont'd.) B. 2. c. Keep the Champlin representative advised of any work which may affect the safety of Champlin employees or property. d. Confine contractor personnel to the authorized work site. e. Provide the equipment necessary for safe work performance including personal protective equipment. Champlin retains the right to refuse or restrict the use of tools, equipment or chemicals on the site. f. Inspect equipment or tools to be used by contractor's employees prior to use. Receive proper authorization for use of all Champlin tools or equipment. g- Ensure that proper "housekeeping" duties are performed relative to the type of work being done. Keep the work area free from safety or health hazards; clean up waste material as job progresses. h. Follow specific instructions supplied by Champlin should emergency alarms be sounded. i. Comply with Champlin permit requirements for all open flames, welding, burning, vessel entries, and other permits. j- Coordinate the use of all radioactive devices or materials with the Champlin Safety Department. k. Ensure that all contractor's employees are familiar with the appropriate Champlin safety rules and regulations. Refinery Manager L-000364 5 champlin REFINING COMPANY Procedure No. Issued: Revised: Page! of 5 706.2 4/1/87 7/28/89 HAZARD AND OPERABILITY REVIEW PROCEDURE I. II. III. ) PURPOSE To establish a uniform approach for identifying the potential safety hazards and operability problems associated with new refinery installations or modifications to existing equipment. This procedure is an integral part of the Refinery Safety Program. SCOPE This procedure shall apply to the following types of work: Any additions of process-related equipment or controls Any modifications of process-related equipment or controls, including changes in control schemes, emergency shutdown systems, or alarm setpoints Any non-like-in-kind replacement of process equipment (Non-like-in-kind means that the replacement is different in some critical aspect such as size, metallurgy, form, or function. Like-in-kind means replacing an item with an identical or newer model or a similar model from a different manufacturer.) Any change in process-related operating procedures (including startup and shutdown procedures). The hazard and operability review is required after the scope of the work is defined and agreed upon, but prior to management review. AFE submittal, purchase of equipment/materials, or start of construction. PROCEDURE A Hazard and Operability Review form must be completed before a project is I) approved for engineering, 2) approved for construction, and 3) approved for commissioning. A copy of the most recently completed, approved review form must accompany the engineering design package in all transmittals (AFE submittals, instructions for subcontractors, etc.). L-000365 champlin REFINING COMPANY Procedure No. Issued: Revised: Page 2 of 5 706.2 4/1/87 7/28/89 HAZARD AND OPERABILITY REVIEW PROCEDURE PROCEDURE (Cont'd.) A. The review Initiator is the appropriate process, operations, project, or reliability engineer that has primary responsibility for implementing the project/modifications. Usually the project engineer will be the Initiator for hardware-related reviews and the operations engineer will be the Initiator for procedure-related reviews. The Initiator's first responsibility is to assemble the required review information. This includes the following: Preliminary P&ID(s) of the proposed modification(s), field checked for accuracy, or properly detailed sketches of proposed and existing hardware All applicable Material Safety Data Sheet (MSDS) information Basic process conditions applicable to the system being modified (e.g.. pressures, flows, temperatures, and stream compositions) Documentation of existing equipment limitations (e.g., relief valve capacities, equipment design limitations) Operating procedures applicable to the equipment under consideration. B. Once the information is assembled, the Initiator should decide whether the project meets any of the following criteria: 1) Involves handling or contacting material heated above the material's flash point 2) Involves handling or contacting material heated above the material's atmospheric boiling point 3) Involves handling or contacting toxic or reportable materials 4) Involves fired heaters 5) Involves any change in electrical classification for an area 6) Involves emergency shutdown systems, including shutdown alarm setpoints 7) Involves pressure/vacuum relief systems L-000366 champlin REFINING COMPANY Procedure No. Issued: Revised: Page 3 of 5 706.2 4/1/87 7/28/89 HAZARD AND OPERABILITY REVIEW PROCEDURE III. PROCEDURE (Cont'd.) B. If the project meets any of the above criteria, the Initiator assembles a full review team to examine the proposal. The full review team should be composed of the following personnel: Review Initiator Operations Representative(s) Maintenance Representative(s) Safety Representative(s) Technical Service Representative(s) Project Engineer Environmental Group Representative(s) Reliability Representative(s) Others deemed necessary by the Initiator If the project does not meet any of the aforementioned criteria, then the Initiator may assemble a smaller review team including at least three members of the full review team, normally the project engineer, an operations representative, and a technical service or reliability representative. The Initiator shall provide review team members with current project documentation no less than 3 days before the scheduled review meeting, unless all team members consent to a shorter schedule. C. The Initiator shall conduct the hazard and operability review meeting as outlined by the review form. He/she will guide the discussion through the specified areas, resulting in the consideration of potential hazards associated with the modification. Approval of the project/modification requires signature of the participants. A copy of the project/modification review form must be forwarded to the Project Engineering department, prior to project approval, to be included in subsequent P&ID revisions and detailed design drawing packages. L-000367 champlin REFINING COMPANY Procedure No. i issued: I Revised: I Page 4 of 5 706.2 4/1/87 7/28/89 HAZARD AND OPERABILITY REVIEW PROCEDURE III. PROCEDURE (Cont'd.) C. Regardless of project size, a copy of the review form and the project/modification shall be sent to a representative of all absent groups who would normally participate in a full review meeting. These representatives must approve the project/modification before it is released for construction: otherwise, these representatives must attend the pre-construction and/or pre commissioning review meetings. D. After the design drawings are complete, but before they are issued for construction, the Initiator shall reconvene all review team members who have not given final approval and shall lead the review. If the project/modification I has been significantly changed since the initial review meeting, all affected review team members shall be recoilvened regardless of their prior approval. In no case shall fewer than three people constitute a review team, normally the project engineer, operations representative, and maintenance representative. The Initiator shall provide project documentation to all reviewers at least 3 days prior to the meeting and at least the operations representative shall check all proposed changes in the field. E. After the completion of installation, but before commissioning, the Initiator shall reassemble all review team members who have not given final approval. If there were any significant field changes, all affected review team members shall be reconvened regardless of their prior approval. In no case shall fewer than three people constitute a review team, normally the project engineer, operations representative, and the reliability engineer. The Initiator shall lead the review. F. Exceptions to this policy are permitted for emergency response situations or immediate needs during unit turnarounds. A three-step procedure is required in these cases: L-000368 champlin REFINING COMPANY , ProcedureNo. I Issued: j Revised: j Page 5 of 5 706.2 4/1/87 7/28/89 HAZARD AND OPERABILITY REVIEW PROCEDURE III. PROCEDURE (Cont'd.) F. 1) The initiating operations representative shall attach the project authorization sheet to the Work Request indicating "Post Installation Review Required." 2) The appropriate operations representative shall approve the modification on the review form. 3) At the completion of the installation, but prior to the commissioning, the review team will meet in the field and sign off the modification on the review form. The operations representative will lead this review and determine which review team representatives shall be present. An example of the review form is attached. However, this checklist is not perfect and will not meet the needs of every situation. All review team members must look beyond the specific questions asked to ensure that other pertinent items are not overlooked. The objective of this procedure is to identify potential safety hazards or serious operability problems, not to mechanically complete forms. RJ P. Pavfttic Refinery Manager Attach. ) 1,-000369 H A Z A R D A N D O '" ** A B ILIT Y R EVIEW Q- 5' X ) Z&ro* i--> s3 o R O co 3 H So 9 -I CccUo 13 e2u a'2. HZ w O O o o s- ^ ^ .2 5oo 5u<3 co-: 'o CU 'Dob- 2 .2 ^M5 Pre-Approval (A FE ) Review > Date Initials Pre-Construction Review Date Initials Pre-Commissioning Review Dale Initials Dale Project Approval* Signature Operations Representative Technical Services Representative Safely Representative Maintenance Representative Environmental Representative Reliability Representative Other Representative Other Representative Project approval means we arc satisfied that (a) the consequences associated with implementing the project have been adequately considered and arc acceptable, and (b) engineering design, fabrication, installation, and commissioning may safely proceed. L-000370 L-000371 z <d 2O | ? S2 in X 1 1 M -g o \ 2 3 3 | l Question 1. Docs the review team recommend additional personnel safety equipment in response to hazards such as: a) noise (hearing protection, mufflers, etc.)? b) corrosive materials (clothing, showers, eyewashes, etc.)? c) toxic or noxious fumes (breathing air, emergency air, respirators, etc.)? d) high temperatures (insulation, barriers, etc.)? c) moving machinery (guards, barriers, etc.)? 1) explosions (relief panels, barriers, etc.)? 2. Docs the review team recommend provision or modifica tion of fire suppression equipment beyond the proposal? 3. Does the review team recommend increasing the supply of fire extinguishing materials (water, foam, inert gas, etc.)? 4. Does the review team recommend additional fire water drainage? 5. Does the review team recommend provision or modifica tion o f fireproofing materials or fire-safe components beyond the proposal? 6. Are there applicable safety or fire codes, standards, or regulations that are not listed in the project documenta tion? Are there violations or exceptions to the applicable documents? 7. Does the proposal require that the site's emergency response plan be revised? L-00.0372 Required Action Responsible Individual and Deadline 111 ii It II 8M .a o fit i|l jll I'agc 5 I -i **J a: ^ zo >* S3 V) ius *.s2" 52 IS 8o- ,8 C >* .25 ia sU J=- 2 2-s 32 i| i S| sf |2 |1 as L-000375 /-v r* - I z< zo > S2 VI u 1c3 SL & 0 1 15 U u Jl L-00037 6 1 : f* !i |ii ill l 1 I z <! 20 1 >* Cl V) & 1 3 3 *8 j Question 1. Docs the proposal exceed the utility supply system capabilities for a) steam (high pressure, low pressure)? b) electricity (high voltage, low voltage)? c) instrument air? d) inert gas7 c) cooling water7 0 fuel gas? g) natural gas? h) heat tracing? 1) other utilities? 2. Docs the review team recommend the proposal include additional protection from utility failures (steam and electric drivers, steam letdown stations, backup electrical buses, etc.)? 3. Does the review team recommend additional protection of the utility systems from the proposed system (backflow prevention, circuit breakers, dedicated supplies, hydrocarbon vents, etc.)? r< oooi u> -J Responsible Individual and Deadline Initial and Date When Action Item Wat Resolved L-000378 3/31/JW l'agc 10 1 :s i S1 .a .1 I ) L-000379 c4 f*i V <n 1 a $ftt ||| ill Z <i Z0 > B1 V) f Detailed Cdmidcnlioa o f General Issues during Pre-Construction llcvicw Qucslkn 1. Are there any unresolved action items from previous reviews? 2. Does the proposal impose any unacceptable thermal stresses on new or existing equipment? 3. Will foreseeable wind loads, snow loads, or earthquake accelerations cause failure of the proposal? 4. Will foreseeable rainfall accumulation or flood levels cause failure of the proposal? 5. Docs the proposal violate any OSHA standards for ladders and platforms? 6. In addition to the standard work permits, lockouts, etc., a) docs the proposal require any special lie-in provisions (hot lap, unit shutdown, etc.)? b) docs the proposal require any special arrangements before on-site installation proceeds (nuclear material permits, excavation, cranes, etc.)? 7. Are there any lie-ins to the bottom o f supply headers? It* ooot to 00 <_> Required Action Responsible Individual and Deadline Initial and Date Wben Action Item Was Resolved 3i i /ll/BV 1'agc 12 I I.1 3 z^ zo > K V5 e0 > s <5. &e 2 I es la1 S 1 '5- 1u *3 1 s 33 o & a jj 3 5 sl 5 CO *1 I o & eo* U 9 .a 1 11e<9* S.BO s5 e- sS II|S* i ~3 ^a "s 2 Cm i 1 .e2 I <e9 M .= I * 2 3 1 111 75 3 1 o6 c <9 Uw *s ll L-000381 U t5o o 5. .a 1 NO SMOKING AND SMOKING RESTRICTIONS I. PURPOSE Smoking must b regulated to ensure that exposure to flammables and combustibles is controlled so that fires do not occur. II. SCOPE In general, smoking is prohibited throughout the refinery and the tank farm areas. Smoking is only permitted in designated stations, shelters or areas. III. PROCEDURE 1. Smoking is permitted only in the designated areas of the refinery where stations for this purpose have been established, the location of such areas is as follows: Refinery Complex at Oak Park Avenue and Nueces Bay Boulevard: Platformer #4 Vacuum Unit Laboratory Offices Terminal Maintenance Plant Security Crude Unit #1 Alky Unit Cumene Unit BTX Unit Warehouse Smoking shelter east of control room. Shelter west of control room. Offices or station in hall. Within an office unless building is otherwise posted. Shelters within refinery, shelters near road at land end of ramps to each dock. Tank 2001 - 2004 Area: Shelter north of Tank 2004 firewall. Terminal office and blending facility: Shelter at road east side of office. Within repair shops and offices as designated, welding shop. Guard gate houses. Building east of control room or shelter across road from Cat Cracker. Shelter across street north side of unit. Shelter at southeast comer of laboratory. Shelter to west across road. Lunch room upstairs only. L-000382 NO SMOKING AND SMOKING RESTRICTIONS PROCEDURE (Cont'd.) t. Boiler Plant Cat Cracker #1 New Plant Control Room Utilities, Area 60 Demex. Vacuum, Crude II, Area 10 Merox, Unibon Unit, Area 20 Catalyst Cracking Unit #2, Area 30 Merox, Sat. Gas, Area 40 Sulfur Plant, Area 50 Shelter southwest of control room. Shelter across road northeast of control room. Northwest comer shelter or southeast shelter. Shelter to north at roadway or the east shelter at main electric power source. Shelter to north adjacent to road. Shelter to north at road intersection. Shelter to north near R.R. track. Shelter to north near R.R. track. Shelter at southwest comer. Waste Treatment Plant Shelter near the two aeration basins. Refinery and Coker Operation on Highway 37 Platformer #3 Offices Maintenance Plant Security Coker Unit Warehouse Refinery Control Room Sulfur Extraction Complex Water Treatment Facility Shelter northwest comer of boundary limits. Within an office unless building is otherwise posted. Within repair shops and offices as designated, welding shop. Guard gate houses. Shelter southeast comer at change house. Inside offices only. Shelter north side at side door. Shelter west side of boundary limits. Shelter east side of electric building. L-000383 NO SMOKING AND SMOKING RESTRICTIONS PROCEDURE (Cont'd.) 1. Smoking in vehicles is prohibited. Smoking is positively prohibited in ail streets and all areas not otherwise designated as smoking areas. Smoking is prohibited in control rooms. 