Document ZnavB58BdDrzEM0kRdmKqXR9J

iSA prrainr Ptyasr raining Manual Ptyasr 11 raining 002703 i CONFIDENTIAL. 8!U2JeJt`? frotecti^ Orrfer f 14th Judicj.il Mr\ *>1 D'i-s- trict Court HAT LIMIT OPEKATOK PHASE TRAINING MANUAL lA+uext to: Oats,: F OA.ejruut: SL 002704 . CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 BAT UNIT OPERATOR PHASE TPAIUTUG I INTRODUCTION The, BAT Qpenaton, Pha4e Tnatntng wa4 made to gtve you, a 4tnu.ctun.ed pnognam to pnepane you, ion. tahtng ovw. 04 a SAT openaton.. It enabte4 evenyone tn.votvQ,d to be. aiocua oi how you. an,e pn.ogn.i44trig thn.ou.gh.out the, pnoce44. TK>14 pnognam, hoeleven,; 4hoyJLd not be. con4tdened to be. aJUL tnetu4tve. At the. conclatton oi the. tnatntng you, ujaJUL be. tested to tn4un.e that you'ne neady to tahe oven youn. new po4ttton. The. pnognam t4 completed by tntttaJLttng and dattng each taL4h on the. 4pace, pnovtded on the. teit oi the, page,. The ta4h4 may be, completed tn any onden. A. Meet with Unit Foneman B. Meet with Anea Su.peavt4on C. Read Monal4/Ethtc4 policy ion, the. Plant 002705 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 Page 1 PHASE V - BAT Openaton Tnatntng Manual, no rr safety SL 002706 A. Locate Safety Showen* in the BAT Unit S. Complete, a BAT Sc jby Shower Checkti^t C. Locate, the. SCSA'-i in the. BAT Unit V. Locate, the. Safety Procedures Marmot in the- Control Room. E. Review the. following Safety Bulletins: #7 Evacuation Ho*ns Sirens ft 10 Opening Vessels to Atmosphere ft 13 tense Inserts ft 16 Notice Tag* #17 Heading Conservation Program ftIS Inspection of Portable Ladders ft2 0 Sate. Storage, of Flammable Combustible Liquids If2 2 Ox,ygen Depletion in Analyze* Buildings ft23 Radiation Control Safety ft26 Industrial Hygiene Monitoring ft27 Receiving Procedure for Tank Truck Delivery ft30 Stocked Road* ft32 Pott Protection, ft33 Utittty Systems Caustic Contamination. P Have a Safety Bulletin Discussion with the BAT P oreman G. Read the Lake Charter Employee Safety Manual cosnoestl^' orfler . prot^ct-i court ect `vill Distill " JU<5 91-U^ Page 3 Operator Training Manual \ \ II SAFETY (Continued) CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 H. Read the tallowing Safety Pn.ocedun.es: #7 Welding, Banning on. Open Flame Penmlts #2 Ignition Source, Penmlts ft6 Lock, and Tag Pnocedune ttS Tank, Entny Pnocedune SL 002707 ft 9 Vehicle Entny Penmlt tt12 Resplnatony Pnotectlon Pnognam #73 Lake. Chanles Hazand Communication Pnognam I. Have a Safety Pn.oae.dan.a4> Discussion with the. BAT Foneman J. Locate, the. Hazaom Blnden, and Mlcnoilche Peaden ion, Matenlal Saiety Data Shaath (MSDS) K. Identify the. Goggle Pn.otQ.ctA.on Aneat, In the. BAT Untt L. Identify the Meaning Pnotectlon Aneas In the, BAT Unit M. Complete, a Housekeeping Inspection Checklist ion. the BAT Unit N. Complete a BAT Cnttlcal Alanms Checklist O. Review all Job Safety Analyses (JSA's) In the