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ACCIDENT PREVENTION MANUAL MANUFACTORING DEPARTMENT Baytown Refinery Revised 1959 Humble Oil & Refining Company EXX-MOR-003263 EXX-MOR-003264 /? Si C 'is/^ //? L^- ' X/v c <0 ACCIDENT PREVENTION MANUAL MANUFACTURING DEPARTMENT BAYTOWN REFINERY IVIIID MPTtMiH 1939 Humblo Oil A Refining Company EXX-MOR-003265 It is the duty of every man (o protect him self and those associ ated with him from accidents which may result in injury or death. Abraham Lincoln FOREWORD 1 The prevention of accidents requires a knowl edge of why accidents accur. Experience over a period of time results in a realij^Q^ CMtSMl ^nations are hazardous and produce accidents and injuries. Our realization then crystalizes in what we call safety rules, safe practices and advice. These have been brought together and constitute this Accident Preven tion Manual. Almost without exception, each rule, practice or advisory item is the result of not one acci dent or injury but of many. They are not from the experience of one man, one department, one plant or one industry. They are from the col lected experience of all industry. Therefore, it follows that the individual who mistakenly pits his own good experience against this collective experience is taking a very defi nite risk of injury. If the safety rules, safe practices and advice contained in this manual are observed many accidents will be prevented. It is recognized that no manual can cover all possible situations which may arise. How ever, a thorough knowledge and observance of these rules and practices and this advice will develop an appreciation of what constitutes a hazardous situation and what can be done about it. EXX-MOR-003266 FOREWORD (Continued) protective devices. It is expected that every employee will use tools and equipment properly and keep them in good condition, that he will use the protective devices which are provided and that he will practice good housekeeping. It is expected that he will be a safe worker. There is no part of our jobs more important than safety, H. W. Ferguson EXPLANATION This revision of our Accident Prevention Manual has been made in such a way as to establish a definite distinction between a Safety Rule, a Safe Practice and Advisory Material, in order that all employees may have a clear understanding of the relative importance of each item. In general, all of the Rules, Practices and advice contained in the Manual should be studied care fully and practiced constantly. In order to provide a uniform basis for enforce ment of the Rules and Practices, all of the ma terial in the Manual has been divided into three classes mentioned above. This division was made by the Foreman and Division Heads on the fol lowing basis: A Safety Rule covers a procedure which must be followed. (Safety Rules will be printed in red.) A Safe Practice is a procedure which should be followed. (Safe Practices will be printed in green.) Advisory Material is considered as informative or precautionary in nature. It is expected that employees will, in general, observe the pre- EXX-MOR-003267 EXPLANATION (Continued) cautions given. (Advisory Materiel will be printed in black.) While the divisions outlined above provide a means of determining what disciplinary action may be taken, it should be borne in mind that the violation of any of them may at any time carry and inflict its own penalty--an injury. These Rules and Practices are based on experi ence over many years. This experience has been bought and paid for in the coin of suffering and loss of time. If the Rules and Practices are known and observed the price will not have to be paid again. INDEX Page Number PART ONE--GENERAL Section A Responsibilities of Supervisors Section B For All Employees Personal Conduct Bicycles Clothing Compressed Gases Electric Equipment Electric Line Work Eye Protection Excavations Fire Protection Flue Gas Generators Furnaces and Fireboxes Glass Equipment and Containers Good Housekeeping Gauging and Sampling Guards and Handrails Hand Tools .. Hazardous Materials Hoists - Cranes .. Ladders and Stairways Life Belts - Life Preservers . .. 15 15 19 20 23 25 28 29 33 34 37 38 39 41 43 44 46 46 49 50 52 EXX-MOR-003268 INDEX (Continued) r INDEX (Continued) Page Number Low Temperature Operations Manual Material Handling 53 53 Operating Equipment General Petroleum Piping Portable Lights Power Tools, Portable Pumps, Turbines, Compressors Railr Js . Respi ry Protection Scaffok Stationary Machinery Welding and Burning Wire Rope, Chain, Manila Rope Asphalt Plant Operations 54 58 61 61 64 64 64 66 68 70 72 74 76 Hydrofiners, Hydroformers, Hydrodesulfuri zation and Dehydrogenation Units 76 Laboratories Phenol Lube Plant 77 79 PART TWO--PERSONAL PROTECTIVE EQUIPMENT Section A Respiratory Equipment Canister-Type Gas Masks 81 Page Number ! Canister Service Identification Fresh Air Hose Masks Air Line Mask or Supplied Air Equipment Abrasive Blasting Equipment Welders Air Line Mask Pressure Demand Respiratory Equipment Scott Air-Pak 30-Minute Scott Air-Pak Dust and Fume Respirators Chemical Cartridge Respirators 90 93 96 97 98 99 102 110 111 113 Section B Face and Eye Protection Goggles Prescription Goggles Face Shields Dust Hoods and Masks Acid Hoods Welding Hoods 115 115 121 123 124 125 126 Section C Head Protection Section D Hand Protection Chemicals and Irritants Heat 127 131 131 4/K 132 A EXX-MOR-003269 INDEX (Continued) Page Number Section E Foot Protection Falling Objects Heat Section F Body Protection Aprons and Suite Coveralls Section G Miscel Life Belts Sweat Pads Ear Protection Protective Creams Knee Pads Safety Shoes tous Items PART THREE--SAFETY SUGGESTION PLAN 132 132 133 134 134 135 136 136 137 138 139 140 141 143 id Part 1 GENERAL Section A RESPONSIBILITIES OF SUPERVISORS 1. The supervisor (defined as anyone directing people or work regardless of ordinary title) is charged with personal responsibility for preven tion of accidents. 2. He must cooperate with other supervisors m preventing accidents. a. All Operating Supervisors shall cooperate and coordinate fully with Mechanical Super visors to the end of promoting safe operations of mechanical work in the vicinity of their equipment. b. All Mechanical Supervisors shall co operate and coordi nate fully with Op erating Supervisors in all cases where work is being done on or in the vicinity of operat ing equipment. c. No work shall be started on operating units until the Mechani cal Supervisor knows definitely that the Op erating Supervisor has been notified what work is to be done and has given his approval to begin such work. Where procedures re- 4 ,1 1 EXX-MOR-003270 quire, this approval must be in writing (Hot Work, Entering, Opening or Blinding, Elec trical Work, HCCGO Work, etc.), d. When conditions arise, either before start ing a job or during the progress of any work, which m the opinion of a supervisor make it unsafe :o proceed, the work Shall be Stopped and he shall notify his immediate supervisor at once. 3 He must know the safe methods of doing the work under his supervision. 4. He must know the Safety Rules, Safe Prac tices and Advisory Items that apply and ob serve them himself by way of example. 5. He is responsible for the prot maintenance and correct use of all safety devices and per sonal protective equipment required for his work. a. The use of safety devices and protective equipment shall be required by supervisors at all times when needed. When in doubt as to the necessity of using safety devices and protective equipment their use shall be re quired. 6. He must instruct in the correct methods of doing the job. a. The supervisor shall explain in detail to a new employee the safety rules and safe prac- tices which apply to his craft or occupation. It must not be taken for granted that a new man knows his work just because he says so. b. The supervisor shall explain in detail the particular hazards of the department in which the employee is working and the precautions to be taken to insure his safety. 7. He is required to follow-up on his instructions and make certain that they are understood and carried out. a. Supervisors are held responsible for taking all possible and rea sonable precautions within their power to There's a lot in Safety for You prevent accidents. They shall satisfy themselves by observ ance and checkup that ACCIDENTS LAY OFF SAFETY PAYS OFF ! all safety rules and safe practices are being observed. b. Supervisors shall not permit the use of im proper or unsafe tools or equipment. 8. Supervisors are held responsible for the gen eral housekeeping conditions on or around the work of which they are in charge. 9. No set of written rules, however complete, can provide for all situations, contingencies, or emer gencies, which are constantly arising. Super- EXX-MOR-003271 r visors are expected to see that intelligence is employed m the selection of methods in per forming the tasks at hand. The following rules are primarily supervisory in nature and are tg be observed and en forced by the supervisor. 10. All excavations shall be adequately covered or properly guarded when left before the work has been completed. 11. Makeshifts of any kind shall not be used. 12. When work is completed all leftover mate rial, junk, tools and equipment are to be re turned to their proper places. 13. All conditions which may affect the safety of men or equipment must be reported at once. When correction is within the authority of the individual, it must be done immediately. 14. All single fixture portable handlamps must be of the explosion-proof type, except in those places where the fixed mount, take-up reel mechanics' lamp has been specifically approved. No portable handlamp, floodlight, or string t ' < light is to be used unless the outside globe or glass and metal guard (where provided) is in place. 15. Portable electric single or multiple outlet ex tension cords (plug boards), handlights and string lights should be constantly observed while in use. They must be returned to the tool room at the end of the job for which they were is sued, where the job is of less than one week's duration. On jobs extending beyond a one week period they may be inspected in place by a qualified person in lieu of returning them to the tool room for such inspection. 16. Supervisors in charge of operating equip ment must make certain, by personal observa tion, that pressure is off, lines and equipment are drained '. ere necessary, vessels and lines are blanked , ' where needed, valves are locked or tagged if necessary, and that it is safe to per form the work before authorizing Mechanical Supervisors to proceed. Particular checking should be made on all acid, caustic, or operat ing equipment. When necessary adjacent or connected lines or equipment should be pro tected against their being broken. 17. Arrangements shall be made to contact at regular intervals, all men working alone in iso lated locations, by telephone or otherwise. These contacts shall be made at least twice a shift, at equal intervals, in addition to the contact at the beginning and end of the shift. More frequent contacts shall be made if the conditions are such as to justify it. 13 i EXX-MOR-003272 r 18 When work is completed all guards, hand rails, etc., must be replaced. 19. All installations requiring the placing of elec tric circuits or conduit underground are to be protected by a layer of concrete to which red coloring matter has been added, 20 Gas tests must be made before entering an open top vessel or excavation where a man's head will be below the top of the vessel or ex cavation. Such gas tests must be repeated at frequent intervals in recognized gaseous areas. Care must be exercised to see that all possible sources of gas accumulations are found and cared for When it is impractical to prevent pos sible gas accumulations, the necessary precau tions must be taken. These may be the use of adequate ventilation or the use of proper per sonal protective equipment. 