2. The Safety Office must be consulted in establishing smoking areas for contract work, turnaround or other alternatives regarding smoking areas. 3. Temporary smoking areas shall be marked with conspicuous signs and the boundary identified. The responsible supervisor shall be accountable for these areas. 4. Violations shall be reported to the respective supervisor for compliance enforcement. L-000384 champlin REFINING COMPANY Procedure No. Issued: Revised: Page j of j 706.4 7/2 8/89 PROCESS EQUIPMENT TRIP BYPASS PROCEDURE I. PURPOSE To define the authority, circumstances, and documentation required for bypassing a process or equipment automatic shutdown (trip) device. II. SCOPE This procedure applies to all equipment such as heaters, furnaces, boilers, compressors, steam turbines, pumps, and fuel gas/pilot gas-shutdown bypass block valves, protected by automatic safety devices. III. GENERAL The bypassing of an automatic safety shutdown device is a serious matter and requires proper authorization and documentation. Action must be taken promptly to return the instrumentation to service once the problem or situation Fs overcome. A shutdown device should be bypassed only for the following reasons: Startup of equipment per design Routine trip testing of equipment Maintaining operation when there is potential for a false trip Malfunction of a trip device which jeopardizes plant integrity. Special operations, i.e. coke drum cutting, unit standby to conserve utilities. The Shift Supervisor and Unit Operator must think through and agree that each situation is protected prior to bypassing a trip to ensure that all necessary precautions are carried out. The keyed bypass will be wired into the computer alarm circuits where available. This will allow the alarms to appear on the computer alarm summary and printed out in the computer log. L-000385 champlin REFINING COMPANY Procedure No. Issued: Revised: Page if 3 706.4 7/28/89 PROCESS EQUIPMENT TRIP BYPASS PROCEDURE IV. TRIP BYPASS AUTHORIZATION 1. The Area Shift Supervisor must authorize the bypassing of any keyed trip. 2. This authority extends to all other devices not covered in Section IV.I., such as jumper wires, wiring solenoid valves, opening of bypass valves on fuel systems, or otherwise defeating the primary shutdown device. 3. If a system bypass remains in the bypass mode for more than 24 hours the Area Superintendent will insure that corrective actions have commenced. V. RECORDKEEPING 1. A log book, containing the following information, will be maintained in each process control room (See Attachment I). Device bypassed description/number Date and time bypassed Date and time returned to service Reason for bypass/comments Signature of supervisor granting authorization to bypass. Work Request number 2. It is the Area Shift Supervisor's and the Unit Operator's responsibility to ensure ail occasions for bypassing trip devices are togged in the book, regardless of duration. . 3. A record of all automatic shutdown devices out of service will be recorded on Sunday of each week by the Shift Supervisor and distributed to the Area Superintendent and Area Supervisor. VI. KEY MAINTENANCE All bypass switch keys or padlocks for chaining valves will be located in a box properly identified and maintained by the Shift Supervisor. L-000386 S champlin REFINING COMPANY Procedure No. ! Issued: j Revised: Page3 of 3 706.4 7/2S/89 PROCESS EQUIPMENT TRIP BYPASS PROCEDURE VII. TRIP MALFUNCTION/UNRELIABLE PERFORMANCE 1. Should a trip be bypassed due to malfunction, a "NOW" work request will be issued to the Maintenance Department for repair immediately. 2. Should a shutdown device be out of service due to poor reliability the Operations Reliability Department will be contacted by the Area Supervisor to evaluate and possibly issue an Engineering Work Order. VIII. HOW EQUIPMENT WILL BE PROTECTED WHILE TRIP IS BYPASSED Whenever, and as long as, a shutdown is bypassed, special precautions will be taken to assure that the bypassed parameters do not exceed safe values. These precautions are outlined in other procedures, but an example would be careful visual monitoring by operations personnel. These special precautions will be noted in the bypass log. Attachment L-000387 O 1 D0388 ______ ;\ SAFETY TRIP DEVICE NO. NAME AND FUNCTION DISARMEt DATE TIME SIGN. REASON/SPECIAL REQUIREMENTS " 2 O tM.W.O. ARMED [ DATE TIME SIGN 5 champlin REFINING COMPANY Procedure No. Issued: Revised: Page j of 6 706.5 7/28/89 EQUIPMENT ISOLATION AND BLINDING PROCEDURE I. PURPOSE This procedure establishes guidelines for preparing equipment for internal maintenance work. It addresses equipment location, isolation, clearing, tagging and blinding. It also includes a system for recording location of blinds. IL SCOPE This procedure applies to all employees, contractors and sub-contractors performing work for Champlin Refining Company. Examples of tasks covered by this procedure are: 1. Pump Repair 2. Valve Removal 3. Pipe Replacement 4. Instrument Repair/Removal 5. Confined Space Entry 6. Compressor Repair III. RESPONSIBILITY The roles of the Area Operators, Craftsmen, Operations Supervisors, Maintenance Supervisors, or others are described on the Safe Work Permit. The Operations Department is primarily responsible for isolating equipment with block valves, for depressuring and clearing equipment of its process contents, tagging associated valves and issuing and maintaining blind lists. The Operations and Maintenance Departments are jointly responsible for ensuring that prepared equipment is safe for work. A complete blind list must be maintained by the Operations Department. Installation or removal of any blind must have approval of the Unit operator. L-000389 champlin REFINING COMPANY ! Procedure No. Issued: Revised: Page 2 of 6 706.5 7/28/89 EQUIPMENT ISOLATION AND BLINDING PROCEDURE IV. DEFINITIONS A. Equipment - Vessels, pits, pumps, exchangers, pressure gauges, D.P. cells, steam turbines, receivers, etc. B. Tag-out Placement of a "Danger, Do Not Operate' tag on equipment whose inadvertent operation may cause a hazard to personnel during their work performance. Tags will contain the following information: 1. A brief description of the reason for tag placement. 2. Name (signature) 3. Date of tag placement C. Lock-out Physical placement of keyed lock with attached tag or chain/lock for equipment isolation. D. Isolation Effective separation of a piece of equipment from an active system. E. Senior Craftsman The craftsman with the most experience in the unit where the work is taking place. F. Area Operator Includes area technicians. V. PROCEDURE 1. Before equipment work begins: A. Operations is responsible for shutting equipment down prior to the performance of maintenance. B. The Area Operator will decommission and install lockouts and tags on all associated electrical equipment, electric valve operators, air starters, steam turbines and other equipment defined under Procedure No. 705.4 ("Lock Out, Tag Out Procedure"). L-000390 m champlin REFINING COMPANY Procedure No. Issued: Revised: Page ^of 706.5 7/28/89 EQUIPMENT ISOLATION AND BUNDING PROCEDURE V. PROCEDURE (Cont'd.) 1. C. Operations will close all block valves going to and from the affected equipment. Double block and bleed, if feasible. D. The Area Operator must tag-out all associated isolation valves. E. Operations must then depressure the equipment. Be sure to confirm that drains and vents are not plugged and use an 'angle worm reamer" if necessary. Drain or vent remaining hydrocarbons and dispose of liquids. F. The senior craftsman for each craft on the job or the Maintenance Leaderman verifies that isolation valves are closed and that the equipment is depressured. Maintenance craftsman or the Leaderman must also place ) their tag on isolation valves. G. A Safe Work Permit is required for all maintenance personnel who perform equipment isolation. H. The operations or maintenance personnel involved in each job may decide to install blinds, depending on the integrity of the block valves, the hazard of the process equipment and the time of exposure. It may also be necessary to blind the equipment in order to finish clearing it. In this situation workers installing blinds may need to wear fire protective clothing and be supplied with breathing air and fire fighting equipment. I. Operations must clear the equipment of the remaining process liquids or gases by purging with steam, nitrogen or water, whichever is most appropriate. Purge gauge glasses and instrument taps when these are present. ) L-000391 EchamplinREFINING COMPANY Procedure No. J issued: Revised: Page 4 of 6 706.5 7/28/89 EQUIPMENT ISOLATION AND BLINDING PROCEDURE V. PROCEDURE (Confd.) 1. J. Entry into confined spaces present special hazards (Refer to 705.2), therefore the following additional precautions are required: 1. Equipment blinding is mandatory for work activities involving confined space entry. Blinds should be installed with the proper gaskets on both sides. In some instances, a short spool piece, or spacer, may be rotated out of the line to achieve equipment isolation. 2. The Operations Department shall supply a blind list for the recording of all blinds. 3.. Install all blinds with an obviously conspicuous plastic streamer attached to the blind. During turnarounds, it may also be necessary to attach a numbered tag to the blind. The tag number must be recorded on the master blind list and the duplicate tag placed on the blind board. 4. The Maintenance Craftsman and the Area Operator must initial the master blind list when blinds are installed. .When all blinds on the list are installed, the Maintenance Leaderman or senior craftsman for each craft on the job and the Area Operator must sign at the bottom of the master blind list. By signing the blind list, both persons are confirming that blinding is complete per the list. 5. When one blind is common to two different jobs, it must be on both blind lists. Each such "common* blind must be specially marked on both blind lists that it is also being used for another job. Obviously, common blinds cannot be removed until both jobs are complete. 6. If blinding is not feasible, a special procedure must be approved by Operations, Maintenance and Safety representatives. L-000392 5 ehamplin REFINING COMPANY Procedure No. Issued: Revised: Page j of 7C6.5 7/28/89 EQUIPMENT ISOLATION AND BLINDING PROCEDURE V. PROCEDURE (Cont'd.) I. J. 7. If a radioactive source is present on the equipment, contact the Instrument or Safety Departments to lock out the source and include it on the blind list. 8. A Safety Department representative must sign the permit form on all initial confined space entries. Refer to Procedure 705.2 for details. K. Verify that all equipment isolation and blinding procedures have been completed and permits issued. L. Verify the effectiveness of equipment isolation efforts by using the correct meter or device to test the air quality in and around the immediate work ) area. M. After the permit has been issued, no new hoses or tie-ins can be added to the isolated equipment unless a new work permit has been issued. 2. When equipment work is complete: A. The Maintenance Leaderman or senior craftsman for each craft on the job contacts Operations and notifies them that the isolation devices are ready for removal. B. After ensuring that all employees, tools and other maintenance equipment have been removed from any confined spaces, the maintenance crafts shall close and secure all vessel manways. An Operations representative must be present just prior to manway closure. C. The Area Operator and Maintenance Leaderman or senior craftsman for each craft on the job must initial the "OK to remove" space on the master blind list. When the blinds are removed, both the Maintenance Leaderman or senior craftsman for each craft on the job and the Area Operator must again initial the master blind list after visually verifying that the blinds are out. ) L-000393 champlin REFINING COMPANY . Procedure No. I Issued: Revised: Page 6of 6 706.5 7/28/89 I l EQUIPMENT ISOLATION AND BUNDING PROCEDURE V. PROCEDURE (Cont'd.) 2. D. The Maintenance Leaderman or senior craftsman for each craft on the job removes all maintenance tags and locks. E. The Area Operator removes all operations tags and/or locks: F. All Maintenance Leadermen or senior craftsmen for each craft on the job return to the control room and sign off the Safe Work Permit. L-000394 H UZJ W 8. o & 3 Rm a ) *6 Unit No. and EQP. Size & Scries Service CHAMPUN REFINING AND CHEMICALS, INC. CORPUS CHRIST! REFINERY Location tUIBW Installation Installed Installed Initialed by Initialed by - L-0<D03'35 W"> 8 706.5 champlin REFINING COMPANY Procedure No issuea rievised Page 3of 3 706.6 1/30/84 7/10/90 MOTOR VEHICLE OPERATING PROCEDURE PROCEDURE (Cont'd.) C. 2. Drivers shall observe the bulk and weight capacity of the vehicle whether it is used to transport material or passengers. 3. The driver should not allow material to extend over the sides of a vehicle. Material protruding beyond the end of a truck shall have a red flag fastened to it at the extremities. (At night, a red light should be used.) 4. Loads which may shift shall be blocked and lashed. 5. The driver shall not move a vehicle until all riders are either off the vehicle or properly seated in the space provided and are protected from injury if cargo is also being carried. 6. Passengers or riders may be permitted by the driver only when safe seating has been provided. This applies to pick-up trucks, flat bed trucks, mobile equipment, powered industrial trucks, scooters and any other means of transporting personnel. iager L-000398 champlin REFINING COMPANY Procedure No. Issued: Revised: Page j of -j 706.7 8/4/89 DRAINS AND VENTS I. PURPOSE This procedure is designed to insure compliance with environmental and safety requirements regarding the installation of blind flanges, plugs or caps on any low point drains or high point vents. II. SCOPE This procedure applies to all Champlin employees and contract personnel that work within the Champlin Corpus Christi Refinery or any associated facilities that fall under Champlin Refining and Chemicals, Inc. jurisdiction. III. GENERAL Drain- A drain will refer to a low point device used for the removal of liquid or gas from a line or vessel. Vent - A vent will refer to a high point device used for the removal of liquid, gas, steam or pressure from a line or vessel. IV. PROCEDURE A. Federal Regulations: 1. CFR 61.242-6 Control Requirements (a) (1) Each open-ended valve or line shall be equipped with a cap. blind flange, plug, or second valve. (2) The cap, blind flange, plug, or second valve shall seal the open end at all times except during operations requiring process fluid flow through the open-ended valve or line. (b) Each open-ended valve or line equipped with a second valve shall be operated in such a manner that the valve on the process fluid end is closed before the second valve is closed. L-000399 champlin REFINING COMPANY Procedure No. Issued: Revised: Page 2 of 3 706.7 8/4/89 DRAINS AND VENTS IV. PROCEDURE (Cont'd.) A. 1. (c) When a double block and bleed system is being used, the bleed valve on the line may remain open during operations that require venting the line between the block valves but shall comply with IV.A. 1(a) at all other times. 