BAT SOP Manual with the BAT 0penaton, P. Find and nead the USDS's In the back oi the BAT SOP Manual Q. (Hatch "Saiety Cnackens" Labonatony Safety Video P. Locate the Unit Slnen Switch ion, the UJTU. Leann how It Is used Page 4 PHASE V - BAT Openaton Tnalnlng Manual ! in ENVIRONMENTAL D O CO A. Read -th.e guldellnzt -to Outfall 20 1 document on the PC In the. Contnol Room. Ute, It to ilnd the. following Ini onmatlon: 1 . Qua. monthly at/eaage c.op pen, limit It Ibt/day. 2. Qua, monthly ai/e-rage nickel limit It Ibt/day. 3. Qua, monthly average chlonlne, limit It Ibt/day. 4. Qua. monthly average chlonlnatcd hydnocanbont limit It Ibt/day. 5. Qua, monthly average Total Sutpende.d Solidt limit It Ibt/day. 6. Ulhat ane, the, thne.0, touncet oj onganlct to Outfall 2 01? 7. bihat tu>o ttneamt make.-up the, BAT-2 01 sample, point? 4J *3 l* O 4J CJ S w 4J o -S 17 *-v a ,5 ^ ft. 7J ?? *HT /V 5"S* S'3 3O*^5 to J-i o B. Complete, an SPCC Che,cklltt C. Lexuut the, location, the., and pnettune, noting oi the, following nuptune, dltht and SRV' t In youn, aaea: i. BAT STRIPPER (PRESSURE) RV __ 2. BAT STRIPPER (VACUUM) RP __ 3. BAT STRIPPER ECONOMIZERS RV _ 4. SAT STRIPPER PHASE SEPARATORS (PRESSURE) RV _ 5. BAT STRIPPER PHASE SEPARATORS (VACUUM) RV 6. BAT STRIPPER PEED TANKS ~ (PRESSURE) RD _ 7. BAT STRIPPER FEED TANKS (VACUUM) RP _ S. SAT STRIPPER CONVENSERS COOLING WATER SRV _ 9. BELT PRESS FEED PUMPS SRV _ 10. BELT PRESS HyPRAULIC SRV Page 5 PHASE V - SAT Openaton Training Manual Ill ENVIRONMENTAL {Continued) V. Complete a Satellite. Accumulation Anen Checklist E. Locate the Gneenbook In -the, Contnol Room and Rend the, SOP' t F. Locate the, Yellow Booh In the, Contnol Room and on the, PC G. Locate the, "Big Mouth" tplll ne,ponl6 In the, Contnol Room and Rend the, example* H. Locate, the. monthly NPDES chants on the, Contnol Room BuJULettn Boand 002709 Of 1M4tthh J7u1d,icpiarol tDecistivtreicOt rCdeorurt No- 51-1145 Page. 6 PHASE V - SAT Openaton Training Manual IV OPERATIONS OVERVIEW A. Read the SAT Openatlng Manual, ath gnettlont o4 the, BAT openaton on. 4oneman <at needed 8. Rev-Lew the. pn.oc.t4t 4low theeht with the. SAT Foreman C. Rev-Lew the, SAT S.Q.P. Manual to you, one 4amlllan wtth tt and can. ate. tt dunging the nett o4 youn tnalnlng pentad and a4ten you. begtn on the job D. Become 4amlllan with the SAT SPC chanting. Review with the SAT openaton, and take oven the chanting a4ten a coaple o4 dayt E. Review) the BAT Unit Goalt document with the SAT Foneman SL 002710 "-KSSs.t'Srt of Mo. Pa.ge 7 PHASE V - BAT Openaton Tnalnlng Manual V FOXBORO CONTROL SYSTEM A. Revtew the use o4 the Foxbon,o System Monitor to^twasue. Leann how to -ia-, when thene asie psio b terns, with the Foxbosio it*e4 with the. SAT openaton. cuid F osieman 8. Lexisin how to aeees* tsiend* o4 impontant tempesuLtuLn.es> on, pn,e*s>usie* C. Leann how to open and cJLo*e oaJtves and make