21 No connections into or alterations to the do mestic water systems shall be made without the knowledge and written approval of the Utility Department Head. 22. The number of employees working on or around an Operating Unit must be kept to an absolute minimum when that unit is being taken out of operation or being put into operation. The Operating Supervisors are responsible for advising the proper Mechanical Supervisors when such operations are in progress. Mechani cal Supervisors must notify the operating per sonnel when they are starting work on any part of an operating unit 23 Exceptions to the Life Belt Rule No. 135 shall apply jnly when experienced men are used on the work. Any time a man inexperienced in the listed occupations is assigned to a job in volving an altitude hazard, he shall be required to wear a life belt, j-T ^Tfttf^ency showers and eye fountains shall c?r checked for correct operation once each dav by the operator on day shift. " Section B FOR ALL EMPLOYEES Personal Conduct 1. All injuries no matter how slight must be re ported to the Medical Department immedi ately. )OOD^ V* / / vs 2. An employee getting his clothing saturated with oil or chemicals must remove the con taminated clothing and wash the parts of his body affected with water. After obtaining a suitable covering he will report at once to the First Aid. 3. Before starting any work on equipment spe cific approval must be obtained from the basic Jk15 EXX-MOR-003273 r equipment owner or his authorized representative m accordance with the procedures established for the work to be done. 4. Notify the operator when coming onto an op erating unit. Do not remain within the unit limits of an operating unit without the specific approval of the operator. 5. Place tools or material on scaffolds, tank bug gies. top of towers, platforms and other ele vations in such a manner that they will not create a tripping hazard or become dislodged and fall. Before moving tank buggies or scaffolds all loose objects must be removed or secured. 6. Before throwing or dropping material from above, the area below' must be properly blocked off or guarded to prevent anyone from passing underneath or creating an additional hazard, such as breaking a pipe line. 7. Conduct which may be termed "fooling" or "horseplay" is strictly forbidden. 8. Climbing over rail road cars, crawling or sitting under such cars or attempting to pass be tween cars that are standing close together on the same track, except at loading racks, is forbidden. 9. Employees must never usecompressed air to clean their clothing or their person, and the air hose must not be pointed toward anyone 10 When using a steam hose extreme be taken to see that no one is in the path of the steam. 11. The use of any makeshift apparatus is pro hibited. For example drums or barrels must not be used for workbenches, supports for scaffolds, etc mg on lines -- fitting-; IS Avoid walking ',n itt fire; r. oosif-; roofs or defective roof- 16 Exercise ;:vs<--v ;o , revirt son, so nor.: walking m the vw.nitv S' Antes holding ' .t-avi EXX-MOR-003274 .' -i -- -:i sr.cula keep :.e.-r -,f 3-speeded loads h-.cV'.r prartioal. J derive equipment h - -1 'e rrps.red or re- 3 3L'..p. as pos avh kMt >nkti t J, ' irt, jjirMf." , ' - a 2 o. r pi jpe r ' a. h - n lifting, d _ 'aci: as nearly ..p"':nt = r,rs:b'- using th: leg muscle' L7se a ' u ,si : ' m ove large r.-avi ohiejts 20. In cases of serious injuries and injuries which might be serious even though apparently not so, call for the ambulance. Dial the Telephone Operator (Dial "O") and give specific information as to the exact location where the ambulance should go. If possible state the extent of the injuries. Give your name and number. 21. First Aid in emergencies is the only occasion when anyone should render aid to an injury. Even then be certain you know what to do. When an individual is not breathing due to drowning, electrical shock, or being overcome by gas fumes, start artificial respiration immediately. Have someone call a doctor as soon as possible. 22. Every employee should consider it a part of his duties to take an active part in all safety work. and should be on the alert to observe and report to his supervisor or the Safety Department any hazard or unsafe condition. 23. To avoid contamination, lunches should not be stored or eaten in areas subject to exposure to toxic materials such as phenols, lead, mercury, aromatics, etc, 24. Wash the hands frequently, always before eating. 25. Use ladders or scaffolds where necessary. Avoid standing on, climbing over or pulling against small pipes such as gauge lines and meter connections. Report promptly any breaks or leaks in such lines. 26. When cutting out rivets or metal, see that no men are working in front of you. Bicycles 27 Bicycle riders must keep to the right side of the road, except where directed otherwise by the traffic signs. 28. Stunt or trick riding on bicycles is prohibited. A firm grip must be maintained on the han dle bars at all times with at least one hand; how ever, it is preferable that both hands be used. 29. Do not attempt to carry heavy or cumber some bundles or fragile materials while riding a bicycle. 30. All bicycles must be EXX-MOR-003275 equipped with reflectors on the rear. - , w'n ' r r; 34. Inspect your bicycle frequently. The brakes should be checked frequently to be certain they are in good condition. Be sure handle bars are not loose. 35. Exercise special care when riding on wet, muddy, or slippery surfaces, and when crossing railroad tracks. Loose shell and gravel have caused many bad spills. Clothing 36. Wear protective hats when working in places where any hazard exists from falling objects. 37. When working on equipment in acid, caustic, or other chemical services wear clothing covering the body. Wear goggles, protective gloves, and where necessary, rubber aprons and boots. 38. Employees must not wear neckties, dangling sleeves or other loose clothing while operating or working close to mov- mg machinery, Gloves must not be worn while using fixed mount abra sive or buffing wheels when the operation in volves bringing the hands close to the wheel. SEE, HARDWAY- tk probably didn't wtar l^^cktbmq 39. All employees wno regularly work on jobs where there is a prob ability of exposure to hot oil, steam, flash fires or skin irritants or any other material which may cause body burns should wear clothing covering their body. This should include some type of arm covering. Employees who m the course of their work are only occasionally exposed should also follow this practice when in operating areas: (1) for self protection and (2) to set a good example for those employees regularly exposed. When additional protective clothing is necessary it must be secured and worn. It should be recognized that synthetic fabric, such as nylon, dacron and orlon offer ineffective protection. Cotton and wool clothing offer sub stantial protection. EXX-MOR-003276 40. Do not tie or attach a rag to your person in such a manner that it cannot be removed w'th one quick movement. 41. Long-cuffed gloves.-should be used in draw ing hot oil samples. 42. No rings, earrings, bracelets, necklaces, wrist watches, etc., should be worn when one is work ing around moving machinery or when exposed to chemicals. 43. The following safe practices regarding cloth ing for women shall apply to all women em ployees, except those whose work is confined entirely within an office. a. Shoes: Leather shoes with low heels (not over one and one-half inches high) shall be worn. Open toes or heels are not permitted. b. Dress: Coveralls are preferred; however, overalls and shirt or slacks and shirt or sweater will be permissible. Loose frills or trimmings are hazardous and should not be worn. Long sleeves should be worn where required by Safe Practice No. 39. c. Herd Covering: While working around moving machinery the hair must be completely covered by a close fitting net, cloth or cap. When working around an open flame the hair must be closely confined. If a flying spark hazard exists the hair must be completely cov ered. When working where a falling object hazard exists, Safety Rule No. 36 applies. 44. When working in the open protect yourself against injurious action of the sun's rays by wear ing proper clothing. 45. Do not work in oily clothing as a flash might prove fatal. Have work clothes washed frequently. 46. Do not wear defective shoes. Thin, torn or slippery soles can cause falls. Avail yourself of the privilege of purchasing safety shoes through the Company and wear them at work. Compressed Gases 17. Protective caps must be kept on compressed gas cylinders at all times when cylinders are not actually connected to equipment 48 Slings must not be used for lifting cylinders 49 Oil or grease must never be used on valves or fittings of oxygen cylinders. 50. Do not attempt to repair leaky valves on cylinders or regulators--remove the equipment to an open space away from fire or workmen. 51. Keep cylinder valves closed at all times when equipment connected to the cylinder is not in at least intermittent use. EXX-MOR-003277 la y:enmg ; .ylxda vs:v,,- stand :o one s;d? m?. f; ; a :k :r:r." press j.= gauge ;hr r:g_,U._: 55 .-a hammer shouiu r.e,'?r be used `km opening ^'binder valves 56. Care should be taken in handling compressed gas cylinders to avoid knocking them over or dropping them. 57. Empty cylinders should be removed from job before resuming operations. Keep oxygen and acetylene cylinders separated whether empty or full. Keep cylinders in as cool a place as possible. 58. Never allow oxygen to strike an oily surface or to come in contact with oil or grease. Fatal explosions have been known to result. Keep gloves and clothing free from oil when using oxygen. 59. When working in a confined space, care should be taken to see that no compressed gas escapes into that space. Leakage of compressed gas may create a hazardous condition from the standpoint of fire, toxicity or asphyxiation. In the case of oxygen, it will be readily absorbed by clothing and subsequent contact of a spark with the clothing may result in serious burns. Electric Equipment 60. Only authorized employees shall start electrically-driven equipment. In the-event that it does not start or run properly they must not tamper with it. 61 In cases of emergencies duly authorized and instructed individuals are permitted to change cartridge-type fuses up to and including 440 volts. Under all other circumstances an elec trician must be called. 62. Vapor-proof globes are not to be removed for any purpose, except for cleaning or by those au thorized to replace burned out light globes. They must be replaced. This does not apply to ex plosion-proof fixtures, which can be opened only by authorized persons. 63. All electrical equipment must be properly grounded. 64. On portable electric equipment with an out side ground wire, the ground connection must be made before making the electrical connection. Work the ground clamp back and forth at the point of connection so that rust, paint, etc., will be scraped off, thus insuring a good contact. 65. All portable electric tools and equipment, ex cept office and laboratory equipment, shall be inspected once a month by the Electric Depart- i 1 23 EXX-MOR-003278 no '00 Is jo - ^! !S ruse should ne .: dl.-. i r_ c * ;' :tpl in an ;~nrfger.C', and m mo on.ccr.-'1' t9. When working voltages or 4+, ,-o!rs or more vo xcenenoed men are reresscry One man m.L -:cep himse.r :n tbc okar and :r. position ' c. a r.:s o, orkmg mate when r.eccssa: \- Co not paint an switer:boards or near detrm equipmcr.i ontil an O rC is secured from me Electric Department '1 When operating nook and ey-- typ-. discon nects a clean dry 'hot-stick" and rubber gloves must be used Rubber gloves must be worn when operating pole top disconnects 7 2 Properly inspected rubber gloves must be worn when working about "live'' wires carrying 440 volts or more. 73. When opening high voltage box-type or other open cutouts a disconnecting pole ("hot-stick") and rubber gloves should be used. 74. An electric extension cord should not be used if it is in bad condition. Check each cord before using it for bad insu lation, broken grounds, or cracked or broken protecting globes. Avoid wrapping the cord around the arms or any part of the body. Avoid standing in water while using the cord. *>\ V r7 #- 75. Employees should regard all wires as live and dangerous and are warned against permitting any object being handled to come in contact with electric lines. The insulation on the wire is no guarantee that it will not cause instant death. Any wire found dangling from a pole or other electrical equip ment should be reported immediately to the Electrical Department. If no one is available at the Electric Department, the Plant Protection Department should be called in order that a guard may be furnished until an electrician can be secured. 