2. CFR 115.251 Control Requirements (a) Except for safety pressure relief valves, no valves shall be installed or operated at the end of a pipe or line containing volatile organic compounds unless the pipe or line is sealed with a second valve, a blind flange, a plug, or a cap. The sealing device may be removed only while a sample is being taken, or during maintenance operations. B. It shall be the responsibility of each operations employee to maintain all drains and vents which are located within the confines of their respective operating units or their jurisdictional area. Once each week, an Operator from each operating area shall be assigned to compile a comprehensive status list of all drains and vents within their jurisdiction. Deliberate observation of these vents and drains should be a regular part of the outside technicians' daily equipment monitoring routine. C. Upon the detection of any open-ended drain or vent, it shall be the responsibility of the operations employee to install the appropriate size blind flange, cap or plug tight enough to insure an adequate seal to prevent the emission of contaminants or pollutants to the atmosphere. D. It shall be the responsibility of the respective operations employee to ascertain any special safety precautions, equipment or tools that may be deemed necessary for the safe operation or removal of the blind flanges, caps or plugs. L-000400 champlin REFINING COMPANY 3'0ceaure No issued Revised Page 1 of 3 706.6 1/30/84 7/10/90 i j MOTOR VEHICLE OPERATING PROCEDURE , I. PURPOSE To establish uniform rules for the operation of motor vehicles. II. SCOPE This procedure applies to all Champlin Refining and Chemicals, Inc. employees and contractors performing work on Champlin property. III. QUALIFICATION Authorized drivers of company vehicles will have their driving records checked annually. Anyone whose license has been suspended for any reason will not be allowed to operate a company vehicle for the duration of that suspension. IV. PROCEDURE A. Use the following techniques to improve your driving habits: 1. Aim high in steering - look well ahead at the center of the driving path. 2. Keep your eyes moving. 3. Get the big picture - avoid surprises, know the situation developing. 4. Drive with a space cushion - leave yourself an out. 5. Attract attention - let them know you're there. B. General Safety Rules 1. While motor vehicles are operated on public roadways, all State and Federal laws must be observed and all passengers must be belted in the vehicle. 2. Before attempting to move any vehicle the driver shall look around the vehicle to determine that it is clear of personnel in the path of travel. L-000396 champlin REFINING COMPANY Procecure No 'ssuea Revised. Page 2o( 3 706.6 1/30/84 7/10/90 MOTOR VEHICLE OPERATING PROCEDURE PROCEDURE (Cont'd.) B. 3. Smoking in vehicles within the refinery is positively prohibited, and could result in termination or, in the case of a contractor, being barred from the plant. Drivers shall comply and enforce the "No Smoking* rule in their vehicles. 4. Posted speed limits (15 MPH), traffic regulating lines, speed bumps, and stop signs must be observed by all vehicles. Vehicles must yield to pedestrians, bicycles, and emergency equipment. 5. While parked alongside or within unit battery limits, near firewalls, or in refinery streets, vehicles shall have their ignition key left in the "off" position. The parking brake shall be set if the vehicle is left on an incline. 6. Vehicles which are parked must be off the right-of-way sufficiently to allow safe passage of other vehicles. 7. Fire lanes and fire hydrants or such other emergency equipment shall not be blocked by parked vehicles. 8. A Routine or Hazardous permit is required for vehicles that enter firewalls or process unit battery limits. 9. The driver is responsible to see that the vehicle is clean of trash that could interfere with vehicle operation, i.e. a bottle rolling under the brake pedal. The driver must also see that the windshield is clean, so as to not have his vision obstructed. 10. Horseplay inside of or with a vehicle is positively prohibited and could result in termination or being barred from the plant. C. Procedures for Carrying Loads or Personnel 1. Before loading or unloading a vehicle, the brakes should be securely set or the driver shall block the wheels to protect personnel on the truck and/or on the ground. L-000397 S champlin REFINING COMPANY j Procedure No. Issued: Revised: Page 3 of 706.7 8/4/89 DRAINS AND VENTS IV. PROCEDURE (Confd.) E. It shall be the responsibility of the operations employee to follow good safety practices during sampling operations. Blind flanges, caps or plugs are to be safely removed by personnel using only the proper tools for the job. The blind flanges, caps or plugs must then be properly replaced to comply with * established regulations. V. TURNAROUND PROCEDURES A. During turnarounds, the area operator must keep an up-to-date list of equipment or lines that have had its vents/drains opened. Prior to start-up, this list is to be used to assure that those vent/drain valves that have been operated during the turnaround are properly closed and plugged. B. Drains and vents not opened during the turnaround, but found unplugged, uncapped or unblinded, are to be added to this list to assure they are not overlooked. L-000401 champlin REFINING COMPANY Procedure No. Issued: Revised: Page l of 3 8 8/4/89 j REMOVAL/RE-INSTALLATION OF OUT-OF-SERVICE FLARE LINE RELIEF VALVES I. PURPOSE Establish a joint Operations and Maintenance procedure which maximizes employee safety when breaking into a flare line in service. II. SCOPE This procedure applies to all employees and contractors involved in removing out-of service relief valves from in-service flare lines on Champlin Refining and Chemicals. Inc. property. III.PROCEDURE * The scope of each job will be discussed with and approved by the Area Operations Superintendent. This procedure will require a Hazardous Work Permit. A. Preparatory Steps 1. Provide adequate scaffold with at least two escape routes when possible. 2. Provide crane for removal of relief valve. 3. Provide safety equipment (fresh air. flash suit including shield and gloves. I-1/2" fire hose) and have at least one back-up suited out in case of emergency. 4. Meet with operations to make detailed plans and verify the proper PSV is being removed/re-installed. B. Pre-removal work 1. Operations Shift Supervisor will ensure all processes are in stable condition prior to beginning work. 2. Review unit operating rates and notify other unit operators that tie into flare fine (in order to avoid overpressuring). L-000402 champlin REFININC COMPANY Procedure No. Issued: Revised: Page 2 0f 2 706 8 8/4 89 REMOVAL/RE-INSTALLATION OF OUT-OF-SERVICE FLARE LINE RELIEF VALVES III. PROCEDURE (Confd.) B. 3. Hook nitrogen to the flare line at the closest connection upstream of relief valve. Sweep flare line with N2 (where design permits). Leave small N2 purge during blind installation. 4. Area Maintenance Supervisor to hold safety huddle with those who will do the work before job is started. C. Be sure all permits have been issued. If more than one relief valve is on the vessel, make sure the valve to be repaired is tagged before removal. . D. Removing of relief valves 1. Breathing air must be worn when opening the flare line. 2. Remove all studs on vessel side of relief valve to allow it to slide away from flare line easily. 3. Remove existing studs and install longer ones in bottom of flange on flare side of PSV. This is necessary to allow space for the 1/2 inch blind. 4. Verify with control room that minimum amount of gas is going to flare and live processes are stable. 5. Remove studs on flare side of valve (according to threaded holes in blind) and slide the special blind in place. 6. Loosen the remaining studs enough to allow the 1/2" blind to slide in use old gasket on flare side. 7. Install remaining studs in threaded holes in the blind and tighten evenly. 8. Remove remaining studs in relief valve flange and remove valve when installing blind flange on vessel side. Tighten blind flange evenly. L-000403 S champlin REFINING COMPANY Procedure No. Issued: Revised: Page 3 of 3 706.8 8/4/89 REMOVAL/RE-INSTALLATION OF OUT-OF-SERVICE FLARE LINE RELIEF VALVES III. PROCEDURE (Cont'd.) E. Re-installing relief valves 1. Remove studs in slotted positions in blind, put relief valve in place, and re-install studs. Remove remainder of studs in threaded part of blind and pull out blind. Replace gasket with new one and tighten flange joint. 2. Re-install studs on vessel side of relief valve and tighten flange joint. 3. Clean up. F. If unit is down, include flare line blind on blind list. G. Area Supervisor must notify Operations Reliability for master record of maintenance for each relief valve removed. L-000404 champlin REFINING COMPANY Procedure No. Issued: Revised: Page 1 of 5 706.9 8/3/89 i BLOCKING IN OR REMOVAL OF IN-SERVICE RELIEF VALVES I. PURPOSE To establish a safe procedure for blocking in or removing in-service relief valves. Provide a tracking system for subject relief valves in each operating area. II. SCOPE This procedure applies to all employees and contractors involved in blocking in or removing in-service relief valves on Champlin equipment. III. GENERAL When a relief valve is removed from service, a working pressure gauge will be attached to the vessel or line at the closest available point to the relief valve location. This gauge is to be closely monitored by operating personnel at that location. A plan to manually relieve the vessel is required if the pressure exceeds the Maximum Allowable Working Pressure (MAWP) of the vessel being protected. IV. PROCEDURE I. Preliminary Preparations and Precautions A. No safety relief valve may be blocked in while the equipment it is protecting is in operation unless one of the three following conditions is satisfied: 1. Approval is granted by the Area Operations Superintendent or his designee. This must be in writing; or 2. Another safety valve remains in parallel service that provides the same capacity; or 3. This safety valve is a small thermal relief type on piping and exchanger equipment. L-000405 champlin REFINING COMPANY i Procedure No. Issued: Revised: Page 2 < 5 706,9 8/3/89 BLOCKING IN OR REMOVAL OF IN-SERVICE RELIEF VALVES IV. PROCEDURE (Cont'd.) 1. B. For relief valves connected to a live flare header, check the precautions listed in Safety Procedure No. 706.8 - "Removai/Re-installation of Out- of-Service Flare Line Relief Valves. * C. The contents of the vessel or line serviced by the relief valve should be considered for the following potential hazards with appropriate personnel protective equipment used: 1. Toxicity of material 2. Flash Point of material 3. Flammability 4. Pressure 5. Temperature 6. Frost bum 7. Possibility of leak in isolation valves 8. Accessibility of relief valve and isolation valves. D. Proper equipment should be used to protect against the hazards listed above: 1. Need for non-sparking tools (brass) 2. Breathing aix 3. Face shield 4. Long sleeves and gloves 3. Flash suits E. Provision should be considered for directing relieved materials away from personnel or other hazard in the event an over-pressure situation were to occur while the relief valve is out of service. 1. Installation of a relief valve of like kind and capacity. 2. Installation of temporary spool piece connecting isolation valve to relief valve destination. 3. Installation of vent pipe or other directing piping to direct relieved vapors away from operating personnel. L-000406 EchomplinREFINING COMPANY Procedure No. Issued: Revised: Page 3 of 5 706.9 8/3/89 BLOCKING IN OR REMOVAL OF IN-SERVICE RELIEF VALVES IV. PROCEDURE (Cont'd.) 2. Removal of Valve and Substitute Over Pressure Protection A. When a safety valve is blocked in, leaving the equipment in operation unprotected from over-pressuring, all of the following conditions must be met: 1. A proven pressure gauge must be installed to the vessel or equipment at the nearest possible location to the relief valve installation. (Note: If the gauge is NOT at the same point as the relief valve, then consideration should be given to any hydraulics of the system to insure proper relief of the vessel is maintained.) 2. In the event of pressure build-up above the MAWP of the vessel, the bypass valve must be operated manually. If no PSV bypass valve exists. Operations must make adjustments to the affected system to keep the operating pressure below the MAWP. 3. If two or more employees are assigned to this operation, they must be in constant contact with each other. 4. Each employee assigned to the above operation must receive instructions in writing from an Area Supervisor before being given the assignment. 5. When process operations are normal, the control board operator and the outside operator shall monitor the affected vessel's internal pressure at least every thirty minutes. During upset conditions, this pressure must be checked more frequently. B. Once removed for repair, a relief valve should be worked on expeditiously and continuously until ready to be returned to service. For routine repair, a relief valve need not be removed from service for over twelve hours. If new relief valve internals are not in stock locally, a longer return to service time may be encountered. L-000407 champlin REFINING COMPANY Procedure No. Issued: Revised: Page 4 of 5 70S. 9 8/3/89 BLOCKING IN OR REMOVAL OF IN-SERVICE RELIEF VALVES IV. PROCEDURE (Cont'd.) 3. Record Keeping of Safety Relief Valves A. A loose leaf notebook will be maintained by each unit or area with all relief valves and pertinent design information listed in accordance with Attachment I "Relief Valve Data". Employees involved in following this procedure will review this form to obtain information regarding the specific relief valve to be removed, and obtain a copy in order for them to include pertinent information during the removal/re-installation. B. After making preparations for removal of the relief valve, the maintenance employee will sign the relief valve form and give it to the Area Shift Supervisor where he will maintain it in the log book until the removal/re installation is completed and the relief valve is back in service. C. Reference to hazards involved or experienced during the removal/re installation will be written under "Miscellaneous Information" on the copy after completing the job and inserted with the original in the notebook to serve as. a maintenance record. 4. Protection Against Closure of Isolation Valves A. All relief valves that are capable of being isolated from the equipment they protect will be provided with a chain and lock on the isolating block valves. The isolation valves will be chained and locked OPEN. B. In each area, each lock, will have its own unique key. All keys will be kept in the area of the operating supervision offices. C. A master key will be kept in the shift foreman's office for emergency use only. L-000408 5 champlin REFINING COMPANY ; Procedure No. Issued: Revised: Page 5 of 5 706.9 8/3/89 BLOCKING IN OR REMOVAL OF IN-SERVICE RELIEF VALVES IV. PROCEDURE (Cont'd.) 4. D. In the event a lock is removed from a relief valve, the lock and key mur be hung in the display case until the lock is returned to service. E. No relief valve lock should be removed from the valve unless: 1. The relief valve is being removed and the above noted procedures are followed; or 2. The equipment is totally out of service and vented. Attach. Ii-000409 ' LOCATION: RELIEF VALVE DATA ATTACHMENT I THERMAL RELIEF: SIZE: SERIAL: TYPE: RELIEVES TO: INLET BLOCK VALVE: INLET LOCK NUMBER: INLET CAR SEAL: SET PRESS: COLD SET: MANUFACTURE: OUTLET BLOCK VALVE: OUTLET LOCK NUMBER: OUTLET CAR SEAL: YEAR INSTALLED: DATE TESTED: MISC. INFORMATION: ) Employee Signature______________________________________ 706.9 L-000410 Date chomplin REFINING COMPANY ' Procedure No. Issued: Revised: Page j of ^ 706.11 7/28/89 USE OF MOTORIZED EQUIPMENT IN LPG STORAGE AREAS I. II. III. ) ) PURPOSE To establish a safe procedure for use of motorized equipment in LPG storage and pipeline areas. SCOPE This procedure will apply to all Champiin employees and/or contractors performing work in the aforementioned areas. PROCEDURE A. Preliminary Preparations: 1. Area Supervisor: Review work scope with job foreman Review work scope with Operator/Technician Review work scope and LPG hazards with all personnel working in the area Perform an on-site inspection 2. Operator/Technician: Perform an on-site inspection 3. On-site inspection should include, but is not limited to: Ground conditions, weather, bleeders, conduit, power lines, piping (exposed/underground), leaks, lighting, access routes, equipment congestion. B. Specific Guidelines: 1. Careful consideration should be given to ground and weather conditions before permitting the use of motorized equipment. Any excavation or maintenance work will be done manually where feasible. L-000411 champlin REFINING COMPANY Procedure No. j issued: Revised: Page 2 of 3 706.11 7/28/89 USE OF MOTORIZED EQUIPMENT IN LPG STORAGE AREAS III. PROCEDURE (Cont'd.) B. I. 0 There will be no routine vehicle traffic movement in LPG areas. Access routes will normally be chained and locked. 