adjustment* to *et-point* V. Lexann how the aJLanm *y*tem wonk*, and how to a&knowledge an atxmm (Not just *itenee the hosin'. ) E. Pnsnt oat eaah *cneen o4 the BAT Unit { S pages) F. PsUnt oat Unit gnnphicS 4 on Stnippen*, Metat* VecJitonsnation Units 002711 }ve Order strict Court , ',t Page. $ PHASE V - SAT Openatosi Tnjaining Manaat VI DECHLORINATION OPERATION A. Rz.v4.eM the. peoce-6-i uitth then uitth the Foeeman. SAT Qpeeattng Manual and B. Ob^eeve the unloading o4 a. ThLotut^ate teach C. Leaen how o an.d then, begin. nunning the e.xce-6-4 thto^iuLiate 4>ample4> 4on the SAT opeeatoe ajtee a jew dayt D. Become ^amtttaA, with the analyzeeu> in. the Dechloeinatton Untt E. A4tee a 4 eu) day-4 begin. making eoundt 4 on the SAT opeeatoe F. Revteu) the VechJLoelnaXton Untt S.O.P. `-o G. OJhtch tnain at -Dechton wtt noemaJULy be uted to teeat the Inclnenaton Secondary Scnubbee OJaten? SL 002712 '1 cohfwentirm orfet Page 9 PHASE V - SAT Openatoe Tealning Manual VII META1S REMOVAL OPERATION A. Rev-Lew -tfte Hetat* RemovaJL pnoce-S-i w-L*>v -the Ope>ULt-Ln,3 ManuuoJL and then, the. Foreman. 8. Rev-Lew -th-e ope-ea-t-Lon, *tant-u.p and *hutdown o4 the Potymen unit* C. Change, out, a, potymen tote, when one, becomes empty V. Leann how and then begin winning the cop pen anaty*e* 4 on the, BAT openaton E. Ajten a. 4ew day*, begin making nound* 4on the BAT openaton F. Rev-Lew the tnoubte*hooting chant* in the BAT S.O.P. Hanwat 0. Rev-Lew the. Metal* Removal *ectton S.O.P.1* H. Vt*cu** the Thtchen.cn openatton with the BAT openaton a.bout common pnoblem*; especially what can be done when the Thtchenen tongue indteatton t* high l. Leann how the *plit~nange acid/can*tlc valve at Tank T06 openate* J. Unden*tand why Maztneat-M t* u*ed. 002713 SubiectC?NFiDENTIAL! =>f nth audcirrnF\iv? rder No. K-uUriet C0Urt Page 10 PHASE V - SAT Openaton Tnatntng Manual VIII BELT FILTER PRESS A. 06-ie/ti/e the 6ett p-ee-6-6 -ut opanation 8. Ravlaw the Sett. P^e-6-i opanating Manual C. Pevtew -the S.0.P.'-6 that coacvw. the 6et pee-i-i D. Stant-up tha bolt p-ee-i-i with the BAT opznaton obtanving E. Shut-down the 6et p-ee^-4 with the BAT ope'iato'i obtanvijig F. Dt-icu-6-i aommon pnoblam-6 with boJLt pnett operation with the BAT opeeatoa G. Lexuut how to uti the 6ett pn-e-4-4 emergency -itop t-etp aope a/td switch H. Lexuui how to cue. thz pontabla 6ett utathaa ^cUaiy SL 002714 PPIDrEoNteTcIAtiLv;e Order cial District Court ' > t; Page T1 PHASE V - SAT Ope^atoa Tnaintng Manual IX P/T STEAM STRIPPER OPERATION A. Re.wH-e.w the pnoeeAA with the SAT Operating ManaaZ and the SAT Foneman B. Re.wH.ew -t>te Automatic eompaten eontnoZ AyAtem on the Fox,bono ion the BAT AtnippenA u>tth the BAT openatoz C. Leonn whene the panametenA ion the Automatic eontnoZ AyAtem one Zocated end how to change them. AZao Zeann whot each panametea wiZZ do V. Leonn the two wayA that the AatometLe eontnoZ AyAtem eon be