76. If anyone should come in contact with live wires or cables and be unable to release his grip on the wires, do not attempt to pull him off with bare hands. Shut off the current if possible, and EXX-MOR-003279 protect the hands with rubber gloves or if they are not to be had, use thick folds of dry cloth to cover the hands before attempting to release the victim. If the wires are directly on top of victim use a dry stick to remove them. 77. Any defective electrical equipment should be reported to your supervisor. 78. Wherever possible portable cords should be hung overhead so that the insulation cannot be damaged by foreign objects or by workmen walking on them. Electric Line Work "y Linen.en snouid nor wear hocus while work ing on tr.e ground, handling heavy materials, or wal'-nr.g Loin one joo to anotner. - iViien piking ' , lie, support the pike at the shoulder--not at t ,-aist 81. Linemen should cany hand line up the pole for handling wire or other material. Groundmen should not throw' material to the linemen. Small tools should be raised in a bucket with a hand tne. When serving linemen, the groundmen should not stand at the foot of the pole--stand to one side. 82. When replacing defective poles, the old pole must be lashed to the new one before any sup porting conductors are removed. Do not remove all wires from a pole that is shaky, place pike poles around the pole first. j J ; i Eye Protection 83, No attempt shall be made by any employee to remove a chip or fort.gn substance of any kind from the eye, other than the use of an emergency eye fountain in case of chemicals 84. Employees must wear the correct type of goggles on all operations where a hazard to the eye exists. Consult your supervisor or the Safety Department as to the correct type of goggles to use. 85. The following work requires the use of gog gles; in addition, supervisors may require their use on other work not specified: 1. Anyone working near other persons where work requires them to wear goggles must also wear them. 2. Working where rust, dust, sand, coke or other foreign objects are blowing about. 3. Handling or mov ing junk, coke, brick cinders, garbage or trash. 4. Working in or go ing in and out of fire boxes. 5. Cleaning and blow ing t u b e s in boilers, stills, exchangers, economizers, flues, etc. A* 29 EXX-MOR-003280 metals asp~a,': pitch ^ chemicals 0 Handling memicals or opening .ortaincm n wh ch such material is received 10. Cleaning, making repairs or adjustments on lines o<- quiprpen'- wh: w contain or nave contained . henr.cais. hght nydrocarbons cr hot oil 11 Opening or closing or adjusting packing on all chem.icaJ or hght nydrocarbon valves 10. Opening, bleeding, venr-ng or draining lines pumps, vessels and > er equipment, which have contained chem s or pressure, either by opening dram valves or flanges. 13. Using air, steam or other agents to open any plugged line or vessel or when exposed to the discharge of such agents being used to purge equipment to the atmosphere. 14. Adjusting packing glands on compressors, pumps, engines, etc., while in operation. 15. Cleaning or lubricating stopcocks, valves, pumps or other equipment where grease plugs, pressure screws or grease guns are used. 16. Investigating or working on or around oil, gas, steam or chemical leaks. r as safety lives 'DVrl'S k t C . a ag e gaag' ai 2 n - C otv arc ::mg ar; S-via b -itC e Ch taping s.g any .ri r -asts _a':;ag rveaking reanaag -i Ar.crt a J.\mg chip j 1 Gi mdmg : i i . a g o .1 buffing e f a ! ! cm.is Ci All sci aping and cleaning on metal surark s ca Cleaning rernov r.g or tightening gauge glasses 24 Performing over head work which re quires looking upword. 25 Using air, steam or water hose for clean ing 26 All operations where there is a hammeung of metal against metal, except carpenters driving nails EXX-MOR-003281 rr -7 when vvorking in che vicinity of electric welding, wear goggles vvirh special lenses. 28. Heating rivets, riveting, caulking and bucking up. 29. Paint scraping. 30 Shearing scrap metal. 31. All welding and burning operations. 32. Working under rolling or stationary me chanical machinery or equipment. 33 Removing asbestos insulation, cutting in sulation, lacing up insulation, handling granu lated insulation and on all close insulation work. 34. Using pick or mattock. 35. Operating cement mixer, cement g' sandblasting, mixing, pouring and puddl, mortar or concrete. 36. Machine operations where a flying chip hazard exists. 37. Cutting and cleaning brick. 38. Drilling into pipe lines. 39. Heating and inspecting heated materials and equipment. 40. Working or replacing glass. 41. Handling rusty cable and materials. 42. Using portable pneumatic tools. 43. Using metal brush. 44. When pulling with pliers, when cutting wire under tension, or when handling wire where a hazard exists of loose ends flying. 45. Drawing hot samples of oil. 46. Drawing samples of light hydrocarbons, gas, or chemicals from lines, vessels or other equipment. 47. Starting fires in furnaces and inspecting fires and fire boxes. 48. Gauging any tank containing chemicals. 49. Drawing water when units are coming on. 50. Working at or near the forge. 51. Using a soldering iron, unless an iron onehalf inch in diameter or less is used. 52. Bending reinforcing steel. 86. No employee shall leave the plant when he xnows that his eye is giving him trouble as the result of circumstar ces connected with his work, without reporting to the Medical Department. This must be done even though the employee thinks there is no foreign substance in his eye. 87. All repairs to goggles should be made by the Storehouse. Excavations EXX-MOR-003282 men to work in any excavation in which the depth of the excavation is equal to or ex< eds the width of the excavation at ground level, and the depth of the excavation is four (4) feet or greater, the following minimum requirements must be met: a. When running soils are encountered the sides of all excavations four (4) feet or more in depth shall be secured by the use of solid sheeting or sheet-piling that is suitably braced b. When saturated, fill and or unstable soils are encountered, the sides of all excavations four (4) feet or more in depth shall be secured by planking or metal, or both, suitably braced to support the sides of the excavation. c. The sides of all excavations in hard com pact soil which are five (5) feet or more in depth and over eight (8) feet in length shall be securely held by shorting and bracing. d. Special consideration and thorough analysis of the situation should be made when it is necessary for men to work in an excavation where the width is greater than the depth and the depth is in excess of five (5) feet. 89. All excavations five (5) feet or more in depth shall be provided with ladders, or their equiva lent, conveniently spaced. Fire Protection 90. The use of burning or welding equipment, rivet heaters, forges, tar pots, portable emery wheels, gasoline torches, soldering equipment, non-explosion proof floodlights or portable elec tric tools, string lights or any other such equip ment, in locations outside of those areas ap proved for hot work, requires a "Hot Work'' Permit. 91. No hot work shall be done on any portable cleaned equipment such as steel drums, barrels, shell and tube heat ex changers, etc., which can be readily moved from place to place with the possibility of be coming confused with a like piece of equipment which has not been .leaned, except in ac cordance with the Hot ork procedures. Tank cars shall be governed by the regulations for working on tanks or enclosed vessels. 92. The use of gasoline or light naphthas for cleaning purposes is strictly forbidden. 93. Smoking, except at approved locations, and carrying matches other than Safety matches anywhere within the plant, are absolutely for bidden. 94. Before chipping, drilling or breaking concrete in the vicinity of operating equipment, permis sion must be secured from the operator and, in possible gassy locations, a Hot Work Permit must be secured. EXX-MOR-003283 95. Where a "Permit To Open" is to be given, it is the responsibility of the operator to determine that no "Hot Work Permit" is in existence with in the area which could be made hazardous by any spill from the opening. For the purpose of this determination all such openings must be considered hazardous. The area involved is to be considered as covering the geographical limits within which there is even a remote possibility of sparks from the hot work falling into any liquids or vapors which may be released by the opening or where liquids or vapors from the opening may flow or travel to a point where sparks might ignite them. If a "Hot Work Per mit" is in existence, the hot work must be stopped or the opening not commenced until the hot work is completed. If the hot work is stopped and, in the judgment of the operator, sufficient material is released by the opening to create a hazard, a new "Hot Work Permit" must be issued before hot work is resumed. 96. No welding or burning shall be permitted on a unit during shutdown or start up procedures. 97. Never use oil or grease on valves or fittings on oxygen equipment, drums or torches. 98. The use of air for opening plugged sewers is unsafe and prohibited. 99. Fire fighting equipment should be used for flies only. 100. Do not block access to fire fighting equip ment wich equipment oi materials. ' ' 1\ i .^6 -1) *li rw i-ilo- v-- "K-.* Usr on!} -in. dii 107. Familiarize yourself with the location of fire extinguishers, fire blankets, and safety show ers in the area where you are working. Flue Gas Generators 108. In the event of a flame-out either while attempting to light a flue gas generator or after it has been in operation for a period, be sure that the chamber is completely purged of gas before attempting to relight it. EXX-MOR-003284 109. The oxygen content of the flue gas must be maintained below the maximum prescribed lim its as set forth in the Operating Manual. Dan gerous or explosive mixtures will exist at higher oxygen levels. Furnaces and Fireboxes 110. When lighting the heat treating furnace the door must be open. 111. Operator must see that all fuel valves are closed tightly and the furnace vented for several minutes before attempting to light fires. The lighted torch must be applied to burner before the fuel valves are opened. 112. The fuel lines must be blinded or discon nected and plugged when the fires are cut out. 113. When lighting gas-fired pots never turn the gas on until you are ready with the lighter. 114. Avoid standing directly in front of firebox openings when lighting fires, stand to one side of the opening. 115. The pilot light (bypass) must be left open when the furnace is in operation. 116. If it becomes necessary to do mechanical work on a vertical furnace while it is in opera tion, the approval of the Operating Foreman and the Zone Supervisor must be obtained. They shall be responsible for seeing that all pre cautions are taken while the work is being done Mechanical work on vertical furnaces, while in operation, should be avoided. Glass Equipment and Containers 117 Sample bottles are to be used only for those purposes for which they are furnished. They are not to be used for carrying drinking water, etc 118 Only clear round glass bottles with screw caps (quart or pint oil samples) may be used for sampling as follows: A. Samples having Reid vapor pressure in excess of 25 pounds must be taken in ap proved metal contain ers. .y- ACClQCSrS... don'i happen ?e the B. Round pint or quart glass sample bottles with screw caps may be used for samples with Reid va por pressures up to 25 pounds. SAFETY C. S a m p 1 e s having Reid vapor pressures of less than 15 pounds require no special protection or marking. D. Samples having Reid vapor pressures of 15 EXX-MOR-003285 to 25 pounds may be taken in approved glass bottles provided at least twenty per cent out age is maintained, and provided they are kept during storage or transportation in metal con tainers. The metal containers may be closed or left open as desired. E Samples having Reid vapor pressures of 15 to 25 pounds in glass containers must have a red tag attached solely for the purpose of indicating the vapor pressure. A separate tag should be used for sample identification. 119. Glass bottles three-gallon or larger, regard less of contents, or one-gallon or larger contain ing corrosive chemicals, shall be transported and handled only in a protective container. 