0 AJI motorized vehicle movement will be carefully guided using a spotter at all times. 0 Operations and Maintenance supervision shall be responsible to look for alternate routes and work methods which minimize the use of vehicles and motorized equipment in LPG areas. 2. Vehicle access routes will be clearly marked: 9 Barrier flags indicating entrance. 9 Barricades erected to protect: Exposed or underground piping Bleeders Protruding valves Conduit Ditches or steep banks 3. Lifts over LPG vessels and piping: 9 Carefully reviewed and approved by the respective Area Supervisor. 0 Check for proximity of power lines. 9 Crane inspection to comply with Refinery standards. 9 In general all lifts over LPG vessels and piping are to be minimized. C. Night Work 1. Night work requiring motorized equipment will be performed only during emergency conditions. 2. Adequate lighting shall be set up to illuminate the work area. 3. A minimum of two (2) spotters will be used to assure safe movement of motorized equipment. L-000412 3 champlin REFINING COMPANY Procedure No. ! Issued: j Revised: I Page ^ of 706.11 7/28/89 USE OF MOTORIZED EQUIPMENT IN LPG STORAGE AREAS HI.- PROCEDURE (Cont'd.) D. Communications 1. Adjoining units are to be notified of scheduled work. E. Permits 1. When issuing permits in these critical areas, the Area Supervisors must be very careful to eliminate the risk of accidental impact of motorized lifting equipment with LPG equipment. The Area Supervisor will sign the permit involving motorized equipment during normal working hours. 2. During off hours and weekends, the responsibility of signing the permit will be assumed by the weekend duty Supervisor or the Shift Supervisor. The Shift Supervisor shall consult with respective area supervision prior to issuance of permits involving motorized equipment. 3. Proper safety equipment will be on site prior to issuance of all permits. lager L-000413 SCAFFOLDING CONSTRUCTION PROCEDURE I. PURPOSE Scaffolds shall be provided and erected in accordance with the applicable standards for persons engaged in work that cannot be done safely from the ground or solid construction and suitable ladders. II. SCOPE This procedure establishes the basic safety requirements for the installation, maintenance and utilization of 2" standard O.D. tube and coupler type scaffolding generally designed for exterior construction, repair or maintenance work. III. BASIC STANDARD SPECIFICATIONS 1. The footing or anchorage for scaffolding shall be sound, rigid and capable of carrying the maximum intended load. Barrels, boxes, bricks, or concrete blocks shall not be used for supports. Legs and shoes must be placed on level area with a base that completely steadies entire scaffold. 2. Guardrails 42 inches in height with a mid rail and 4 inch toeboards shall be installed on all open sides ofa scaffold 6 feet or more above ground. 3. Guardrails shall be rigid of 2* x 4* wood or its equivalent. Wire, rope, cable or lesser material shall not be substituted. 4. Any damaged part of scaffolding that would weaken its performance shall be immediately replaced. 5. Scaffold uprights shall not exceed spacing of 10 feet on center lengthwise and not be more than 6 feet apart along the width. The platform shall be at least 30" wide made of 2* x 10* planks that are sound. 6. A ladder or the equivalent for safe access shall be provided. The ladder shall extend 3 feet above platform. 7. Scaffold planks shall extend over their end supports at least 6* but no more than 12* and shall be secured with number 9 wire and/or cleats. ) L-000414 SCAFFOLDING CONSTRUCTION PROCEDURE BASIC STANDARD SPECIFICATIONS (Cont'd.) 8. Where planking is overlapped, each plank shall extend over the other's end at least 12 inches. A plank shall not overlap an unsupported end of another plank. 9. The ends of planking shall be cleated or tied with No. 9 wire to prevent splitting and dislodgment. Abutted ends must rest on separate bearers and be nailed or tied down with No. 9 wire. 10. Individual scaffold design varies widely in order to meet the existing circumstances and the intended use. Therefore, 29 CFR 1910.28 must be referred to for the particular scaffold's construction detail regarding OSHA standard's compliance; such as, inside vessels or the waler jack used on tank walls. L-000415 c champlin A Subsidiary of Union Pacific Corporation REFINERY OPERATED VACUUM TRUCK SAFETY STANDARDS PROCEDURE NO. 79 PURPOSE A vacuum truck that services the refinery is required to have those features that make it intrinsically safe. Precautions must also be taken to ensure that operating practices conform to those requirements that control the inherent hazards of the circumstances surrounding the need for a vacuum truck. SCOPE Vacuum truck compliance with the safety requirements and DOT specifications is the responsibility of the respective organization that owns and operates this equipment. Champlin supervisors ordering a vacuum truck may decline acceptance of a vendor's services should the unit be considered lacking the essential safety features for the job. SAFETY REQUIREMENTS 1. The vacuum drive shall be powered by a separate diesel engine equipped with a high level control. 2. Engine exhaust stack should be equipped with a flame arrestor, but must be vertical in order not to exhaust under the truck. 3. Trucks should have no catalytic converter or other excessive hot spot. 4. A safety venturi should be Installed that will dissipate vapors discharged at a diluted (too lean to burn) rate for most of the loading operation above the tank and away from the exhaust at the flammable range. As an alternative, the discharge of the vacuum pump must be vented by hose or other means to a remote location. This will eliminate flammable vapors from accumulating under or near the truck at grade level while loading on a vacuum. 5. Flammable liquids are to be discharged through gravity flow or a regular pump rather than by air pressure. Less air will mix with the flammable vapors inside and not create a possible pressurized flammable mixture inside the vacuum tank. This would also prevent a possible pressurized tank with a flammable mixture being present and later being driven down the highway. OSHA has prohibited using air to discharge flammable or combustible liquids in plant systems. The use of air to discharge a flammable liquid has long been recognized as a poor safety practice. 6. Each vacuum truck shall have a small combustible gas indicator. Gas tests shall be taken on a calm or little wind day prior to picking up a flammable liquid spill or anytime it is necessary to position the truck downwind of a. pickup point. Form SFMO L-000416 -l- refinery operated VACUUM TRUCK SAFETY STANDARDS PROCEDURE NO. 79 SAFETY REQUIREMENTS 7. 8. 9. 10. 11. 12. 13. 14. Operational check of safety valve is necessary on the regular preventa tive maintenance schedule of vehicle with an annual mechanics inspection and service of safety valve. A bonding cable must be attached to the truck on a reel. Whenever loading or discharging a flammable liquid, the truck shall be bonded to the source and the source ground. The only occasion where bonding and ground ing may not be practical would be while picking up a remote flammable liquid spill. Non-skid surface should be Installed on all -regular steps, walkways, etc. on the truck. Slipping and falling are some of the more common injuries around vacuum trucks. A minimum of 30 to AO feet of hose for loading purposes is necessary in order for truck to be parked a safe distance away from flammable liquid spills. Vacuum trucks that may be subject to hauling a toxic product, especially one containing hydrogen sulfide, shall be equipped with a self contained air escape pack. Vacuum truck drivers shall have had training and be reinstructed annually. This training shall include an understanding of the safe rules and procedures in the operation of a vacuum truck and an awareness of potential fire hazards when handling flammable or combustible products. Those who operate vacuum trucks shall be assigned to this equipment and must possess a valid Texas driver's licence suitable for transporting waste cargo over the highway. The tank of the vacuum truck shall be designed to permit interior water washing and steam cleaning from the exterior. L-000417 c champlin A Subsidiary of Union Pacific Corporation VACUIM TRUCK OPERATION PROCEDURE NO. 57 PURPOSE The operation of a vacuum truck must conform with those practices that ensure the safety of personnel and equipment. SCOPE Adequate controls are to be exercised in the onsite operation of a vacuum truck. While there are those responsibilities of the vacuum truck personnel, Champlin supervisors shall require that the proper safety precautions are followed: 1. The truck should be kept clean and free of residual materials. Normal stepping positions shall be painted with a non-skid grit surface. Slipping and falling are some of the more corrmon injuries around vacuum trucks. 2. Serious personnel hazards are practically non-existent around vacuum trucks while operating on vacuum. The operator should nevertheless stay within the area where the vacuum truck is in use. 3. There are several potential hazards associated in pressurizing the tank for unloading. a. Remain clear of unloading line hook up. Liquid products, rocks, etc. can come out under considerable pressure. People have been knocked over and rolled along the ground which caused bad bruises under such circumstances. b. The trucks should be operated within the operational pressure limits at all times. Top domes and tank domes have been blown off from over-pressurizing the tank. c. Never pressurize a tank to unload a flammable product. This may create a flaimable vapor mixture under pressure. d. Once the tank has been pressurized, it must be depressurized prior to driving it on any road or highway. 4. Balance the pressure within the tank to atmospheric pressure whenever going to pressure from a vacuum; or to a vacuum after being pressurized. 5. Never use any external pressure source (outside the truck) to pressurize the truck for unloading. Form SFT-10 (8-77) -1- L-000418 VACUUM TRUCK OPERATION PROCEDURE NO. 57 6. Chemicals, acids, etc., that are not compatible with water or hydrocarbons shall not be picked up with a vacuum truck. Such chemicals may produce toxic vapors, heat, or cause a fire or explosion. 7. Cleaning out the tank on a vacuum truck is performed in the same manner as cleaning any other tank. If flammables or toxic products have been hauled and if people are to enter these tanks, the same procedures must be followed that apply to cleaning any other small tank. 8. Most of the hazards around a vacuum truck occur when they are used for hauling a flammable or combustible product or products containing toxic vapors. Fhceshield, respirator, a chemical suit, gloves, boots and a fire extinguisher should be available on the vacuum truck for emergency use. 5. The vacuum truck should be positioned upwind preferably, otherwise cross wind, but never downwind of any pick up point unless combustible gas tests indicate no flarrmable vapors present and the layout is prohibitive for taking advantage of the wind. 10. Vacuum trucks shall not be used around process areas unless gas tests' indicate no flammable vapors. 11. When little or no wind is blowing, no pick up of flammable liquid spills shall be made unless gas tests indicate no flammable vapors. The truck is to be at least 30 to 40 feet away from the spill area. 12. The vacuum truck shall have at least 30 to 40 feet of suction hose (minimum) to permit locating the truck a reasonable distance from a spill area. 13. Bonding and grounding of vacuum trucks is essential. Treat all material as if it emits flammable vapors in order to protect against such possibilities. When loading or discharging a flammable liquid, the truck and source should be bonded and the source should be grounded. This is not very practical to do when picking up a remote flammable liquid spill, however, all other times it shall be dene. '14. Set the portable fire extinguisher off the truck and upwind some 20 - 25 feet from the truck whenever loading or unloading flammable liquids. Unloading of a flammable product shall be through a pump and not discharged with air. 15. Since there is a potential fire hazard when loading or unloading a flammable product, or loading any product following the transport of a flammable product, no smoking shall be allowed. ) -2- L-000419 c champlin A Subsidiary of Union Pacific Corporation VACUUM TRUCK OPERATION PROCEDURE UP. 57 16. Handling crude oil or other products containing hydrogen sulfide with a vacuum truck has the same HjS potential as found in other production operations where the H2S hazard is present. a. When operating in a closed system, there is no H2S hazard as long as there are no leaks. b. There may be a hazard when hooking up or disconnecting the vacuum truck's lines. This is especially true when disconnecting after a toxic product has been flowing through the lines. Precautions must be taken to control this - breathing equipment may be necessary. c. Whenever picking up a spill of any product containing H2S, always keep upwind; and if there is little or no wind, test atmosphere with an H2S level indicator to determine whether breathing equipment is needed. 17. Clean up any spilled product without delay. 18. Vacuum truck operations should not be done at night except under emergency situations and only with the authority of the Area Superintendent or his designated representative. Form STMO {8*77} L-000420 -3- e champlin A Subsidiary of Union Pacific Corporation COLOR CODE & KEYED HOSE COUPLINGS PIPE - HOSE PROCEDURE NO.66 Issued: May 14, 1980 I. PURPOSE Strategic pipe circuit terminals are color coded to identify their content which will also serve as an employee awareness factor. Keyed coupling with color related hoses distinguishes the intended service, aids in preventing their interchange and helps ensure the delivery of the proper product. II. SCOPE ) III. Identified, pipe circuits and the type of hose serve a particular purpose which must be adhered to in all refinery units. Employees' Instruction regarding the proper use and care of pipe terminals and hoses is a line supervisory responsibility. PROCEDURE A. Pipe Color Code at Connector Terminal (Color coded section is to extend 6' from end of drop) Yellow-----------------Orange-------- - - White-------- - - Green ------ Blue -----------------Green-Black Stripe Red ______ Gas Steam Nitrogen Plant Air Potable Water Breathing Air Legend Fire B. Approved Couplings and Corresponding Hoses; minimum specifications. Service Coupling Color Hose Description Plant Air National Quick lock with 5/8" S.S. band 4H812, blued steel. Red Contender hose 3/4" by 50' 200 psi work pressure, 800 psi burst test. Nitrogen National Quick lock with 2, 3/8" S.S. bands 0BMH8, cadmium plated steel. Yellow Triplex hose h" x 50' 400 psi working pressure, 1600 psi burst test, 2 ply. ) Steam Form SFT*10 (77) Steam Spud (Boss) internal ground joint MS-6. Mating internal with wing lugs, 2 bolt interlocking clamp, GS-6, Cadmium plated malleable iron. Black Plicord steam hose, 3/4" by 50', 250 psi, burst 450F, wire reinforced, tested for static bond. L-000421 e champlin A Subsidiary of Union Pacific Corporation Page 2 COLOR CODE & KEYED HOSE COUPLINGS PIPE - HOSE PROCEDURE NO. 66 Service Coupling Color Hose Description tJ Utility Crows foot, Dixon Black Contender 3/4" by 50', Water AM-6 with 5/8" S.S. 200 psi working pressure, band, Cadmium plated, 800 psi minimum burst malleable iron. pressure. Acid 757.