tanned oii and the AtnippenA eontnoZZed manaaZZy B. ObAenve o Atnippen Atant-ap. F. Panticipate/heZp In o Atnippen Atant-ap onee inom the Fox.bono and onee oat at the AtnippenA G. ObAenve o Atnippen Ahutdown H. Panticipate/heZp in a Atnippen Ahutdown onee inom the FOKbono and onee oat at the AtnippenA I. Leonn to nan a watea GC on the atnippen bottoms, and oiten a iew dayA, begin nannlng theAe ion the BAT openoton J. Leonn the Zoeotlon oi both the Atnippen pneAAune and vacuum naptune diAhA. Leonn to teZZ them opant and how to teZZ which dineetion they AhouZd be ioeing when pnopenZy inAtaZZed K. VZacuaa the need ion watea a eat ituAh on the BAT Atnippen bottomA pampA with the Maintenance ioneman on one oi hiA machiniAtA. SL 002715 of uhk t vu''e';uve urder JUw1Clai nistrict Court No. 91-11^5 Page 11 PHASE V - SAT Openoton Tnaining ManaaZ 7 X IMPORTANT SAT PIPELINES A. Tna.ce the caustic sappty Uac-4 to BAT Netats ^om the, Inctnenaton Anea and CoVunbta Southenn Road B. Tna.ce, the, 4ccd Vine, ^nom DechVon to NetaJLs C. Tna.ce, the, add suppty in.om CPC to Metats V. Tna.ce the Stntppen Fonwand Vine ^nom the Stntppens to Metats E. Tna.ce the P/T Samp heed Vine hnom the suiimmtng pooZ to the Stntppen Feed Tanks. Note the Zocatton oh the stnatnens F. Tna.ce the P/T Actd seppty Vine to the Stntppen Feed Tanks G. Tna.ce the Stntppen PecycJLe Vines h^om the Stntppens to the Stntppen Feed Tank* H. Locate the BAT QuantenVy PtpeVLne and Eciatpment Inspection Booh tn the Foneman's ohhtce I. Locate the BAT PtpeVLne Inspection Zone on the map SL 002716 Page 13 PHASE V - BAT Openaton Tnatntng Manuat _______ _______ _______ _______ _______ _______ _____ _______ _______ _______ _______ _______ _______ _______ _______ _______ _______ _______ _______ _______ _______ _______ ---------_______ XI LOCATE THESE MAJOR PIECES OF BAT UNIT EQUIPMENT: A. Nonth Vzcktoninat-Lon Tna-ln Tank-6 TO7 T02 B. Soutk DzzkZon^na-i-ion Tna-Ln Tnah-6 TO 3 TO 4 C. Sodium Fonma-tz Vz-6tnuction EHiuzni Manifold D- Incinenaton Szcondany Sznubbzn Manilatd E. Sodium Tk-io-6u-t4atz Stonagz Tank F. BAT S-tzam Stnippz;u> G. BAT Stzam Stnippzn Ezonomizen* H. BAT S-team Stnip pen Condzn-6zn-6 I. Rz44.uk Pka-6z Szpancuton-6 J. pH Ad j u-6-tmznt Tank-6 TO5 TO6 K. Eq.uaJtizaXion Tank-6 L. Rap-id M-Lx Tank-6 M. FtozzutaXon Tank-6 M. Spti-ttzn Box 0. Lcunea. Gnav-Lty SzttJizn-6 P. Studgz Tk-Lckznzn Q. Bz-tt Pnz-6-6 Fzzd Tank R. BzJtX Pnz-6-6 S. F-itinaXz Tank T. Bzit Pnz-6-6 U)a-6k OJa-tzn Tank U. Maztnza-t-M Tank V P/T Stonm UOcLtzn Sump and Pump-6 W. VC-11 Stonm waXzn and Pnocz-6-6 U)aXzn Sump-6 and Tank X. TE-ir Sionm UJaXen Sump and Tank SL 002717 of l4fhC7 r Protective Order Judicial District Court No. 91-1145 Pagz 14 PHASE V - BAT OpznaXon Tna-Lning Manual XII QUALITY A. Read tk(L M^-6Ion Stcutzme.rU. oj -the. WTU QLT S. Re-v-tetu -the SPC Chart 4or Copper -t>a/npe->> C. Identic >J the. PONC Item 4 or the. BAT