126. Empty bottles and bottles containing clear products should not be placed where they might act as a burning glass and direct the sun's rays on flammable material. Good Housokooping 127. Remove or bend down all nails wherever they may be, using a hammer or other suitable implement, as protruding nails are a serious hazard. Do not bend down nails by stepping on them. All nails in the heads of kegs or wooden barrels shall be removed when the containers are opened. A 41 EXX-MOR-003286 128. Keep all aisles, passageways, stairs^ platforms and ladders clear of all obstructions. Material should not be placed where it will of fer a stumbling hazard, and should be piled with due regard to safety. 129 Never allow oily waste, oily or paint soaked rags or clothes to lie around. They should be placed in closed metal containers. Oily or chemically damaged boards should not be used to build scaffolds. 130. Any oil or chemicals spilled on stairs, plat forms or walkways or any other walking areas should be cleaned up immediately, it may cause a fall. 131. Waste material should not be allowed to accumulate but should be cleaned up and hauled away. 132. Floors should be kept clean and in good repair. 133. Wherever practical remove nails from lum ber before handling and be sure lumber with protruding nails is properly piled to eliminate danger of men stepping on the nails. 134. Bend all wire lacing and reinforcements to avoid exposed ends. Gouging and Sampling 135. Do not go on top of tanks during hurri canes, electrical storms or icing conditions. 136. Samples must be properly identified so that Laboratory personnel will be alert to the special hazards involved in handling the various ma terials. 137. Red tags are to be used on all containers holding samples having a Reid vapor pressure above 15 pounds. Approved sampling bombs are excepted. 138. Keep to the windward of hatches when gauging and sampling in order to avoid, as far as possible, breathing vapor or fumes as they may be harmful. 139. The small hatch is to be used for gauging and samping when pos sible. If the small hatch is inadequate for sam pling, the large hatch may be used for this purpose. When sampling is complete, be sure the large hatch is complete ly closed. 140. All hatches that are found open or partially open should be closed. If it is impossible to close hatches properly re- ____ 43 M J1 EXX-MOR-003287 \2'ners "nou'.d not be -!?<* d Guards and Handrails 145. All excavations must be adequately guarded or covered with planks to prevent anyone from falling or stepping into them. Planks of ade quate strength and length must be used. Covers and guardrails must be replaced before leaving a job where the work is not continuous. 146. Openings in handrails made to facilitate the handling of material must be adequately guard ed. Permanent handrails and guardrails must be replaced immediately after the need for the opening is ended. 147. Handrails must not be used as a support for material, rigging or scaffolds. Indiscriminate use of these handrails may result m their failure. The following loading conditions are approved where the handrails are in good condition, and installed according to Engr. Std. A15.02-10T: a. No rigging equipment of any kind shall be fastened to any part of the horizontal hand rail angles. b. Only very light rigging may be anchored to the vertical angles at the lower end, since a lateral force of 100 pounds exerted at the top in a direction perpendicular to the walkway may cause an overstressing of the post angle c. The maximum safe concentrated vertical load at mid-span on one horizontal angle is 300 pounds, with 600 pounds being permitted at the midpoint of timbers placed across the handrails. For this reason, the following pre cautions shall be taken: 1. No more than three 12-inch wide scaffold timbers shall be placed on any one 6-foot long span. 2. No heavy equipment shall be placed on these timbers. 3. No more than four men should be per mitted on these timbers at one time. 4. The maximum overhang of scaffolding timbers placed on handrails shall be 12 inches. The timbers shall be anchored in place with nails driven into the lower side and bent over the horizontal leg of the angle. 5. Vertical scaffolds erected over handrails EXX-MOR-003288 shall be supported from floor beams--not from the handrails. 148 Any employee removing covers from man holes or pits m floors or in the ground must re place them or see that the openings are ade quately guarded if left open. 1 -J-Q When working on a ladder, scaffold or piece of equipment over a road, walkway, or passageway a warning sign "Men Working Overhead," must be prominently placed below. Hand Tools 150. Do not use defective tools. 151. Use maul or ham mer on striking wrenches only. 152. The use of two open end wrenches to secure leverage by plac ing one into the jaws of the other is prohibited. A atm 153. Files without han dles must not be used (glass work excepted). 154. When using a wrench be sure it fits properly and in apply ing force push or pull evenly and steadily. Hazardous Materials Some commonly used materials and substances are not ordinarily thought of as presenting a hazard. Others are recognized at once as being definitely hazardous. Between these two ex tremes are many materials and substances which have the potential of being hazardous if im properly handled. If the word "chemical" is used we usually think of something dangerous. This may or may not be true. Strictly speaking, water is a chemical. However, it is not normally considered hazardous. In order to avoid confusion, the term "Haz ardous Material" is used for this section. A "Hazardous Material" is considered to be one which may cause injury or illness by (a) skin contact, (b) being inhaled or (c) being swal lowed. 155. When a valve, fitting, line or piece of equipment, which has been in a "Hazardous Material" service, is to be sent to any shop it must be tagged with the approved "Hazardous Material" tag. This tag must be properly filled out, showing the name of the hazardous ma terial, the name of the person applying the tag and the date. An exception to this is equipment in "Heavy Aromatics in oil boiling above 700 F" service where the special yellow caution tag is to be used. In all cases these tags are to be ap plied by the mechanical man who removes the equipment which is to go to the shop. 156. Where available a connected water hose must be at hand when equipment in hazardous material service is to be worked on where the material may cause injury by skin contact. EXX-MOR-003289 157. Caustic or acid solutions should never be placed in galvanized containers. 158. The air pressure used to remove any haz ardous material from tank cars shall not exceed thirty pounds per square inch. 159. Do not gauge acid or caustic tanks when materials are being unloaded into the tanks. 160. Hazardous material samples must be clear ly marked and carefully handled. Do not place such samples on high shelves, steps or walkways where they may fall or be knocked off. 161. When necessary to dilute acid, never pour water into acid, pour acid in water slowly and carefully. Avoid as much as possible disposing of acid in sewers or in places where there is water. 62 '/'otacue toxic materials sue.-, as benze-ie. aniline, bromine ,--anou': acids etc should be handled either under u hood having = g.,cd draft or in the open air sutside of any building or enclosure 163. Skin contact with all hazardous materials should be avoided. In ase of accidental contact with the eyes or skin the material should be washed off with large quantities of water. The injury, in most cases, is proportional to the time of contact so chat imavdiaw action is `deal. Any injury from the contact should be reported tc the Medical Department at once for treatment Any contaminated clothing should be removed ar.d not worn until properly cleaned 164. Specific information regarding the various hazardous materials which may be encountered is to be found in a separate booklet entitled "Hazardous Materials." Hoists-Cranes 165. Men are not allowed to ride on blocks, hooks, balls or crane loads. They may be hoisted in an approved sling or chair. 166. A warning signal must be sounded before rotating the cab of a crane. Helpers must then move to a position easi ly seen by the operator before the cab is rotated. 16" Hoisting Equip ment Operators should keep their eyes on the man giving signals. Do not allow cables to stack up on the side of the di urn. 168 In giving hoisting signals keep attention on ihe load . 169. When operating cranes or doing rigging work within ten feet of electric wires call the Electric Department and request the necessary protection. DO Drums on hoists are to be checked for sufficient turns of cable at all times and in no EXX-MOR-003290 instance, when under strain, should the number of turns of the cable on the drum be less than five. 171. When handling heavy loads with pneumatic tired mobile cranes or auto cranes which are provided with outriggers, the outriggers should be out and on good blocking. Such machines shall be operated on good hard firm ground or mats. 172. When hooking onto a heavy load with cranes that are equipped with swinging gear, see that the swinging gear is disengaged to allow the machine to center itself over the load 173. No hoist or chain block is to be used for a load greater than its rated safe working capaci ty. These tools should be inspected before each to assure that they are in good condition. l Operate all cranes and hoists under full control. In hoisting, keep the hands on the controls. 175. When operating traveling hoists see that no one is in the path of the load. Keep yourself in the clear at all times. Ladders and Stairways 176. Ladders must be in good condition. They must be equipped with safety shoes or securely fastened to prevent slipping. 177. Ladders must not be placed in front of a door unless the door is locked or adequately guarded. 178 Portable ladders used by an individual for a specific job must be taken down and placed in a safe place when the job is com plete. 179. In placing a ladder it should be placed so that the horizontal dis tance from the foot of the ladder to the base of the elevation to be reached is equivalent to approximately one fourth of the length from the ladder base to the point of support. 180. In descending a ladder always face the ladder and keep a firm hold. 181. When necessary to climb ladders, use a handline to raise or lower material, carpenters building scaffolds and riggers doing construction work are excepted. However, they should see that a reasonably free use of the hands is pro vided at all times. 182. Always use stairways, ladders or elevators. Do not climb the equipment. 183. While going up or down stairways avoid carrying tools or material in such a way as to prevent the free use of one hand. 184. When working from a ladder care should EXX-MOR-003291 always be taken to keep from leaning too far and falling. Ufa Belts--Life Preservers 185. An altitude hazard shall be construed as existing whenever men are required to work from any sort of scaffold, platform or other elevation which does not provide sufficient pro tection to the worker. Under such conditions men shall be required to wear life belts. Excepting: (a) Men working from approved scaffolds. (b) Men working on approved carriages. (c) Men working on roofs with less than onefourth pitch (on all other tank roofs men must wear lif- belts, also on any roof when working with.j- mx feet of the edge). (d) Riggers. (e) Carpenters erecting scaffolding or other timber framing. (f) Structural iron workers when erecting structural iron. 186. When a life belt is worn, the life line must be supported independently of the scaffold, car riage or platform from which the men are working. 187. All life belts and ropes should be thorough ly inspected before being used. If found to be defective they should be discarded. 52 S'w. -N Low Temperature Operations 189. Equipment operating at low temperature must not be hammered while in service. 190. Equipment shall not be operated at tem peratures below the temperatures for which they are designed. 191. Vessels containing refrigerants including hydrocarbons, such as, propane, propylene, eth ane, methane, etc., shall not be vented to atmos pheric pressure until they are pumped free of liquid from the bottom draw off. 192. Cold liquids shall not be enclosed in vessels or lines without proper safety valves or venting to allow for thermal expansion. 