-95% Monel or Polypropylene, Gray Quick disconnect, petroleum, spiral shank nipple - 2, 5/8" bands. Chemflex suction - discharge hose 2" by 25', polypropy lene liner, spiral wire lock. Caustic Stainless, quick Black Plycord petroleum, 100 psi 51 Baume couplers with 2 S.S. working pressure, 400 min. 5/8" bands. burst wire-inserted suction hoses, Buna-N oil resistant cover, 2" by 25*. ) Crude Oil Swedged on fittings, Blue Blue flexwing, 100 psi/400 to High raised face, flange min. burst polyethylene Aromatics back welded to nipple. tube, oil resistant cover, 2", 3" and 4" size by. various lengths, full vacuum rating. Wash Down (Maint.) Rocker lug, aluminum alloy, Natl. Std. thread, expansion ring. White or Black Fire hose, IV x 50', 250 lb. test, polyester cover, single jacket. Fire Reel Rocker lug, aluminum alloy, Natl. Std. thread, expansion ring. Red Rigid non-collapsible, 1%" by 50' or 100', 19B multi purpose, 250 psi maximum pressure. Fire & Emergency Rocker lug, aluminum Red & Yellow double jacket Collapsible, polyester, single jacket, IV' by 50', tested to 500 psi; 2!s" by 50', tested to 500 psi. Mildew and chemical resistant. Breathing Brass Quick connect, Black Rigid, V by 50', Red tested Air sleeved Hansen. or Red to 315 psi working pressure. Black tested to 250 psl working pressure. Oil, age and abrasion resistant cover. Single brade. Form SFT-10 <*77> L-0C0422 champlin A Subsidiary of Union Pacific Corporation COLOR CODE & KEYED HOSE COUPLINGS PIPE - HOSE PROCEDURE NO. 66 Page 3 Hose Application 1. The department manager and the process, terminal or maintenance superintendent are accountable for providing the proper hose and their corresponding couplings and fittings. Hose application must be for the service it was designed for and assigned to. The couplings or connectors originally provided for the various hose service must not be interchanged. Hose fittings shall not be altered, adapted or improperly used to make connections which vary from the designed mating keyed configuration. .2 Only those fittings specified in this procedure are permitted for the hoses described. ) 3. Steam hose is to be used only for 250 psi maximum steam pressure, utility pressure at 150 psig and not to exceed 400F. Hose clamp bolts are to be kept tight to prevent fittings from coming apart under pressure. Hose may be connected to a fixed coupling mate by twisting it a few turns before joining the two together. Loosening the connector clamp fitting by its bolts in order to turn it in relation to the hose is prohibited. 4. Nitrogen pressure within the hose must not exceed 400 psig. 5. Fire emergency hose is restricted to fire suppression service or con trolling emergencies. Vehicles shall not be permitted to run over fire emergency hoses. Such hoses when removed from their stations are to be completely drained and returned to their proper places. .6 Collapsible hose used for utility or maintenance purposes will be identified. 7. Caustic hose with quick connect couplers shall be used for this service at pressures below 43 psig and temperatures below 150F. Pipe is necessary for transferring this material at higher pressures or temperatures. .8 Acid transfer utilizing the chemflex hose with quick connect couplers shall not exceed' 43 psig. 9. Hoses not in use are to be hung on racks to eliminate tripping hazards and minimize deterioration. Drain hoses before freezing weather secs in ) Form SFT*10 (77) L-000423 e champlin A Subsidiary of Union Pacific Corporation COLOR CODE & KEYED HOSE COUPLINGS PIPE - HOSE PROCEDURE NO. 66 Page 4 10. Relieve the pressure on hoses after each use. Turn the material flow off. Vent and drain the hose in the containers provided upon discontinuing the operation or job. 11. Chemical hoses shall be drained and neutralized at the time they are stored. 12. Damaged or deteriorated hose shall be tagged and routed to the maintenance tool room for inspection. Dependent upon their deter mination, the tool room will schedule and arrange for hydrostatic testing. When hose can be satisfactorily repaired it may be returned to service. Form SFT*10 (8*77) L-000424 CHG 01909 PORTABLE FIRE EXTINGUISHING EQUIPMENT I. PURPOSE The procedure outlined below is a recommended guideline to be used in the selection, placement and maintenance of portable fire extinguishers. This procedure establishes the minimum requirement for fire protection equipment. II. GENERAL Consideration shall be given to the class of fire which may occur. A. Classification Of Fires 1. Class A fires occur in ordinary combustible materials, such as wood, cloth, paper, rubber and many plastics. 2. Gass B fires occur in flammable liquids, gases, and greases. 3. Gass C fires occur in electrical equipment. 4. Gass D fires involve combustible metals. B. Location And Distribution 1. Definition a. Light hazard office and change rooms. b. Ordinary hazard - Warehouses, stockrooms, tool room, electrical shop, machine shop, control rooms. c. Extra hazard - all process areas, laboratory, paint shed, gas pumps, all pump pits. 2. Fire extinguisher size for flammable liquids - Gass B. Basic Minimum Type of Hazard Maximum Travel Extinguisher Rating Distance to Extinguishers Light Ordinary Extra 5B 10B 20B 50 ft. 50 ft. 50 ft. L-000426 PORTABLE FIRE EXTINGUISHING EQUIPMENT GENERAL B. Location And Distribution (Cont'd.) 2. a. Process Areas - Floor area less than 2,000 square feet. I - 30 lb. dry chemical located within 30 feet of the vessel between the exit and the vessel. b. Process Areas - Area over 2,000 square feet. 1. 1 - 30 lb. dry chemical for each 2,000 square feet plus 150# or 250# wheeled unit. 2. Heavy extinguishers should be located on level area near where they may be needed. C. Individual Mounting and Identification 1. Extinguishers should be mounted in conspicuous and readily accessible location and the location unobstructed. 2. Extinguishers should be hung on bracket shelves or handles so that the top is between 36* and 48* from the floor. a. Indoor locations 1. Fire extinguishers mounted indoors should not be located in aisleways where damage can occur from material handling equipment. b. Outdoor locations 1. Extinguishers should be mounted on building walls, structural columns or substantial posts not to exceed 30' from fire exposure. 2. Mark the location visible from all areas by a distinctive red painted circle, square or triangle. 3. Where Ansul K-150-C or K-350-C wheeled units are used, they should be at least 50' from any potential fire hazard. L-000427 PORTABLE FIRE EXTINGUISHING EQUIPMENT GENERAL D. Inspection 1. Monthly > all types of extinguishers. Inspect the seal and if broken recharge the extinguisher. Note if access to extinguisher is clear or obstructed. Lift from the hook and make sure the unit is full. Visually inspect for any leaks or deteriorated or plugged hose. 2. Annually a. Class "A", 'B* and "C" - complete check. E. Maintenance And Testing 1. A seal should be affixed to the extinguisher so that if the extinguisher is operated, the seal will be broken. 2. Immediately after using an extinguisher or after accidental discharge, the Safety Department shall be notified of the location of the discharged extinguisher. 3. All extinguishers coming into a plant should be coded and a record of all extinguishers should be kept. A tag or record card should be mounted at the extinguisher and should be signed by the inspector on each inspection. The extinguisher must also contain information such as date of recharging and date of hydrostatic test. F. Instruction And Training Instructions should be supplemented by yearly or more frequent demonstrations. L-000428 e champlln A Subsidiary of Union Pacific Corporation Issued; Jferch 3, 1980 Rev. (1) Decarrber 7, 193 FIREWATER SYSTEM USE FOR PURPOSES OTHER THAN FIRE FIGHTING PROCEDURE NO. 64 PURPOSE Uncontrolled use of water from fire suppression systems has the potential of rendering its integrity and capability insufficient in the event of fire. Indiscriminate use of water from this system therefore cannot be tolerated. Limited use under controlled circumstances is permissible to keep the demand on fire water at the minimun and hold the system in reserve. SCOPE Use of fire water for an inminent emergency does not fall within this procedure. ) Activities which use water tint require taking it from fire hydrants, monitors or other connections to the fire control systems are covered by this procedure. Use of Fire System for other than its Intended Purpose; The job Supervisors (operations, maintenance or contract), area superintendent and operator must determine when any part of the fire water system is required for other uses. Should this be essential, prior arrangements must be made with the Safety department as outlined herein. A log of this activity will be maintained by the Safety secretary. Notification of discontinuance is mandatory. 1. Application of 1 1/2 inch rigid hose reels to wash down is permissible. Hose must be wound on reel after each use and nozzle must be on hose. ,2. ' Fire hoses must remain at unit stations in reserve for suppression of fire, control of spills and other emergencies having dangerous potential, ffeintenance hose shall be used for other water demanding activities including the fire watch. 3. Use of the fire water systems hydrants or plugs with maintenance hose for fire watches is permitted. Monitors must not be adapted for such use. 4. The tool roan will stock an adequate amount of 2 1/2 inch, 1 1/2 inch 300 psi hose with national standard thread in 50 foot lengths for mainten ance use. A supply of adaptors such as hexagon internal national standard thread to external international pipe thread, hexagon external I.P.T. to N.S.T., and etc., shall also be available for both hose sizes. ) 5. Temporary tight connections are to be made only on a fire hydrant and approval by the Safety office is required. In such instances, the adaptor illustrated herein must be employed. Such tight connections must be removed at the adaptor when not in actual use. L-000429 Form SFT*10 (77) -1- e chomplin A Subsidiary of Union Pacific Corporation Page 2 FIREWATER SYSTEM USE FOR PURPOSES OTHER THAN FIRE FIGHTING____ PROCEDURE NO. 64 6. The use of monitors or line hose reels in a manner that alters them or leaves them unattended is not allowed. For example, removal of a nozzle fran a monitor and installing a hose line to establish a water source is not an accepted practice, neither is removal of a nozzle fran any hose station for use with maintenance hose. 7. Use of firewater to fill or wash our process vessels or tanks without tight connections or washing down with monitors requires notification to the Safety office. The possibility of reverse flow or siphoning must be eliminated by installing a check valve in such a water supply line, whether made up of hose or pipe. 8. Operations shall monitor water usage to ensure that there is an ample supply in reserve to sustain the processes and as necessary to aunent the fire water system. ) Form SFT-10 (77) L-000430 e champlin A Subsidiary of Union Pacific Corporation "iG~T CONNECTION ACAPTZR NFPLz 2'k SXTEFNAL >PT TO N'ST CPrCX VALVE 2'lT -NTEPNAL :PT tNlP-LE 2`lz NTEPNAL NST external :pt 5Ai__VALVED WYE 2'IC INTEPNAL NATIONAL STANCAPO TriPEADS WITH 2 NST 27T EXTcPNAL > Form $FT10 (8-77) L-000431 S champlin ^ REFINING COMPANY CHG 01910 . Procedure No. Issued: Revised: Page 1 of 6 708.1 6/5/87 9/08/89 RESPIRATORY PROTECTION PROGRAM I. PURPOSE This procedure defines guidelines applicable to respiratory protection where a known air contaminant does (or may) exist. It also identifies work practices, equipment and training requirements applicable to the use of respiratory protection. This procedure outlines information for personnel using respiratory protection per OSHA CFR 1910.134. II. SCOPE Champlin Refining Company shall provide the type respirator that offers adequate protection against atmospheric contamination exposures and oxygen deficient atmospheres. Respiratory protective equipment must be specifically approved by NIOSH for a given application. III. RESPIRATOR DESCRIPTION AND USE A. Air Supplying Respirators Air supplying respirators are those which provide breathable air to the user. They include the following: 1. Self-Contained Breathing Apparatus Self-contained breathing apparatus (SCBA) are devices that have a portable supply of breathable air. The air affords protection against the inhalation of toxic gases or a lack of adequate oxygen. Champlin utilizes the Scott brand of SCBA. Champlin has the 30 minute and 5 minute air paks in both low and Ugh pressure models (Scott II-A and Scott 4.5). The five minute paks are for escape purposes only and do not contain a warning sound indicating a low air supply. All air paks are strategically located throughout various process units, on the fire truck and at the safety office. Employees assigned to each operating area are responsible for knowing the location of their SCBA(s). L-000433 champlin REFINING COMPANY Procedure No. Issued: Revised: Page 2 of 6 708.1 6/5/87 9/08/89 RESPIRATORY PROTECTION PROGRAM III. RESPIRATOR DESCRIPTION AND USE (Cont'd.) A. 2. Air Supplied Escape Respirators Champlin utilizes the Scott Ska-Pak in the 50 Block for escape purposes only. This unit supplies 5 minutes of breathable air to the user should an emergency release occur. 3. Combination Self-Contained and Air-Supplying Respirators This type of apparatus receives breathing air through an air line hose. Air is supplied from a bank of large breathing air cylinders located remotely away from the user, or from an air cart. The respirator unit is sometimes combined with a 5 minute escape cylinder worn on the user's hip. The escape cylinder is designed to provide a limited amount of air if the regular air line supply is cut off. The 5-minute escape pak is mandatory in an IDLH (Immediately Dangerous to Life and Health) atmosphere. Hose line units, with spare masks and related equipment are available on air trailers and at the safety office. The breathing air trailers are to be checked for readiness by Safety and/or the maintenance supervisor prior to use. When air line respiratory equipment is used, it is mandatory that a person be stationed at the bottle rack or trailer to insure the proper operation of the units. Bottles must be switched when the pressure reaches 250 psig. B. Air Purifying Respirators An air purifying respirator is a device equipped with filter pads or cartridges designed to trap limited amounts of specified air contaminates. They are not suitable for use in oxygen deficient atmospheres. 