U rvit V. locate, and Read the Internal Contract** In the Control Room E. Locate and Read the Internal Specif icatloru, In the Control Room Internal Spec booh F. Locate the Blank. Improvement Action Form* in the Control Room SL 002718 canwSSrt oraer subject DistrK CU oE nrn- -U45 Page 15 PHASE V - BAT Operator Training Manual 1 J XIII GENERAL A. Read the, poH.Csce-4 o the. WTU Contnot Room B. Re.vte.ut -tha othesi u.ntts> tn the Control Room by n,za.dtng the. Wcute. Treatment. Sesivtc.esi CcLpabtttttz^. BookJieX Si 19 CONFIDENTIAL; Subject to Protective Order of 14th Judicial District Court No. 91*1145 Page 7 6 PHASE V - SAT Opewtoa TnasLntng Manual / Gutdetinet ton SAT Qoenaton OnxUL Te^t Tett II SAT Openaton Tnaining 0JaU.fi to Vechtonination unit. A4k tnainee what o count, /tow, when and why. What it the. importance o4 the. oven4tow vatve to Out4att 201? How doet the. T04 Levet Contnot Vatve wonh. What one. the. capacitiet o4 the. Qe.ehtontnati.on. Feed pump4? How do you. untoad a thio4ut4ate tnuch? What it the. 4un.eti.on. o4 the anatyzent in. the Qechtonination Unit? Home att anatytieat equipment in the Unit. Watk to SAT Stnippen Unit. Atk tnain.ee to decentbe the pn.oc.et4 4tow4 to the Stnippen Feed Tanht. How do the Stnippent wonh? What it the Junction o4 the phate tepanatont, condentent, economizent? Whene doet the 4&ow 4nom the Stnhppent go? WaJLh to the Hetatt Remo vat Unit. A4k tnoinee to detentbe the entine pnocet4 4nom the pH adjuttment tanht to the bett pnet4. How doet the 4ptit nange vatve at TQ6 wonh? What pH do you, maintain in the Unit? How tong do you have to connect a pH adjuttment pnobtem begone untotvabte pnobtemt 4tant? What it the impontan.ee o4 the Haztneat-fA? What doet the potymen do? How do the Lametta Gnavity Setttent wonh? What it the impontan.ee o4 the Thichenen, tank and what indicahiont one o4 utmo4t impontan.ee? How doet the bett pnet4 wonh (dny nun.) ? CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 CONFIDENTIAL: OfS1u4btjhecJt utdoicPPiarrolotteDecci tstiivtvreicOt rCdeorurt ! FOR BAT OPERATOR SCHOOL LQSATP THE. FOLLOWING MAJOR PIECES EQUIPMENT: 1. North Dechlorination Train 2. South Dechlorination Train 3. Which train will normally be used to treat the Incinerator Secondary scrubber water? 4. SFD Effluent and Incin Sec Scrubber manifold at Dechlor 5. Sodium Thiosulfate Storage Tank 6. BAT steam strippers 7. Stripper feed economizers 8. Stripper condensers 9. Reflux phase seperators 10. pH adjustment tanks 11. Equalization tanks 12. Rapid Mix tanks 13. Flocculator tanks 14. Lamella Gravity Settlers 15. Sludge Thickener 16. Belt Press Feed tank 17. Belt Press $L 0Z7 21 18. Filtrate Tank 19. Belt Press Wash Water tank 20. P/T storm water sump and pumps 21. VC-2 storm and process water sumps and tank 22. TE-2 st rm sump and tank CONFIDENTIAL- , protect iv Oruei: Subject to F , strict. CoaiJt 14th JuNdoic. ia91l -U45