193. Avoid body contact with liquid refrigerants. Manual Material Handling 194. Don't attempt to clean pipe threads c: flanges with your hands 195. When lifting, moving or carrying pipe keep the hands and fingers out of die mris of the pipe. Keep feet and hands from umiermarh pipe when it is lowered. 1 196. In backing off flanges, catch them with EXX-MOR-003292 bar or pipe, never with the hands. The motion or weight of flange may cause severe laceration. 197. When two or more men are lifting an object together they should agree on a given signal to pick up or let down, to avoid placing a strain on one man or throwing the load on him. Operating Equipment General The following Safety Rules, Safe Practices and Advisory Material refers to all operating equip ment: 198. When any work is to be performed inside an enclosed space under circumstances which would render the work or working conditions hazardous if external conditions should change, a requirement that a stand-by man be provided shall be specified on the pernr to enter or to perform hot work. It will prii ly be the re sponsibility of the operator who ,ns the permit to designate when the stand-by man is neces sary. The person performing the work shall be responsible for seeing that a stand-by man is provided. 199. When any work is to be performed inside an enclosed space where a hazardous condition exists or may be created by work inside or other mechanical work in the vicinity, one man shall be designated to remain in constant attendance immediately outside to give warning, or render assistance in any emergency. The supervisor in charge of the work shall be responsible for de ciding when a stand-by man is required, for securing the individual to function in this ca pacity. and for providing proper equipment and instructions. 200. The stand-by man shall be a rr a who understands the work being performed, who is capable of recognizing conditions which are haz ardous. and who can render adequate assistance in emergencies. The equipment to. be furnished (rope, extinguishers, blanket, gas mask, etc.,) shall be determined and secured by the Me chanical Supervisor in charge of the work. The instructions to be given the stand-by man shall be determined by the person or persons involved in the determination for the need of a stand-by man. If the stand-by man is assigned any other duties it shall be the responsibility of the super visor assigning the stand-by man to see that such duties do not take him away or detract from his primary duty as, stand-by man. If an operating man is available he may be used. 201. If at any time, either before or during the work, the inspector, operator, or mechanical su pervisor in charge of the work, thinks a stand-by is necessary, one shall be provided. 202. Before giving an O. K. for equipment to be repaired the operator must check that all the necessary precautions have been taken that the required permits have been issued and that the persons doing the work have been advised of any special hazards. 203. No one shall enter any vessel which has contained oil, chemicals or other harmful ma terials, until the vessel has been properly pre pared, and the necessary permits have been issued. 55 EXX-MOR-003293 204. Before returning equipment to service after repairs, the operator must inspect it to assure that it is in proper condition to operate. 205. When work has been performed inside any enclosed vessel, before closing the vessel a re sponsible supervisor must make a personal in spection to assure that all persons are out of the vessel. 206. Because of thermal expansion, liquid must not be blocked off in any line or piece of equip ment where the temperature of the liquid can be raised from any source of heat. Failure to bleed, vent or circulate the liquid may result in the rupture of the line or equipment due to thermal expansion and a possible subsequent explosion. Attention is called to refrigeration systems, ex changers, coolers, condensers, cooling jackets, steam traced lines, pancake coils, and sinr'ar types of equipment. 207. Operators must see that water or test liqu,-. has been drained from equipment hydrostati cally tested, after the final test has been made and before the equipment is placed in operation. 208. Tightening or adjusting of process equip ment in service must not be done until the Mechanical Department Mechanic doing the work has made a personal check of the work and received the approval of the Operating De partment. Some member of the Operating De partment must be in the immediate vicinity when the work is being done. 209. Guy lines are not to be made fast to refinery operating equipment, pipe lines, tanks or their supports unless authorized by the Basic Equipment Owner. 210. Never enter a hopper car while the unload ing facilities are in motion. 211. Do not blow a tank with air where the flash point of the liquid is below 150 F. When air is used to blow liquid in a tank, be sure the air is closed off before going upon the tank to gauge or sample. 212. Packing must not be removed from a gland by blowing it with pressure. made sur- *.ha other val'es proper'.knt i m and other -molovees are in the clear 115 in cutting a steam line into service see that all condensate is drained fiorr. hnrs to avoid dangerous water hammer >\n Do not shut in vessels A-ineh : jntain steam or ocher condensible vapors Ceding > ill con- EXX-MOR-003294 dense the vapor and produce a vacuum which may collapse the vessels. 217. Never bleed light hydrocarbons into the air at a rapid rate of flow as static electricity will be generated and may ignite the flowing light hydrocarbons. Whenever light hydrocar bon must be released to the atmosphere it should be done slowly under a blanket of steam. 218. Do not insulate any leaks in lines, fittings, stills or towers Before covering any equipment with insulation, observe that all bolts are in place and tight. Petroleum 219. The light aromatic hydrocarbons present additional hazards to those of the ordinary pe troleum hydrocarbons. In addition to the vapor inhalation hazard, they may be absorbed by skin contact. Care should be taken to avoid skin contact. (a) Before entering vessels or enclosed areas, such as pump pits, where light aromatic hy drocarbons have been stored or handled, a gas test must be made to be sure the concentration is within safe limits. (b) Gas masks and protective gloves must be used when gauging and sampling these ma terials in tanks or tank cars. I (c) Protective gloves must be used when sampling these materials at units. (d) In case of skin contact with these ma terials they must be immediately washed off with soap and water. 220. Heavy aromatics in oils with a boiling point of 700 F. and above may cause a serious skin irritation. This irritation is most likely to occur upon continuous repeated contact. However, any skin contact with these oils should be avoided. In order to secure adequate protection the following regulations are to be observed: (a) When sampling or gauging on equipment handling these oils, extra care should be taken to avoid skin contact. The hands should be washed with soap and water after such operations. (b) When opening or cleaning equipment processing or handling these oils protective equipment such as impervious gloves, aprons or suits, etc., must be used. (c) In case of skin contact, the affected parts must be washed with soap and water. (d) If any of these oils are spilled on the clothing, the clothing should be removed and a shower taken. If a change of clothing is not available, coveralls may be provided upon authorization of the foreman or his author ized representative. (e) Any skin irritation must be reported to the Medical Department. EXX-MOR-003295 (f) Tanks and equipment handling oils con taining heavy aromatics shall be posted with the approved caution sign. (g) When tanks which have contained these oils are removed from service for cleaning, the Safety Department is to be notified. (h) When mechanics are given an O. K. to work on lines or equipment handling these oils, the line or equipment must be tagged with the approved caution tag by the operator designating the work. (i) When a valve, fitting, line or piece of equipment, which has been in heavy aromatic oil service, is to be sent to any shop it must be tagged with the approved caution tag by the person sending the material. The tags may be secured from the process operator. (j) All samples of these oils submitted to the Laboratories must be tagged "Caution--may contain skin irritants." (k) For additional detailed information refer to the special "Manual for Safe Handling of High Boiling Oils from Catalytic Cracking." All persons subject to exposure to these oils should secure a copy of this manual. (l) Any exposure to possible contact with these oils must be reported to the Medical Department in accordance with the procedures given in the above mentioned manual. 221. If highly volatile products come in contact with cue sKin > ash xherr, otf a: once as they max cause severe ourns If irritation or burning ro oms report to the First Hid Room a: once ic; treatment and then to your super','.cor Piping 22 2 All bleeder replacement; snuuld be mad-: trom extra neavy pipe minimum sire threequarter-inch If this :s not pram: a, the Techni cal Division should be called. 223 The following procedure is to be rolloxxod m opening all underground pipe lines ivr.ci,- the identity of the line is net known After the Operator has pointed out to the Mechanical Supervisor the line believed to be the correct one, a hole not larger than one-eighth-inch in diameter shall be drilled (wet) or punched into the line. Tim Operator shall then inspect the line to deter, : whether it is the proper one He shall then ,ssue a permit to open and or blind for the actual opening of the line. In all cases the Operator must be present when the line is opened. Portable Lights 224. All single fixture portable hand lamps must be of the explosion-proof type, except in those places where the fixed mount take-up reel type mechanics' lamp has been specifically approved. No portable hand lamp, floodlight, or string light is to be used unless the outside globe or glass and metal guard (where provided) is in place. 225. All single and multiple outlet extension 61 EXX-MOR-003296 cords (plug boards) must be equipped with explosion-proof receptacles. A Where Hot Work is not authorized, use only the following types of lighting facilities. 226. The use of an unapproved flashlight is prohibited. 1. Flashlights of the permissible type. 2. Approved portable explosion-proof hand lamps. 227. Only the standard approved string lights 3. Approved portable explosion-proof flood may be used. String lights shall be used only lights. where Hot Work is authorized, either by special 4 Approved extension cords (plug boards) Hot Work permit, or by designation of the area with explosion-proof fixtures. as open for Hot Work at all times. (The ap B. Where Hot Work is authorized, the fol proved string lights must be manufactured with lowing types of lighting facilities may be used. multiple (not less than two) moulded connec 1 1. Items as listed above under A-l, A-2, tions and fixtures, the fixtures to be colored red A-3, A-4, and each fixture to carry a warning label in 2. Approved portable string lights, manu black letters on a yellow background "WARN factured with two or more molded rubber ING-USE ONLY WHERE HOT WORK IS fixtures vulcanized into the flexible rubber AUTHORIZED"). cord, each fixture with outer globe and 228. Portable electric single or multiple outlet extension cords (plug boards), hand lights, and string lights should be constantly observed while in use. They must be inspected at the end of the job for which they were issued, but at intervals of not less than one week. They must be re turned to the tool room at the end of the job guard. 3. Nonexplosion-pn floodlights. C. Shops and Garage: 1. Items listed above. 