1. This respirator removes gases and/or vapors by passing the contaminated air through cartridges containing charcoal or other special material which intercepts the contaminates. Cartridges are to be specifically approved to filter the contaminant it is used to protect against. L-000434 champlin REFINING COMPANY Procedure No. Issued: Revised: Page 3of 6 708.1 6/5/87 9/08/89 i I RESPIRATORY PROTECTION PROGRAM III. RESPIRATOR DESCRIPTION AND USE (Cont'd.) B. Air Purifying Respirators 1. Respirators/cartridges should be replaced when: a. Smell, taste, or skin irritation under the mask is experienced. b. Inhalation is restricted. c. Benzene respirator cartridges must be changed out at the end of each shift after use. d. Three (3) months have passed since installation date of respirator and it has been removed from its original packing container. e. Inspection reveals damage or faulty condition. Air purifying respirators in use at Champlin include both disposable and full face dual cartridge models. The disposable type in use include the 3M 8712 for removal of organic vapors and the 3M 8725 for combination organic vapor/acid gas, Cl2, and S02. These respirators are to be used as prescribed by the manufacturer's guidelines. The full face respirators in use include the MSA 7204, 3M 7800, and the Pro Tech HSC B222 of the dual cartridge variety. They are to be used in areas where low level (<50 ppm) benzene concentrations can be encountered or other hydrocarbon vapors are present. These full-face dual cartridge benzene respirators are located in select control rooms throughout the refinery. They are to be returned to the Safety Department at the end of each shift in which they are used in order for them to be sanitized and have new filter cartridges installed. L-000435 champlin REFINING COMPANY Procedure No. Issued: Revised: Page 4of 6 708.1 6/5/87 9/08/89 RESPIRATORY PROTECTION PROGRAM III. RESPIRATOR DESCRIPTION AND USE (Cont'd.) B. 2. Particulate Respirators A particulate respirator (also known as a mechanical filter respirator) is designed and approved for use in filtering dust, fumes, mist, or a combination of these airborne contaminants. This respirator is not approved for use where the exposure contaminant has a PEL (Permissible Exposure Level) rating of .05 mg/M3 or less. It also is not approved for use when the exposure concentrations of a contaminant is greater than five (5) times the PEL. Champlin approves the 3M type 8710, 9910, and 9920 particulate respirators. These respirators cannot be used in oxygen deficient atmospheres. Air Purifying Respirators 3. Combination Vapor and Particulate Respirators The combination vapor and particulate respirator has the features of both 'l' and "2" outlined above. C. 1. Selection and Use Attached (in Table I) is a listing of commonly found materials at this location and the appropriate means of respiratory protection. IV. OPERATION AND MAINTENANCE A. Safety Manager and Engineer The Safety Manager will evaluate the effectiveness of the Respiratory Protection Program and recommend changes as deemed appropriate. The safety department inspects emergency respiratory equipment and does minor repain. Records concerning unit/device location and condition are maintained in the Safety Department. Safety Engineen are responsible for conducting respiratory protection training. L-000436 EchamplinREFINING COMPANY Procedure No. Issued: Revised: Page 5of 6 708.1 6/5/87 9/08/89 RESPIRATORY PROTECTION PROGRAM IV. OPERATION AND MAINTENANCE (Cont'd.) B. Supervisors and Employees The supervisor and employee are responsible for proper selection and use of the prescribed respiratory equipment. They must continually monitor conditions to determine the necessity for further protection. Respirators must be returned to the safety office to be cleaned, disinfected, inspected and certified for re-use. C. The User Each employee using a respirator is responsible for having knowledge of the operation of the respirator to be used. Only equipment issued by Champlin will be used. After the respirator has been used, users are responsible for removing oil, grease, dirt, paint, or other contaminants from the mask, hose, cylinders, harnesses and trailers. Should a problem develop with a respiratory device, remove it from service and notify the safety department. Used breathing air cylinders shall be replaced with cylinders charged with a full rating of air. Breathing air cart cylinders are to be replaced with full cylinders when pressure is below 250 psig. V. OXYGEN DEFICIENT ATMOSPHERE If an employee must enter a known IDLH (Immediately Dangerous to Life and Health) atmosphere, the following precautions must be taken: A. The Safety Manager or Safety Engineer must approve entry into IDLH atmospheres for work. In emergency situations where life or plant safety is in immediate danger, then those personnel specifically trained, properly equipped and prepared will be permitted entry provided precautions are determined appropriate by the abovementioned personnel or the shift supervisor. L-000437 EchamplinREFINING COMPANY Procedure No. Issued: Revised: Page 6>f 6 708.1 6/5/87 9/08/89 RESPIRATORY PROTECTION PROGRAM V. OXYGEN DEFICIENT ATMOSPHERE (Cont'd.) B. At least two standby persons, ready with Scott Air Paks or hoseline units will be stationed nearby in the event assistance is required. C. Employees entering IDLH atmospheres shall be equipped with .hoseline units with escape cylinders. D. Direct communication (visual, voice, or hand signal) shall be maintained between the standby crew and those persons entering the hazardous atmosphere. VI. TRAINING A respirator training program that meets the guidelines of OSHA 1910.134 shall be maintained. Persons authorized to use a respiratory protective device must complete a training session applicable to the particular device. Respiratory training will consist of the following: A. Qualitative fit testing will be conducted for those personnel required to use negative pressure respirators. B. Attend annual safety training meetings consisting of respirator use instructions and application. C. Don the various devices and wear them to remain familiar with their operation. D. Discuss the specific location of each respirator in ihe unit. VII. FACIAL HAIR NIOSH has determined that facial hair in the seal area of a respirator will prevent a good seal. Therefore employees must be clean shaven where the sealing surface of a full facepiece or half facepiece contacts the face. Attach. L-000438 Chemical or Hazard Methanol MTBE (Ether) Nickel Carbonyl Sulfur Dioxide (S02) Sulfuric Acid Tetra-Ethyl Lead Toluene Treating Chemicals Welding Fumes TABLE I SELECTION AND USE OP RESPIRATORS Exposure Level Means of Protection Respirator Type 200 - 1000 ppm > 1000 ppm 9 Air Purifying Respirator 3M - 8712 9 Air Line Respirator 0 Scott Air Pak 400 - 1000 ppm > 1000 ppm 9 Air Purifying Respirator 3M - 8712 or 8725 9 Air Line Respirator 9 Scott Air Pak Any level 9 Air Line Respirator 9 Scott Air Pak < 50 ppm > 50 ppm 9 Air Purifying Respirator 3M - 8714 or 8725 9 Air Line Respirator 9 Scott Air Pak < 50 ppm > 50 ppm 9 Air Purifying Respirator 3M - 8714 or 8725 0 Air Line Respirator 9 Scott Air Pak See "Tetra-Ethyl Lead Handling Procedure" for special instructions. 100 - 1000 ppm > 1000 ppm 9 Organic Vapor Respirator 3M - 8712 or 8725 9 Air Line Respirator 9 Scott Air Pak Any level Refer to MSDS for appropriate protection Low levels 9 Air Filtering Respirator 3M - 9920 Threshold Limit Value (TLV) 200 ppm 400 ppm .05 ppm 3 ppm N/A 2 ug/ft3 100 ppm - Special Instructions 1. Air purifying or air filtering respirators oust be used only in adequately ventilated areas where there is at least 19.5X oxygen. 2. Be sure to read "Warning" on each respirator package and always follow use guidelines. 3. For materials not covered in this table the user oust consult the appropriate HSDS for respirator selection. 4. Where the concentration of any of the aforementioned materials creates an IDLE atmosphere it is required that an egress bottle be worn with air line respirators. 708.1 L-000439 -2- Chemical or Hazard Ammonia Asbestos Benzene Catalyst or Coke Dust Chlorine Cumene Gasoline General Hydrocarbons Hydrochloric Acid HP Acid H2S Inert-Gas Nitrogen TABLE I SELECTION AND USE OP RESPIRATORS Exposure Level Means of Protection Respirator Type Threshold Limit Value (TLV) Any level > .2 Fiber/cc < 50 ppm > 50 ppm Any Any 50 - 500 ppm > 500 ppm 300 - 1000 ppm > 1000 ppm 300 - 1000 ppm > 1000 ppm < 50 ppm > 50 ppm < 3 ppm > 3 ppm > 20 ppm IDLE 02 < 19.5X 0 Air Line Respirator 0 Scott Air Pak 25 ppm 9 Air Line Respirator .2 Fiber/cc 8 Full Face Dual Cartridge 1 ppm 9 Air Line Respirator 9 Scott Air Pak 9 Air Filtering Respirator 3M - 8710, 9910, Gerson 1710 5 mg/m3 9 Air Line Respirator 9 Scott Air Pak 1 ppm 9 Organic Vapor Respirator 3M - 8712 or 8725 9 Air Line Respirator 9 Scott Air Pak 50 ppm 9 Organic Vapor Respirator 3M - 8712 or 8725 9 Air Line Respirator 9 Scott Air Pak 300 ppm 9 Organic Vapor Respirator 3M - 8712 or 8725 * Air Line Respirator 9 Scott Air Pak 300 ppm 9 Air Purifying Respirator 3M - 8714 or 8725 9 Air Line Respirator 9 Scott Air Pak 5 ppm 9 Acid Gas Respirator 3M - 8714 or 8725 9 Air Line Respirator 9 Scott Air Pak 3 ppm 9 Air Line Respirator 9 Scott Air Pak 20 ppm 9 Air Line Respirator/vith Egress Bottle 9 Scott Air Pak -1- L-000440 5 champlin REFINING COMPANY Procedure No. Issued: Revised: Page j of g 708.2 i 0/20/75 1/19/90 NOISE ABATEMENT AND HEARING CONSERVATION I. PURPOSE To provide guidelines for evaluating the hazard from noise exposure and for minimizing the development or aggravation of permanent hearing impairment resulting from noise exposure. II. SCOPE Champlin Refining and Chemicals, Inc. will continually strive to protect and conserve employees' hearing from loss of acuity due to workplace noise exposure. This procedure reflects the guidelines to the Occupational Noise Exposure Standard (OSHA 29 CFR 1910.95). III. IMPLEMENTATION A. Engineering 1. Where feasible, engineering controls will be used to prevent noise exposures in excess of the Standard. 2. Process Engineering will evaluate new equipment installations and/or changes in existing equipment to assure adequate noise control considerations and solutions are considered. B. Monitoring 1. In all occupational environments which may expose an employee to noise levels of a time weighted average (TWA) of 85 dB or more, measurements will be taken of all continuous, intermittent, and impulse sound levels, between 80 dB and 130 dB. 2. Where occupational noise levels exist that may create employee exposure in excess of the limits prescribed, warnings will be posted by clearly worded signs. L-000441 champlin REFINING COMPANY i Procedure No. Issued: Revised: Page 2 of 8 708 2 10/20/75 1/19/90 NOISE ABATEMENT AND HEARING CONSERVATION III. IMPLEMENTATION (Cont'd.) C. Testing 1. Baseline a. Baseline audiograms will be established for all full-time Champlin employees. b. All prospective full-time employees will be given a pre-employment baseline audiogram. c. Audiometric testing of employees will be conducted under the direction of a licensed physician and may be performed by the physician, an audiologist or nurse who has satisfactorily demonstrated competence in administering the audiometric examinations. d. Testing to establish a baseline audiogram will be preceded by at least 14 hours without exposure to workplace noise. Hearing protectors may be used as a substitute for the requirement that baseline audiograms be preceded by 14 hours without exposure to workplace noise. e. Employees will be specifically notified of the need to avoid high noise levels of non-occupational noise exposure during the 14-hour period immediately preceding the audiometric examination. f. Audiometric tests will be conducted in an environment consistent with ambient noise level requirements of the Occupational Noise Exposure Standard. 2. Scheduled Testing a. All employees exposed to a TWA of 85 dB or greater will be tested at least annually. b. Audiograms indicating any unusual pattern may require retests on a more frequent basis as may be indicated by the specific situation. L-000442 champlin REFINING COMPANY ' Procedure No. Issued: Revised: Page 30/ 8 708.2 10/20/75 1/19/90 ; NOISE ABATEMENT AND HEARING CONSERVATION III. IMPLEMENTATION (Cont'd.) C. Testing 3. Evaluation a. Audiograms will be screened and compared with baseline audiograms. Any audiogram that indicates a standard threshold shift (an average shift of 10 dB or greater at 2,000, 3000 and 4,000 Hz from the baseline in either ear) will require retesting. b. Audiogram comparisons not complying with prescribed norms will be evaluated by a qualified professional. c. The employee will be notified of the audiogram results. 4. Follow-Up Procedure a. Except where a physician or an audiologist has determined that a standard shift is neither work related nor aggravated by occupational noise exposure, the following actions will be initiated and documented: (i) Employees not using hearing protectors will be fitted with hearing protectors, trained in their use and care, and instructed to use them. (ii) Employees already using hearing protectors will be refitted and re-trained in the use of hearing protectors and provided with hearing protectors offering greater attenuation as necessary. (iii) A copy of the audiogram will be provided to the employee when the employee intends to see his or her personal physician or a hearing specialist. (iv) The employee will be referred to an audiologist or otologist when it is suspected that a medical pathology of the ear is caused or aggravated by wearing hearing protectors. L-000443 champlin REFINING COMPANY Procedure No. issued: Revised: Page 4of 708.2 10/20/75 1/19/90 NOISE ABATEMENT AND HEARING CONSERVATION III. IMPLEMENTATION (Cont'd.) C. Testing 4. a. (v) The employee will be informed of the need for an otological examination when a medical pathology unrelated to the use of hearing protectors is suspected. (vi) When an employee has a noticeable hearing loss, the Supervisor of Health Services will inform him or her by letter stating that it is advisable to see a physician or an otolaryngologist. (vii) Should follow-up audiometric testing establish that a standard threshold shift is not persistent and the employee is not exposed to a TWA of 90 dB or greater, then the employee will be informed. 5. Audiometric Testing Specifications a. Audiometric tests will be pure tone, air conduction, hearing threshold examinations conducted separately for each ear at frequencies of 500, 1000, 2000, 3000, 4000, and 6000 HZ. b. Audiometric tests will be conducted with equipment that meets the specifications of, and is maintained and used in accordance with ANSI Standard Specifications for Audiometers S-3.6-1969. c. Pulsed-tone and self recording audiometers will meet the applicable requirements specified in the current occupational noise exposure regulations. d. Audiometric examinations will be administered in a room meeting the requirements of the current occupational noise exposure regulations. L-000444 a champlin REFINING COMPANY Procedure No. Issued: Revised: Page 5 of 8 708.2 10/20/75 1/19/90 NOISE ABATEMENT AND HEARING CONSERVATION III. IMPLEMENTATION (Cont'd.) C. Testing 6. Audiometer Calibration a. The functional operation of the audiometer will be checked prior to each day's use in accordance with established procedures. b. Audiometer calibration will be checked acoustically at least annually with an exhaustive calibration performed at least every two years in accordance with the applicable sections of the specified ANSI Standard Specifications for Audiometers S-3.6-1969. D. Hearing Protection 1. Hearing protectors will be provided to all employees exposed to a TWA of 85 dB or greater. 2. The use of hearing protectors will be mandatory for all employees who: a. Are exposed to occupational noise levels in excess of the permissible noise exposure levels as indicated in the following table: L-000445 champlin REFINING COMPANY j Procedure No. Issued: Revised: Page 6 of 8 708.2 10/20/75 1/19/90 NOISE ABATEMENT AND HEARING CONSERVATION III. IMPLEMENTATION (Cont'd.) D. Hearing Protection A-Weighted Sound Level (Decibel) 80 81 82 83 84 85 86 87 88 .................... 89 90 91 92 93 94 95 96 97 98 99 100 .................... 101 102 103 104 105 106 Reference Duration (Hour) 32 27.9 24.3 21.1 18.4 16 13.9 12.1 10.6 9.2 8 7.0 6.1 5.3 4.6 4 3.5 3.0 2.6 2.3 2 1.7 1.5 1.3 1.1 1 0.9 L-000446 champlin REFINING COMPANY i Procedure No. Issued: Revised: Page 7of j 708.2 10/20/75 1/19/90 i / NOISE ABATEMENT AND HEARING CONSERVATION III. IMPLEMENTATION (Cont'd.) D. Hearing Protection 2. b. Are exposed to 8-hour TWA of 85 dB or greater and have not yet had a baseline audiogram established, or have experienced a standard threshold shift. 3. Employees will be given the opportunity to select their hearing protectors from a variety of suitable protectors and will be trained in the use and care of the protectors selected. 4. Proper fitting will be demonstrated at the time of issuance of each hearing protector; supervision will assure appropriate usage. 5. All hearing protectors provided must attenuate exposures to at least a TWA of 90 dB except in the case of employees who have experienced a standard threshold shift, in which case hearing protectors must attenuate to a TWA of 85 dB or less. E. Training 1. A training program has been established, maintained, and will be administered for all employees exposed to a TWA of 85 dB or greater. 2. The training program will include the following information: a. The effects of noise on hearing. b. The purpose of hearing protectors, the advantages, disadvantages and attenuation of various types. c. Proper selection, fitting, use and care of all protectors provided. 