2. Fixed mount take-up reel type mechan ics' hand lamp upon specific approval of location. for which they were issued where the job is of 231. Attention is called to the fact that ex less than one week's duration. On jobs extend plosion-proof electrical equipment approved for ing beyond a one-week period they may be Class 1 Group D service, which is "atmospheres inspected in place by a qualified person in lieu I containing gasoline, hexane, naphtha, benzene, of returning them to the tool room for such t butane, propane, alcohol, acetone, benzol, inspection. ' lacquer solvent vapors, or natural gas," is not 229. All repairs to Company flashlights must be made by authorized persons only. safe for use in Class 1 Group B service which is "atmospheres containing hydrogen, or gases or vapors of equivalent hazard such as manufac 230. Approved Portable Lights. tured gas." EXX-MOR-003297 232. Attention is called to the fact that the port able blinker lights now in use are not approved for Class 1 Group D service and discretion must be exercised in their use. They should not be placed in known or expected gaseous areas. Power Tools, Portable 233. Use rubber band or friction tape to retain pins on impact wrenches. 235. When operating portable grinders care should be taken to warn others working close by. Pumps--Turbines--Compressors 236. Governors on steam turbines should be tripped every month and inspected every three months, and should be kept well oiled and in good condition at all times. 237. In starting reciprocating pumps be sure the discharge valve is open. 238. When starting steam turbines stand out of line of the rotating elements. Never allow any one to stand on the side of the turbine or in direct line with rotating elements. 239. Steam lines and steam ends of pumps should be drained and vented before starting up and after shutting down. Railroads 240. No permanent or temporary installation r shall be closer than V-2" horizontally or 23' vertically from any railroad rail without specific authorization by Railroad Department Fore man. In all cases he must be notified before such installation is made. 241. Do not board or ride on railroad equip ment unless you have been authorized to do so 242. When working in or on any railroad car (box car, tank car, gondola, etc..) the standard blue flag and derail must be placed at the open ends of the track. 243. Regulation "STOP" signs (Blue Flag) must be set out to protect all loading racks or spots before connections for loading and unloading operations are made. These signs a^e to be placed at least three (3) car lengths om the end of the loading rack or spot. Wh, derails are provided they must be in place anu locked. Static ground wire must be attached before con necting any cars, containing or to contain prod ucts with a flash of 150 F or lower, for loading or unloading. Ground wires must be removed before ordering switch. 244. Browning crane must not be operated on railroad tracks without first securing permission from the Railroad Supervisor. 245. Browning Crane Operator must return all switches used to the same position as they were before he used them. 246. Whenever a section of track is under repair and is not safe for trains to pass over, that sec- 64 EXX-MOR-003298 tion of track must be protected by a blue flag and derail at the open ends. 247. Jumping f -m rack to car, or from car to car, or from car to ground is prohibited. 248. Use extreme care when walking the rail road track or crossing in front of moving cranes, locomotives or trains. Stumbling or tripping may result in serious injury. Respiratory Protection 249. Where a gas haz ard exists a gas mask of a type suited to protect against the specific con dition must be worn. When opening any line or equipment containing gas, a mask must be worn until the pressure on the line or equip ment is completely re leased and the area free of gas. Where the pres ence of hydrogen sul phide (H,S) is known o: air mask must be worn u line or equipment is completely released and the area free of gas. 250. The following work requires the use of res pirators; in addition supervisors may require its use on other work not specified: Dust Respirators: (b) Installing or repairing lead lining in enclosed vessels or enclosed spaces. (c) Cleaning tubes m boilers, stills, flues, etc., where a dry or dusty condition exists. (d) Dismantling concrete, brick or other materials of a similar nature. (e) Acetylene burning and cutting in con fined spaces. (f) Handling materials in powder or semi powder form or which cause dust particles to be present in the atmosphere (aluminum sulphate, bulk soda lime, sulphur, filter clay and all powdered chemicals). (g) Handling litharge. (h) Filling sandblast and gunite machine. (i) Handling cement in enclosed areas and dumping cement bags. (j) Anyone standing or working near other persons whose work requires the use of a respirator must also wear one. Canister Respirators (k) All paint spraying operations, except in approved booth or when spray painting with lead which requires a supplied air respirator. (l) All operations where annoying or irri tating gases or fumes may be present in such small quantities that large gas mask EXX-MOR-003299 canisters or supplied air equipment are not needed. 251. Shop men must always use the suction fan and spray booth when spray painting in the shop, unless otherwise directed by the foreman m ' - ''; --- D ; n=nt 253. In mounting stairs with a mask on, walk up slowly and rest a minute at the top before beginning operations. 254. Guard against harmful gases generated by faulty combustion or volatilized by heat. Lead, paint, and poor ventilation are common hazards. Scaffolds 255. Trestle scaffolds must have a base with the least dimension equal to not less than one-half the scaffold height. The scaffold legs shall be spread at equal angles from the vertical. 256. Trestle scaffolds shall be decked, where possible, with a minimum of three 2 x 10 boards. 257. Each decking board shall have an overhang of eight to twelve inches on each end. 258. When erecting scaffolding close to any electric wires or equipment, if there is danger of contact by workmen, the Electric Department must be notified and the necessary protection requested. 259. Swing scaffolds must be lowered to the ground and lashed around the hanger when workmen leave. 260. A safe means of access should be provided to all scaffolds. - i _ :.z . i i. ' '- cuat-'b.' .Ur'1' ' -m '. 1 r - i " ' -.c.c sub-tani .a', rrar rr.up-._p n . r' " " ~n guardrails Us- e-mugl. p'anks rscv'.1,. sum sirnt footing In2 The rsposmi -;dg;-s m -Cn^'id- si.mM ->e guarded bv s-,,n la-i ra U - v ""i es" maffcl Is .65 F a Is- 0 dgs-S nr s. ...0 'It'"- "' i maximum .iistar.se -f s.\ '.t-- t omm- 264. When swinging scaffold is erected it must be tested by raising the platform one foot from the ground and applying the load. Always in spect the air hoist, tie off chain and tie off ring. 265. Do not overload any scaffold or platform. 266. The practice of extending scaffolding by placing a plank across two tiers of bricks is satisfactory provided it does not exceed 12/r in height. 267. Scaffold material should be carefully in spected before each use. EXX-MOR-003300 r I I I 268. Scaffolds should be constructed to provide sufficient working space to permit workmen to move freely and safely about their work. 1 nere should be sufficient head room. 269. See that scaffolds on hot equipment are protected to prevent fire, injury or damage. Re move all such scaffolds promptly after job is completed. Stationary Machinery 270. The operation of any machine except by an authorized employee is prohibited. 271. Do not work on any machinery while it is in motion if it is practical to shut it down. All guards must be kept in place while the machin ery is in motion and not being worked on. 272. No major repair work should be done over moving machinery. When working close to mov ing machinery a guard must be provided be tween the machinery and the men working. 273. Tool rests on abrasive wheels must be kept adjusted close to the wheel and above the center of the wheel. 274. Only authorized employees shall be per mitted to change or replace grinding wheels on permanent installations. 275. In machine sawing, small pieces should be pushed with a stick. 276. Never reach over a moving saw to get ma terial from the other side. 70 277. Leave all guards in place when sawing, if possible, and do not go away leaving a saw running. 278. When operating a machine, keep hands and fingers in the clear. 279. When using a drill press the work should be securely clamped to the table or in a jig or chuck. When part is held in hand, an accident is likely to occur should the drill catch or stick. 280 Do not attempt to operate a machine until you have acquainted yourself with the operating switches. 281. Do not stand directly in front of a press when using filler block or in line of work when pressing off tapers. 282. Do not use emery wheels that are out of round, or stand in line of high speed wheels 283. a. Be constantly alert when operating the steam hammer, never put your hands under it. b. When flanging or otherwise forging bulky pieces, use sufficient blocking to pre vent overbalance. c. The steam hammer should never be used on cold steel. d. Take the chill out of all tools before using them under the steam hammer. e. Do not forge material at the steam ham mer below a dark cherry red. 284. Do not use the hands to remove metal cut tings from pipe, rods or other material being 71 EXX-MOR-003301 cut, machined or threaded. Use a rake or brush and prevent cuts. Welding and Burning 285 Cutting or welding must not be done using an empty cylinder, barrel, or dium as a work bench. 286. Cylinders must never be taken inside of the container upon which work is being done. 287 Provide adequate ventilation in areas where natural air circulation is limited before welding and burning operations commence 288. Gas welding and burning torches must be removed from all vessels or closed containers, or the hose must be disconnected at the regu lators, at the end of any shift when the torches will not be used in the vessel or closed container on the following shift. 289. If the use of a gas welding or burning torch in a vessel or closed container is discontinued during a shift, with no definite assurance that its use will be resumed during that shift, the torch must be removed or the hose must be dis connected at the regulator. 290. Welding machine grounds must not be made to handrails, stairs or to projections from receiving houses, pump houses, steel power or lighting towers, or on any active oil, gas, steam, air or chemical line. Work grounds shall be made to the object being worked on and as near as practicable to the place where the welding is to be done. The location of grounds for weld ing m any area where a Hot Work Permit is required shall be selected jointly by the welder and the individuals responsible for Hot Work Permits. 291. Before burning into or heating any hollow or partially hollow vessel or equipment; such as ball floats, pistons, impellers, enclosed vessels, pipe, valves, fittings or similar equipment, which has been in service of any kind, the vessel or equipment must be properly vented, unless the operation is performed under controlled condi tions so that any overpressuring will be avoided, as in the case of heating barrels of oil or opening plugged lines or similar operations. 292. Arc welding sets must be located in places free from vapors. When placed in the vicinity of operating equipment, the location must be approved by the operator. 293. Welding Oil and Gas Lines in Service a. No welding shall be allowed while the line is being moved in any manner. If weld ing machines are in the proximity of the handling of the line all motors shall be stopped and torches, if being used, shall be extinguished. b. No welding is to be done on oil or gas lines in service if the internal pressure is below atmospheric. Oil lines must be full before any welding is permitted on lines in service. c. The work ground connection shall al- 73 EXX-MOR-003302 ways be fastened to the line that is being worked upon, and under no circumstances shall welding be allowed on any other line than that to which the ground connection is attached. 294. When welding and cutting m high places provide a means of catching hot metal, electrode stubs, etc., where a fire hazard can be created or where others may be struck by the falling objects. 295. No caulking of leaky couplings or other fittings should be allowed within 200 feet of any welding operation, or welding machine running idle. 296. Before plugging in or removing the 440 volt connection, the power line switch should be .,Dened to prevent a flash. Care should be taken >. see that the 440 volt plugs are kept dry and ipat all welding cable sections are properly joined and kept dry. When operations are dis continued during the shift, the power line switch should be opened to shut off the power. At the end of the shift the machine should be discon nected at the main power source. 