3. Copies of the occupational noise exposure standard are available in the Health Services Department. L-000447 champlin REFINING COMPANY Procedure No. ! issued: Revised: Page 8 of 8 708.2 10/20/75 1/19/90 NOISE ABATEMENT AND HEARING CONSERVATION III. IMPLEMENTATION (Cont'd.) F. Recordkeeping 1. Accurate records will be maintained for a minimum of 30 years of all employee exposure measurements. L-000448 champlin REFINING COMPANY Procedure No. Issued: Revised: Page j of j 708.3 3/11/77 5/31/88 RADIATION SAFETY PROGRAM I. PURPOSE Use of radioactive materials are to be controlled to ensure that employees are not exposed to harmful radiation, and that radioactive materials are not lost or released to the environment. II. SCOPE This radiation safety program applies to the procurement of all radioactive materials, radiation devices and radiation services. It also applies to all areas in the refinery where radioactive materials or radiation devices are used, installed, or stored. IH. PROCUREMENT OF RADIOACTIVE MATERIALS, RADIATION DEVICES AND SERVICES Before a purchase order is issued for procurement of any radioactive materials, radiation devices, or radiation services, the approval of the Safety Department Radiation Safety Officer (RSO) must be obtained. It is the duty of the RSO to obtain the necessary license or regulatory agency approval and to inform the buyer of any restrictions. IV. INSTALLATION, RELOCATION, OR REMOVAL OF DEVICES CONTAINING RADIOACTIVE MATERIALS 1. Personnel who determine that any device containing radioactive material is to be installed, relocated or removed by either Champlin personnel or outside contractors must inform the Radiation Safety Officer. 2. If the work is to be performed by Champlin personnel, then it will be conducted by or under the direct supervision of an individual authorized on the Texas Radioactive Material License. If the work is to be performed by an outside contractor, the RSO will determine if they are properly licensed for such activities. L-000449 champlin REFINING COMPANY : Procedure No. ; Issued: j Revised: j Page 2 of 3 708.J 3/11/77 5/31/88 RADIATION SAFETY PROGRAM IV. INSTALLATION, RELOCATION, OR REMOVAL OF DEVICES CONTAINING RADIOACTIVE MATERIALS (Cont'd.) 3. Upon receipt of a device containing radioactive material, the RSO will survey it to determine if it is properly shielded. 4. Prior to removal of a radioactive gauge from storage, the RSO will ascertain that the radioactive source is properly shielded, and secured or locked in that position. 5. After installation or relocation, the RSO will perform an initial radiation survey or obtain it from the outside contractor. V. PERSONNEL MONITORING 1. Routine personnel monitoring is not required at the refinery during normal usage, installation, relocation or removal of a radioactive gauge. Since the Radiation levels are very low; no one is expected to receive a dose of 300 mrem in a calendar quarter. 2. If the RSO determines from a physical radiation and anticipated workload that an individual is likely to receive a dose of 300 mrem in that calendar quarter, then that individual will be provided a pocket dosimeter and a record of his dose maintained by the RSO. VI. STORAGE OF RADIOACTIVE MATERIALS 1. Devices containing radioactive materials may be temporarily stored in any normally unoccupied and secure location within the refinery provided that the source is secured or locked within the device and that the device is appropriately labelled with a "Caution - Radioactive Material" sign. The area or room must be secured or locked to prevent unauthorized removal of the device. 2. The RSO must be informed when the device is placed into long term storage and will post the area with a "Caution - Radioactive Material" sign if necessary. L-000450 champlin REFINING COMPANY Procedure No. | Issued: 1 Revisedj j Page of 708/3" 3/11/77 5/31/88 RADIATION SAFETY PROGRAM VII. \ POSTING. LABELLING AND ENTRY PERMITS 1. Although Texas Regulations for Control of Radiation 21.204(a) excepts a room or area from posting because of a sealed source whose radiation level does not exceed 5 mrem/hr at 12 inches from the surface of the source container or housing, it is the policy of Champlin to post such areas where practical so that personnel are aware of the presence of radioactive material. 2. Personnel must obtain an entry permit from the RSO before entering vessels or enclosures which contain radioactive devices. The RSO will return the radioactive source to its shielded position, secure the source and place a lock out tag on the device until the work inside is completed. 4. Each device containing a radioactive material shall be labelled with a "Caution - Radioactive Material" sign and a label which identifies the radioisotope and its activity including date of measurement or reference. VIII. EMERGENCIES If a radioactive device is involved in a fire or explosion, the Radiation Safety Officer shall be notified and personnel should not enter the area, except to save a life, until the RSO has conducted a survey. ) L-000451 S champlin REFINING COMPANY ! Procedure No Issued. Revised: Page l of 7 708.4 6/2/88 HAZARD COMMUNICATION PROGRAM I. PURPOSE To establish a program that will ensure that the hazards of all chemicals produced, imported, stored, or used at Champlin's Corpus Christi Refinery facilities are communicated to affected employees, customers and contractors. II. SCOPE This program applies to all employees of Champlin and contract personnel who perform work on Champlin's Corpus Christi Refinery facilities. III. POLICY It is Champlin's policy that workers be informed about any hazardous chemicals which may be encountered in the workplace, as well as the appropriate protective measures for working safely with these substances. rv. PROGRAM A. Hazard Evaluation 1. It will be the responsibility of the Safety Department to arrange for an evaluation of the hazards of Champlin manufactured products. 2. The manufacturers of products purchased for use within the refinery will be responsible for conducting this hazard evaluation and providing information with initial shipments. B. Hazardous Chemical List 1. A complete inventory of all hazardous chemicals used within the Corpus Christi Refinery will be maintained in the Safety Department. L-000452 champlin REFINING COMPANY Procedure No issued: Revised: Page 2 of 7 708.4 6/2/88 HAZARD COMMUNICATION PROGRAM IV. PROGRAM (Cont'd.) B. Hazardous Chemical List (Cont'd.) 2. A listing of hazardous materials located within each operating unit will be developed by the Safety Department and maintained in the respective 'Hazardous Chemical Information Guide* which is located in the unit's control room. The area supervisor will be responsible to insure that these lists are maintained and updated as necessary. C. Material Safety Data Sheets (MSDS) 1. MSDS development for products manufactured by the Corpus Christi Refinery will be accomplished through the Safety Department and forwarded to the operating areas for incorporation into the respective 'Hazardous Chemical Information Guide*. 2. Chemicals which are purchased for use within this location must be accompanied with an appropriate MSDS. It will be responsibility of the Purchasing Department to request MSDS on all purchased chemicals and these in turn will be forwarded to the Safety Department upon receipt. 3. The warehouse supervisor will be responsible to insure that ail chemicals received have an up-to-date MSDS on file in the Safety Department before that material is introduced into the workplace. 4. If an appropriate MSDS is not received from the'manufacturer, written requests for this information will be made from the Purchasing Department using the attached Request Letter and MSDS Form. (Attachments A & B) 5. The Safety Department will evaluate the MSDS for completeness and request changes where necessary and forward the updated MSDS to the appropriate supervisor for inclusion in the MSDS Manual. L-000453 EchamplinREFINING COWPANY Procedure No. Issued. Revised: Page 3 of 708.4 6/2/88 I HAZARD COMMUNICATION PROGRAM IV. PROGRAM (Cont'd.) C. Material Safety Data Sheets (Cont'd) 6. Copies of the MSDS for the hazardous chemicals to which employees may be exposed shall be available in each control room, maintenance area, and laboratory. The Safety Department will maintain a master copy of all MSDS's located within the refinery. D. Container Labeling 1. Those who receive hazardous materials shall be accountable for determining that the containers are properly labeled. Criteria for container labeling is as follows: (a) They are clearly labeled as to content (b) The label must contain appropriate warnings (c) The name and address of the manufacturer should be clearly indicated. 2. The warehouse supervisor will insure that all containers received through the warehouse meet the labeling criteria. 3. Environmental Affairs will be accountable for labeling waste disposal containers. 4. Maintenance of labels on temporary storage drums within operating and maintenance areas will be the responsibility of the respective area or maintenance supervisor. 5. Labeling of permanent storage containers (i.e. reactors, vessels, exchangers, etc.) will be accomplished via the vessel identification number. A listing of vessel name, number and hazardous material contents will be contained in the respective area's "Hazardous Chemical Information Guide". Storage tanks will be labeled according to NFPA 704. 6. The Terminal Department will insure that all outgoing shipments will be accompanied with the appropriate D.O.T. Placard and/or label. L-000454 champlin REFINING COMPANY Procedure No Issued: Revised: Page 4 of 7 708.4 6/2/88 HAZARD COMMUNICATION PROGRAM IV. PROGRAM (Cont'd.) E. Laboratory Chemicals 1. Any hazardous laboratory chemical which is used in such a manner that employee exposure may result, shall be subject to the following criteria: (a) The laboratory supervisor shall insure that labels on incoming containers are in place. (b) The laboratory supervisor shall maintain Material Safety Data Sheets and assure that they are readily accessible to laboratory employees. (c) Laboratory employees shall be apprised of the general hazards of the chemicals in their workplace by their supervisor. (d) The laboratory samples will be properly identified by tag or label before being accepted for analysis. F. Employee Training and Documentation 1. The employee training program concerning hazardous materials will be conducted by the Safety Department for both existing and new employees. This training program will be provided to all existing employees initially and to new employees during their safety orientation. Newly transferred employees will also be provided training concerning hazards of products which differ from their previous work area. This training will include the following: (a) A programmed instruction module for both hazardous material classifications and MSDS information will be presented. A copy of the "MSDS User's Guide" will also be presented to each employee for their use. (b) A list of the chemicals and associated hazards which they may encounter in their work area. L-000455 EchamplinREFINING COMPANY Procedure No Issued: Revised. Page 5 of 7 708.4 6/2/88 HAZARD COMMUNICATION PROGRAM IV. PROGRAM (Cont'd.) F. Employee Training and Documentation (Cont'd.) 1. (c) The location and availability of the refinery's written Hazard Communication Program, Chemical Inventory and associated Material Safety Data Sheets. (d) Methods and observations that may be used to detect the presence or release of hazardous chemicals in their work area. (e) The physical and health hazards of chemicals which they may encounter and measures whereby they can protect themselves such as personal protective equipment, work practices and emergency procedures. (0 An explanation of container labeling and location of vessel inventory listing with associated chemical contents. (g) An explanation of the Safe Work Permit system with special emphasis on chemical hazard information which will be transmitted prior to both routine and non-routire work tasks. 2. When a new material is introduced into a work area, training will be conducted concerning its hazards. 3. Safety meetings will be conducted periodically to review this program and associated material hazards. 4. The Safety Department will maintain all training records concerning the Hazard Communication Program. These records will include attendance lists, program outlines, employee written examination, and audio-visuals. L-000456 champlin REFINING COMPANY Procedure No Issued; Revised; Page 6 of ? 708.4 6/2/88 HAZARD COMMUNICATION PROGRAM IV. PROGRAM (Cont'd.) G. Confined Space and Hazardous Non-Routine Tasks Prior to entry into a confined space or the performance of hot work, the Safe Work Permit Procedure will be followed and authorized by the appropriate personnel. Procedures concerning this permit are presented in the Safety Procedure Manual. Special permits which include HF Alkylation Unit Entry and "Bulk Chemical Unloading" will be issued when these functions are performed. Hazards associated with other routine and non-routine work tasks that are not covered by a special permit will be conveyed by the unit operator via the Safe Work Permit. H. Unlabeled Pipes or Valves Work activities on unlabeled pipes or valves will be performed after the unit operator has specified on the permit the chemical that is contained in the respective valve or pipe at the time the work is to be performed. The employee performing the task may then refer to the MSDS for the material hazards. I. Outside Contractors 1. The Planning and Purchasing Departments will coordinate a safety orientation for contractors performing work on Champlin property. This will be conducted by the Safety Department prior to the commencement of work. 2. This orientation will apprise the contractor of Champlin's Hazard Communication Program and other pertinent information whereby the contractor, in exercising its duty, may inform their employees of safety procedures and associated work hazards. The Hazard Communication portion will include the following: L-000457 5 champlin REFINING COMPANY Procedure No j issued, i Revised i Page 7 of 7 708.4 6/2/88 HAZARD COMMUNICATION PROGRAM PROGRAM (Cont'd.) I. Outside Contractors (Cont'd.) 2. (a) Hazardous chemicals to which they may be exposed while performing their work. (b) Provide the contractor access to the MSDS User's Guide. (c) Explain that the MSDS for all hazardous chemicals are on file in each Operating control room. Maintenance area and the Safety Department, and are available for their use. 2. (d) Suggestions for appropriate protective measures for contractor employees, i.e. personal protective equipment, safe work preparation, etc. 3. Records will be maintained in the Safety Department concerning this contractor orientation. Manager L-000458 champlln DEFINING COMPANY ATTACHMENT A Date REQUEST Manufacturer/Distributor Name Manufacturer/Distributor Address City, Town, State, Zip Code Subject: Request for Material Safety Data Sheets and Labels Gentlemen: According to our records, we have purchased the products (chemicals) listed below from your company for use within our facilities. To ensure that we have the health and safety information for these products, we request Material Safety Data Sheet (MSDS) and a sample label, if readily available, tor each of the products listed, these MSDSs should contain all of the information specified in Section (g) ot the Hazard Communication Standard (29 CFR Part 1910.1200). We are enclosing blank forms (if an MSDS is not readily available) that you may use to provide us with the appropriate information. Please mail these completed MSDSs at your earliest convenience to the address below. Your assistance in this matter is appreciated. Very truly yours. Enc. MSDS Request File Champlin Refining Company PO. 00x9176 1801 Nueces Say 8lvd. Corpus Christ! Refinery Corpus Christi. TX 78408 L-000459 PNOOUCT NAME -- < r< i wn i n wflbb I (Simitor to Form 0SHA-20) PREPARED 8Y AT7ACHHEMT 8 TELEPHONE ___ oate prepaaeo MA*U#ACrUMjr* IMMC AOOMO* tmm. C*. Amm. mA XIF Mi OKMICAL MUtl AMO fTMCMYO* oaorew. tajmlt SECTION I KMCMOCMCT HOMM W. T*AC* MAMS AM* TWOMTM* fromiiiu SECTHM HAZAfI00US MGREDIEIVTS aaimt*. amcmovattcol * aoLvotrs tlt ammo ALLOT* AMO MCTALUC QOATIMO* w--" , CATALTWT ALLOT* % TVV <%*mrn I i1 I olvott* omco tMuAjLsI*ooOaCtTimA*L o* eoc rua ormm rrj MW SECTION III PHYSICAL DATA mwmr mn>u UK tolanu <%> SECTION IV-FIRE AND EXPLOSION HAZARD OATA HA2AA0 (OCNTinCATtOM SYSTEM (Sm0 * NPM Mo. 704 M) HiaO 1SM0K Hft 0-No EipniOcom hum* L-0004 60 champlin REFINING COMPANY | Procedure No I Issued. Revised: Page l of 7 708.4 6/2/88 HAZARD COMMUNICATION PROGRAM I. PURPOSE To establish a program that will ensure that the hazards of all chemicals produced, imported, stored, or used at Champlin's Corpus Christi Refinery facilities are communicated to affected employees, customers and contractors. II. SCOPE This program applies to all employees of Champlin and contract personnel who perform work on Champlin's Corpus Christi Refinery facilities. III. POLICY It is Champlin's policy that workers be informed about any hazardous chemicals which may be encountered in the workplace, as well as the appropriate protective measures for working safely with these substances. IV. PROGRAM A. Hazard Evaluation 1. It will be the responsibility of the Safety Department to arrange for an evaluation of the hazards of Champlin manufactured products. 