297. In electric welding, all parts of the body should be covered to prevent skin burns from ultra violet rays. Wire Rope, Chain, Manila Rope 298. Chains are to be used only in places and on work where their use has been specifically authorized. 74 299. Repairs must not be made to chains by bolting links together. 300. Hemp rope is not to be used for slings on material contaminated with acid. 301. Do not place any guy line, mooring line or load line in such a position that it will tighten against refinery operating equipment, pipe lines, tanks and machinery. 302. Rope, caDle, or any type of sling should be protected with pads or blocks where it is taken around sharp edges. 303. Hand or guide ropes should be attached to the hoist tackle and, in case where loads have a tendency to shift position, half-hitches should be placed over the loads. One-half inch rope is to be used for handlines only and is not to be used as a drift line. 304. Hoist cables should not be used if more than three outside adjacent wires are broken within a length of one lay, or if outer wires are worn two-thirds of their original diameter, or if marked corrosion appears. 305. Avoid the use of ropes which show exces sive wear or which may have been weakened due to exposure to the elements or to chemicals. Test ropes before trusting your life to them. 306. When landing mooring lines watch the weight on the heaving line. Serious injury can result from being struck by this weight. 307. Mooring lines should always be considered 75 EXX-MOR-003303 as hazardous. Avoid crossing over or under such lines. When it is necessary to cross over or under these lines make sure the line is not being moved. Asphalt Plant Operations 308. Do not use air on cutback asphalt tanks when these tanks are hotter than 180 F. Per mit the tank to cool below this figure before agitating with air. 309. Before using the asphalt heater for any purpose--loading, circulating or receiving as phalt--check the pilot light before turning the gas into the burners. If the pilot light is out. steam out the firebox for approximately ten minutes to clear it of possible explosive mixtures before applying a torch. The pilot light must be kept burning at all times. 'If, \ioVer j.r. 1 ir.at~nnh through the as phalt receiving e to residual tanks without first displac.ng ...e air <n the irc.ivmg line to Asphalt Plant storage It will be necessary to hav- the Propane Plant do the actual displac ing This is necessary becaust other users of this line introduce materials into it at a high temperature whien will cause internal burning m the line if air is present Hydrofinors, Hydroformers, Hydrodesulfuri zation and Dehydrogenation Units 311. Be sure that all air has been displaced from lines or vessels (even if only a small sec tion has been opened) before introducing hydro gen into equipment. 76 312. The vapors from regeneration of the co balt-molybdenum catalyst must be vented to a safe place to prevent exposure to any possible discharge of carbonyls. Laboratories .,15 When boi.ng hoi - n the r.o-c u : - end the rork soon! J be ''-lei s' ti d tr- a b anno' W injured u hie ck s'-" old ot.W Ter as. jf a ccik soft'1'' brterc boring - H h;':,ow faults :orks 51b A hushing shewn f .'.-ter sir uiu m : i " running into ant sink nr 'irrur. -in'- i'' ->i lions aic bring discarded For this puuusr m;. approved type of sinks (.those equipped ' ~ water sealed drains) shall be used Hot oil m recess of 2nu F should not be poured. mW sinks Material with a RVP above 25 lbs shall not be discarded into the sewer system. Matera Is m the l5-2c lb RVP must not be discarded into the sewer s>stem m quantities greater than one pint in five minutes Where 15-25 lb RVP material is discarded into a sink indoors, the sink must be located under an ooerating draft hood EXX-MOR-003304 317. Hot samples, such as still bottoms, should be covered if allowed to stand to cool. 318. Whenever a distillation test is performed on a sample of high pei oxide content (over 5 peroxide number) or blends containing isopropyl ether, one gram of pyrogallol per 100 cc: of sample must be placed m the distillation flask just before heat is applied. Cracked gasolines, especially those that have aged and contain no antioxidant must be handled with care and must not be evaporated to dryness without either shielding the equipment or using pyrogallol; the hazard is one of explosion due to the presence of peroxides. When chaser is used in the cracked gasoline distillation, it is not necessary to use pyrogallol. 319. When making preforme :,um tests on the stocks mentioned above, the urs of the fume hood must be closed. 320. The use of acetone with CO, to produce a low temperature bath is to be avoided. The use of kerosene, mixtures of di-ethylene glycol and water, or isopropyl alcohol is permitted. 321. Before placing in a closed container any liquid (kerosene, di-ethylene glycol, etc.) in which solid CO, has been used as a refrigerant, the material should be heated to 105 F. minimum to dispel the disolved CO?- 322. Liquid nitrogen should not be poured from one container to another; it should be trans ferred by the use of a dip pipe and air pressure and should be added cautiously to Dewar flasks in order to prevent collapse of the flask. Liquid nitrogen must not be placed m a tig! dy closed container. Phenol Lube Plant All employees working at this plant must be familiar with and observe the general safety rules and safe practices. In addition, because of the special nature of the chemical, phenol, used at this plant they must know and observe the following: 323. When phenol comes in contact with the skin it should be washed off at once with large quantities of water. Immediate removal of phe - nol is absolutely imperative. If phenol is splashed on the skin or clothing in large quanti ' ties, the individual should resort to the use of the shower provided, removing all clothing while | under the shower and thoroughly washing the affected part of the body with large quantities j j of water. He should then report to the First Aid Room for immediate treatment. j | 324. Any phenol burn must be reported to the ' Medical Department for immediate treatment. 325. Gas masks must be worn: a. When handling straight phenol in an ; open system where contact with phenolic j vapors is possible. . b. When opening safety valves on tank cars for venting purposes or when liquefy ing solidified phenol. 78 EXX-MOR-003305 326 Protective gloves and an acid hood must be worn when working on or adjusting pumps or other equipment m order to protect against splashes of liquid or crystalline phenol. Goggles and gloves must be used when unloading tank cars of phenol. 327 Protective gloves must be worn when work ing on lines, pumps, or other equipment where skin contact with a phenolic substance of any kind is possible. 328. Rubber boots must be worn when it be comes necessary to protect the feet and lower legs against contact with phenol. It is very im portant to have the legs of trousers outside the boots to prevent phenol running down into the boots. 329. Clothes contaminated with phenol not be worn until laundered. 1st 330. For collecting samples for testing purposes, use the special containers provided (green bot tles or a container marked with a red X). 331. Do not walk on the phenol tank roof. 332. Fittings or equipment in phenol service sent to any shop must be tagged with the spe cial warning placards provided. 333. At least two men must be present when phenol tank cars are unloaded. 334. No scaffolding shall be erected or disman tled while equipment containing phenol is in operation except with the specific approval of the Chief Operator. 80 Part Two PERSONAL PROTECTIVE EQUIPMENT Personal protective equipment is provided to enable work to be carried on wfiere the hazard involved cannot be eliminated. The ideal solu tion, and always the first thing to be considered, is to remove the hazard. Since this is not always possible, especially where the condition is of an emergency or temporary nature, the use of personal protective equipment is the only prac tical solution. The selection of the proper per sonal protective equipment for the needs of the job is very important. As a guide in making this selection, the following information is provided. Most items of personal protective equipment are stocked in the Area Tool Rooms. Equipment not stocked in the Area Tool Rooms is available from the Main Storehouse. It can be secured in the same manner that materials are ordered; i.e., by calling the Storehouse Order Desk, 'phone 795, and placing an order for the item needed, indicating the material receiving station to which the item is to be delivered and the hour the item is required. Stores personnel will process thz order and deliver the item indicated. Safety shoes will be handled from the Safety Warehouse. All repairs to safety equipment, such as gog gles, respirators, etc., will be made at Sub store-Toolroom No. 1, Central Shop Building. 81 EXX-MOR-003306 Safety prescription glasses may be obtained in accordance with the procedures outlined in this section of the Accident Prevention Manual. Following is a list of Substores-Toolrooms, their locations and hours they are in operation: Sub-Store Tool Roorr,1 Location Hours in Operation No. 1 Central Shop Building 7~30 AM to 12:00 Midnight No. 2 South of D. A. U. (Monday thru Friday) 7 :30 AM to 4:00 PM No. 3 No. 4 South of No. 4 Pipe Still East of FCCU No. 1 (Monday thru Friday) 7:30 AM to 4:00 PM (Monday thru Friday) 7.30 AM to 4:00 PM No. 5 Treaters' Shop Bldg (Monday thru Friday) 7:30 AM to 4:00 PM No. 6 No. 7 No. 8 South of Pipe Still No. 1 East of Hydroformer No. 1 Butyl Unit Storehouse (Monday thru Friday) 7:30 AM to 4:00 PM (Monday thru Friday) 7:30 AM to 4:00 PM (Monday thru Friday) 7:30 AM to 4:00 PM Portable Major Unit Turnarounds (Monday thru Friday) Determined by M & C All Substores-Toolrooms are closed on No. 1 shift, on Monday through Friday, and all shifts on Saturdays and Sundays. Issues ''of safety items on these shifts will be made by personnel on duty at the main Storehouse, Phone 1503, in the same manner as tools issued on these shifts. 82 Section A RESPIRATORY PROTECTION Certain of our operations may at times contami j nate the air we breathe, introducing noxious or nuisance dusts or corrosive vapors, or toxic fumes or gases. The effect of these contaminants * ] may range from minor discomfort to actual j menace to health. This condition creates the * need for a device which will either remove the substance from the air we breathe or supply us with uncontaminated air. 1 In general, seven different types of respiratory protection are provided. These are: Canister-type gas masks. Fresh air hose masks. Air line or supplied air equipment. 83 EXX-MOR-003307 Pressure demand hose masks. Self-contained emergency masks. Dust (Filter Type) Respirators. Chemical Cartridge Respirators. Each type of equipment has a definite purpose, but its limitations must be kept in mind. One limitation is common to all, they will not pro vide protection in an atmosphere contaminated by a substance which may be absorbed through the skin. An individual with a punctured ear drum may not be adequately protected from gas by a gas mask. Under certain conditions it may be possi ble for gas to be drawn through the punctured ear drum into the lungs. In order to provide the greatest possible protection for such employees the following procedure must be followed: Any employee who is require'" to wear a gas mask, ither canister or fresh or type, must he asked if he has a punctured > ur drum If hr has he should be instructed `e -rouro, from the Tool Room a device known s an rai defender " This device should be inserted in the punctured ear before the mask is put on It should not be removed until after the mask is removed. If at any time, gas is no ticed while wearing the mask, leave the con taminated area at once and check the equip ment 84 CANISTER-TYPE GAS MASKS The action of a canister-type gas mask is one of absorbing gases which may be mixed with air by draw. , them through a container, called a canister, ed with a chemical, x he efficiency of the chemicals in the canister is dependent on the amount of gases which may be present. Large amounts, or high concentrations, overload the absorber rate and some of the gases pass on through. Therefore, this equipment should be used only in low con centrations of gases. It is also necessary that an adequate supply of oxygen be present in the atmosphere where such EXX-MOR-003308 equipment is used. The canister does not supply oxygen; it only removes a definite limited quan tity of the gas for which it was designed. For these reasons, the canister-type masks are not approved for use in closed containers. Excep tions to this are in cleaning tanks where tests have indicated a gas concentration of less than 20% of the lower explosive limit. Operation When first using this equipment, secure in structions from your su pervisor or the Safety Department. Be certain that the mask is equipped with the prop er canister for the gas encountered. Be sure the seal has been removed from the bottom of the canister and that the knurled connection be tween the hose and canister is tight. Before entering the gas area, always test the facepiece to make certain that it is tightly fitted and does not leak. This must be done every time the mask is put on. After using the mask, it is im portant that the time card be marked with the amount of time used, as the canister is approved for a maximum of ten (10) hours use. Where excessive fogging of lens is experienced, Anti-fog compound may be secured from the Area Tool Room. Correct r5se of Gas Mask The correct way to put on the canister-type gas mask is illustrated in the accompanying photographs. 