2. The manufacturers of products purchased for use within the refinery will be responsible for conducting this hazard evaluation and providing information with initial shipments. B. Hazardous Chemical List 1. A complete inventory of all hazardous chemicals used within the Corpus Christi Refinery will be maintained in the Safety Department. L-000452 champlin REFINING COMPANY Procedure No Issued: Revised: Page 2 of 7 708.4 6/2/88 HAZARD COMMUNICATION PROGRAM IV. PROGRAM (Cont'd.) B. Hazardous Chemical List (Cont'd.) 2. A listing of hazardous materials located within each operating unit will be developed by the Safety Department and maintained in the respective "Hazardous Chemical Information Guide" which is located in the unit's control room. The area supervisor will be responsible to insure that these lists are maintained and updated as necessary. C. Material Safety Data Sheets (MSDS) 1. MSDS development for products manufactured by the Corpus Christi Refinery will be accomplished through the Safety Department and forwarded to the operating areas for incorporation into the respective "Hazardous Chemical Information Guide". 2. Chemicals which are purchased for use within this location must be accompanied with an appropriate MSDS. It will be responsibility of the Purchasing Department to request MSDS on all purchased chemicals and these in turn will be forwarded to the Safety Department upon receipt. 3. The warehouse supervisor will be responsible to insure that all chemicals received have an up-to-date MSDS on file in the Safety Department before that material is introduced into the workplace. 4. If an appropriate MSDS is not received from the' manufacturer, written requests for this information will be made from the Purchasing Department using the attached Request Letter and MSDS Form. (Attachments A St B) 5. The Safety Department will evaluate the MSDS for completeness and request changes where necessary and forward the updated MSDS to the appropriate supervisor for inclusion in the MSDS Manual. L-000453 chcmplin REFINING COMPANY Procedure No, Issued: Revised: Page 3 of, 7 708.4 6/2/88 i HAZARD COMMUNICATION PROGRAM IV. PROGRAM (Cont'd.) C. Material Safety Data Sheets (Cont'd) 6. Copies of the MSDS for the hazardous chemicals to which employees may be exposed shall be available in each control room, maintenance area, and laboratory. The Safety Department will maintain a master copy of all MSDS's located within the refineiy. D. Container Labeling 1. Those who receive hazardous materials shall be accountable for determining that the containers are properly labeled. Criteria for container labeling is as follows: (a) They are clearly labeled as to content (b) The label must contain appropriate warnings (c) The name and address of the manufacturer should be clearly indicated. 2. The warehouse supervisor will insure that all containers received through the warehouse meet the labeling criteria. 3. Environmental Affairs will be accountable for labeling waste disposal containers. 4. Maintenance of labels on temporary storage drums within operating and maintenance areas will be the responsibility of the respective area or maintenance supervisor. 5. Labeling of permanent storage containers (i.e. reactors, vessels, exchangers, etc.) will be accomplished via the vessel identification number. A listing of vessel name, number and hazardous material contents will be contained in the respective area's 'Hazardous Chemical Information Guide*. Storage tanks will be labeled according to NFPA 704. 6. The Terminal Department will insure that all outgoing shipments will be accompanied with the appropriate D.O.T. Placard and/or label. L-000454 champlin REFINING COMPANY Procedure No Issued: Revised: Page 4 of 7 708.4 6/2/88 HAZARD COMMUNICATION PROGRAM IV. PROGRAM (Cont'd.) E. Laboratory Chemicals 1. Any hazardous laboratory chemical which is used in such a manner that employee exposure may result, shall be subject to the following criteria: (a) The laboratory supervisor shall insure that labels on incoming containers are in place. (b) The laboratory supervisor shall maintain Material Safety Data Sheets and assure that they are readily accessible to laboratory employees. (c) Laboratory employees shall be apprised of the general hazards of the chemicals in their workplace by their supervisor. (d) The laboratory samples will be properly identified by tag or label before being accepted for analysis. F. Employee Training and Documentation 1. The employee training program concerning hazardous materials will be conducted by the Safety Department for both existing and new employees. This training program will be provided to all existing employees initially and to new employees during their safety orientation. Newly transferred employees will also be provided training concerning hazards of products which differ from their previous work area. This training will include the following: (a) A programmed instruction module for both hazardous material classifications and MSDS information will be presented. A copy of the 'MSDS User's Guide* will also be presented to each employee for their use. (b) A list of the chemicals and associated hazards which they may encounter in their work area. L-000455 EchamplinREFINING COMPANY Procedure No Issued: Revised: Page 5of 7 708.4 6/2/88 HAZARD COMMUNICATION PROGRAM IV. PROGRAM (Cont'd.) F. Employee Training and Documentation (Cont'd.) 1. (c) The location and availability of the refinery's written Hazard Communication Program, Chemical Inventory and associated Material Safety Data Sheets. (d) Methods and observations that may be used to detect the presence or release of hazardous chemicals in their work area. (e) The physical and health hazards of chemicals which they may encounter and measures whereby they can protect themselves such as personal protective equipment, work practices and emergency procedures. (0 An explanation of container labeling and location of vessel inventory listing with associated chemical contents. (g) An explanation of the Safe Work Permit system with special emphasis on chemical hazard information which will be transmitted prior to both routine and non-routir e work tasks. 2. When a new material is introduced into a work area, training will be conducted concerning its hazards. 3. Safety meetings will be conducted periodically to review this program and associated material hazards. 4. The Safety Department will maintain all training records concerning the Hazard Communication Program. These records will include attendance lists, program outlines, employee written examination, and audio-visuals. L-000456 champlin REFINING COMPANY Procedure No, Issued: Revised: Page 6 of 7 708.4 6/2/88 HAZARD COMMUNICATION PROGRAM IV. PROGRAM (Cont'd.) G. Confined Space and Hazardous Non-Routine Tasks Prior to entry into a confined space or the performance of hot work, the Safe Work Permit Procedure will be followed and authorized by the appropriate personnel. Procedures concerning this permit are presented in the Safety Procedure Manual. Special permits which include HF Alkylation Unit Entry and "Bulk Chemical Unloading" will be issued when these functions are performed. Hazards associated with other routine and non-routine work tasks that are not covered by a special permit will be conveyed by the unit operator via the Safe Work Permit. H. Unlabeled Pipes or Valves Work activities on unlabeled pipes or valves will be performed after the unit operator has specified on the permit the chemical that is contained in the respective valve or pipe at the time the work is to be performed. The employee performing the task may then refer to the MSDS for the material hazards. I. Outside Contractors 1. The Planning and Purchasing Departments will coordinate a safety orientation for contractors performing work on Champlin property. This will be conducted by the Safety Department prior to the commencement of work. 2. This orientation will apprise the contractor of Champiin's Hazard Communication Program and other pertinent information whereby the contractor, in exercising its duty, may inform their employees of safety procedures and associated work hazards. The Hazard Communication portion will include the following: L-000457 chcmplin REFINING COMPANY Procedure No { Issued. ! Revised: i Page 7 of 7 708.4 6/2/88 HAZARD COMMUNICATION PROGRAM f. PROGRAM (Corn'd.) I. Outside Contractors (Cont'd.) 2. (a) Hazardous chemicals to which they may be exposed while performing their work. (b) Provide the contractor access to the MSDS User's Guide. (c) Explain that the MSDS for all hazardous chemicals are on file in each Operating control room. Maintenance area and the Safety Department, and are available for their use. (d). Suggestions for appropriate protective measures for contractor employees, i.e. personal protective equipment, safe work preparation, etc. 3. Records will be maintained in the Safety Department concerning this contractor orientation. finer^Manager L-000458 champlln REFINING COMPANY ATTACHMENT A Date REQUEST Manufacturer/Distributor Name Manufacturer/Distributor Address City, Town, State, Zip Code Subject: Request for Material Safety Data Sheets and Labels Gentlemen: According to our records, we have purchased the products (chemicals) listed below from your company for use within our facilities. To ensure that we have the health and safety information for these products. we request Material Safety Data Sheet (MSDS) and a sample label, if readily available, for each ot the products listed* These MSDSs should contain all of the information specified in Section (g) of the Hazard Communication Standard (29 CFR Part 1910.1200). We are enclosing blank forms (if an MSDS is not readily available) that you may use to provide us with the appropriate information. Please mail these completed MSDSs at your earliest convenience to the address below. Your assistance in this matter is appreciated. Very truly yours. Enc. MSDS Request File Champlin Refining Company P.O. Bo* 9176 1801 Nueces Bay Slvd. Corpus Chnsti Refinery Corpus Chnsti. TX 78408 L-000459 PWOOUCT NAME * V mii rm flb(>l (Simtior to form 0SHA-20) ___________ PNEPAPED BY ____ ATTACHMENT 8 TELEPHONE ._____________________ OAtEPPEPAPED MMMW#crunor namc SECTION 1 uonCMCr ru^oM ma AOOMOO tNmmkm. Mmm. On. Jmm. md tO C cwoaicai. MA^t amo nwotrrwo (mm mamc amo otmomtim CHOUCAA, AAMH.Y jAOWUlA asccnon HAZAIIOOUS tMGAEDtEMTS MUMTt. AAOCtVATTVO. A AOCWMTO % U.Y (MUM AUOTO AMO MCTAUJC OOATUMM MM MCTAL % CATA4.YVY AUJOTO OOkVOTTO Aoomvo MCTAUX eOATHMO nun mctai Put COATMM OM COM AlUX OTMCM omo TVY (VMM MKJM MOIMT f*fj yamoo Aorwntr <mh> mu yamoo ooisnrr 1) SCcnoi1 ffl-PHYSICAL OATA MOXC ORAMTV MPMU acacott. voutnt* or vqujmc (%> ------------------------------> AW AMMMCSAMOOm SECTION IV- HUE ANO XPtOStON HAZAftO OATA M^AAMAOMT I AUTO lOMITIOM I AAMMUlMH | LCL __________________ __________________ ______ ______________ _______ i*i2______ ______ si .1 1 aaocm. ~m maHTwm mocmuma UW. 1 1 1i ! V i # 3 champlin REFINING COMPANY Procedure No. Issued: Revised: Page * of ^ 708.5 11/29/89 SIGNIFICANT ADVERSE REACTION REPORTING PROCEDURE I. PURPOSE To establish a procedure for the reporting, processing and retention of pertinent information relating to any alleged significant adverse reaction to health or the environment attributed to chemical substances manufactured or processed by Champlin Refining and Chemicals, Inc. H. SCOPE Applies to all Champlin Refining and Chemicals, Inc. facilities. III. PROCEDURE A. All complaints, notifications and/or allegations of significant adverse reactions to health or environment relative to chemicals manufactured or processed by Champlin Refining and Chemicals, Inc. shall be referred to the General Superintendent of Safety and Environmental for processing. For the purpose - of this procedure, significant adverse reactions are reactions that may indicate a substantial impairment of normal activities, or long-lasting or irreversible damage to health or the environment. B. All verbal allegations or notifications of a significant adverse reaction shall be documented via memorandum to file. 1. All persons making a verbal allegation shall be informed that the allegation may be recordable under the Toxic Substances Control Act (TSCA) Section 8(e) and indicate that a written and signed allegation should be submitted. 2. In the event the person making the verbal allegation does not submit a written allegation then no further action is required. C. Allegations originating from the public sector shall be directed to the Environmental Department for review and investigation. Alleged work-related employee complaints shall be referred to the Safety Department for review and investigation. L-000462 3 champlin REFINING COMPANY ; Procedure No. I issued: i Revised: i Page 2 of 3 708.5 11/29/89 SIGNIFICANT ADVERSE REACTION REPORTING PROCEDURE III. PROCEDURE (Cont'd.) D. Significant adverse reactions that must be recorded include but are not limited to the following types: 1. Long-lasting or irreversible damage, such as cancer or birth defects. 2. Partial or complete impairment of bodily functions, such as reproductive disorders, neurological disorders or blood disorders. 3. An impairment of normal activities which is experienced by all or most of the persons exposed at the time. 4. An impairment of normal activities which is experienced each time an individual is exposed. E. All valid allegations shall be documented by a record which, at minimum, will consist of: 1. The original allegation as received. 2. Name and address of location that received the allegation. 3. The date the allegation was received. 4. The implicated substance, mixture, article, company process or operation, or site effluent, emission or other discharge. 5. Pertinent information about the person making the allegation (i.e., company employee, individual consumer, plant neighbor, etc.). 6. If the allegation involves a health effect, the sex and year of birth of the affected individual should be recorded, if available. 7. A description of any health effect, how it became known and the route of exposure. 8. A description of any environmental effects identifying affected plant and/or animal species, or portion of the environment. L-000463 a champlin REFINING COMPANY rocedure No. Issued Revised: Page 3 of 3 708.5 11/29/89 i J SIGNIFICANT ADVERSE REACTION REPORTING PROCEDURE III. PROCEDURE (Cont'd.) 9. The results of any self-initiated investigation of the allegation. While the regulation does not require any investigative action, if such an investigation is performed, then the results of that investigation must be included in the record. 10. Copies of any further required records or reports related to the allegation, i.e., cases requiring completion of OSHA forms must also be included. (This does not include internal records or reports maintained by the Company except as above.) 11. Allegation records shall be readily accessible according to the alleged cause of the significant adverse reaction. Allegations are specifically required to be filed by chemical identity, but if not identified it is to be filed by mixture identity, article identity, company process or operation, or site effluent, emission or other discharge. Records retention period for significant adverse reaction allegations is 30 years from the date first reported or known by the person maintaining such records. F. The allegations records file shall be maintained by the Environmental Department who will receive all original complaints and forward a copy of each allegation to the Law Department. G. The General Superintendent of Safety and Environmental, after consultation with the Law Department, shall provide prompt notification as to the disposition of the report to the affected management and employees. L-000464