1. Check to see that seal has been removed from bottom of canister. 2. Buckle on harness with canister in back in the same way you put on a coat. EXX-MOR-003309 3- Bring hose over shoul der before placing mask on face to permit un hampered use of hands. Put on face piece by grasping head straps, lead with chin. 5. Test mask. Crimp hose to shut off air sup ply and inhale. If there is no leak in hose and mask, face piece should contract tight against face. 4. Tighten lower straps first. This brings face H p piece snugly around the chin. Next tighten cen P ter adjusting straps. This makes face piece 6. Ready to go into gas eous area. If odor of gas is detected, leave area immediately and re check mask. If any de fects are und notify Storehous fit contours of face and cheeks. Then tighten top strap to make mask fit forehead. If properly adjusted, mask should fit face snugly. - 7. When use of mask is finished, it is important ' - that time card be mark ed, showing number of minutes mask was in service. 89 EXX-MOR-003310 Canister Service Identification Four different types of canisters are used at Baytown. Each ype affords protection against a specific type or combination of gases. Be cer tain that you have the correct canister for the gas to which you may be exposed. The approved service and identification of the canisters used at Baytown are as follows: Red Canister HAZARDS (Typo of Working Conditions) Provides protection against combina i tions of acid gases, organic vapors, ammonia and carbon monoxide in low concentrations and heavy smoke. Use in concentrations not exceeding 2%. REMARKS This is called an all-service canister. Provides protection against various combinations of gases, but in small concentrations only. Time limit on this canister is 2 hours. Contains soda lime, activated charcoal, silica gel, hopcalite, and cotton wool filters. 90 Yellow Canister HAZARDS (Typo of Working Conditions) Provides protection against acid gases --hydrocarbon vapors, acid fumes, hydrogen sulphide, S02, gasoline va pors. Use in low concentrations only. 20% of lower explosive limit on organic va pors, 2% concentration in acid gases. REMARKS Most commonly used canister in oil refineries. To be used where there is a possibility of both types of gas--hydrocarbon vapors and acid gases--being present. May be used in emergency for short periods as protection for either type. Time limt on this canister is 10 hours. Contains activated charcoal and soda lime. Green Canister HAZARDS (Typ* of Working Conditions) Provides protection against ammonia in concentration not exceeding 3%. REMARKS Note that 3% concentration of ammonia may cause serious skin irritation. Time limit on this canister is unlimited. Replace if ammonia odor can be detected. Usually con tains silica gel or malic acid. EXX-MOR-003311 "1 Black Canister HAZARDS (Type of Working dondltioni) Provides protection against organic vapors such as aniline, benzene, ether, gasoline, tetraethyl lead. Use in low concentrations only. (20% of lower explosive limit.) REMARKS Use where there are no acid gases present. Time limit on thi^ canister is 10 hours. Contains activated charcoal. Maintenance and Inspection Masks should be carefully inspected before each use. The facepiece should be checked for any defects, such as loose or cracked lens, defective exhalation valve or head straps broken or miss ing. The hose should be checked to assure that it is securely fastened to the facepiece and can ister and that there are no breaks in it. The canister should be checked to see that there is sufficient time remaining for the job at hand and that the canister is not over one year old. Keep the mask clean and in good condition. Make no repairs to the mask--return it to the Storehouse at once if you find any defect. Limitations and Cautions The canisters must be renewed once every twelve (12) months, whether used or not. They must not be used beyond the time limit given m the Canister Service Identification Chart Canister gas masks shall not be used in any enclosed area, such as a closed vessel, condenser box, excavd|ion or manhole, unless gas tests indicate that the quantity of gas present is within the safe limit of the canister. Care must be taken in using such equipment to assure that the capacity of the canister is not exceeded. This may occur in such work as repairing leaks in gas lines even when working in the open. If there is any doubt, use a fresh air mask or sup plied air mask. Only the all-service or red canis ter mask is approved for use where there is heavy smoke; the others will give no protection Do not use gas mask factpie~es which have been used by others until the> have been sterilized Return, the masks to rhe Storehouse. FRESH AIR HOSE MASKS Fresh air hose masks or pressure demand hose masks must be used in all cases where it is nec essary to enter any enclosed area where tests indicate hydrogen sulphide (H2S) gas to be present even in slight concentrations; in all cases where flammable gases are present in con centrations above 20% of the lower explosive limit; in all cases where it may be necessary to EXX-MOR-003312 enter a closed vessel which has not been pre pared in accordance with the standards for such preparation; in all cases where the gas cor zntration exceeds the allowable limit for canisters; in entering areas where there is heavy smoke; or where there is an oxygen deficiency. Operation The facepiece should be adjusted and tested as in the case of canister masks. See that the hose and life lines are not entangled. The blower MUST be placed where there is plenty of fresh, uncontaminated air. Where a hand-driven blower mask is being used the crank must be turned continuously from the time the man puts on the facepiece until he has returned to pure air and has remov ed facepiece completely. A life fine must be at tached to the hose mask harness. Hand-driven Fresh Air Hose Mask Maintenance and Inspection The facepiece should be inspected as instructed in the case of canister type masks. The hose should be carefully in spected to assure that there are no defects and that all joints are tight. The blower should be checked and tested to see that it is operating properly. The life line should be inspected to assure that it is in good condition and securely attached to the hose mask harness. When through using the equip ment, clean the exterior of hose and the life line. Be sure all parts of the equipment are returned to the Tool Room. Limitations and Cautions Do not use more than 150 feet of hose on each blower connection. Care must be used to avoid placing the blower where the air may be contaminated--do not place it in the vicinity of sewer manholes or catch basins. Keep to the windward side of any possible contaminating source. U 1 95 EXX-MOR-003313 Always have a man present to assist in any emergency which might arise. Be certain that the gas or vapor is not of a type which may be harmful to the skin, for example, a high concentration of ammonia. AIR LINE MASK OR SUPPLIED AIR EQUIPMENT An air line respirator, for connection to com pressed air lines, provides essentially the same protection given by fresh air masks. It dif fers from the l^ejnask mainly in two 'features : It has a hand operated, quickly detachable cou pling connected to the belt or body harness so the operator can con nect onto a compressed air hose, and a flow- limiting device with capacity to permit air flow only between 2 and 20 cubic feet per minute. A trap and filter are installed in the compressed air line ahead of the mask to remove any oil, water, scale or gas from the air. They are used where operations require continuous use of a mask. They offer no breathing .resistance and are consequently not fatiguing. ABRASIVE BLASTING EQUIPMENT This type of equipment is designed for protec tion against harmful or objectionable atmos pheres that are not immediately dangerous to life, but which may cause harm only from continuous exposure. Sandblasting, guniting and metalizing operations require the use of this type of equipment. Operation The mask face piece should be adjusted and tested in accordance with the instructions given for the canister type gas mask. The hood should be attached securely to the facepiece and ad justed around the neck to prevent dust particles from entering. The con trol valves should be ad justed for maximum comfort before work is started. Maintenance and Inspection The facepiece should be inspected as instructed in the case of canister type masks. The lens should be checked to see that it is in good con- 1 97 EXX-MOR-003314 dition and the connections are tight. The regu lators and filters should be checked tc assure that they have the inspection tag on them. The filters must be replaced every 6 months. They should be drained daily. The regulating and relief valves should be tested once a week. Limitations and Cautions Do not tamper with or attempt to make any repairs or adjustments to this equipment. If in need of repair or adjustment, return it to the Storehouse. Do not permit anyone to stand close to sand blasting, guniting or metalizing operations. If passers-by are close to you, stop and warn them away. WELDER'S AIR LINE MASK This equipment was designed for welders who must work in areas where fumes and other conditions make it nec essary or desirable to have respiratory pro tection. The mask is similar to the abrasive blast ing equipment, except that it is made of leather and the facepiece is fitted with a holder for welder's filter lenses. 98 PRESSURE DEMAND RESPIRATORY EQUIPMENT Pressure demand respiratory equipment has been adopted at the Baytown Refinery and is approved for use in many situations, including the cleaning of leaded gasoline tanks where fresh air equipment is required. It has several im portant advantages over the blower type fresh air equipment. The air entering the mask is supplied from compressed air cylinders, the safety of the wear er is not dependent upon the location of the blower. His breathing air cannot be contami nated by gases, dirt, or dust. Air is supplied to the mask through small diameter hose which cannot kink and is practi cally indestructible. The hose is rather easy to handle and the wearer can work up to 250 feet from his air supply. This is 100 feet further than with the blower equipment. The hose is strong enough to double for the additional escape line required on the blower equipment for rescue purposes. The pressure demand respiratory equipment consists of compressed air cylinders, pressure regulator valve, supply hose, harness, pressure demand regulator and facepiece. i 1 EXX-MOR-003315 Harness in place show ing the pressure demand regulator. The yellow or main line valve stays locked open at all times. The opposite red knob is an emergency by-pass valve which is to be opened only in the event something happens to cause the demand regu lator to be inoperable. Shows the hose connec tion to the harness. The connection swivels 180 vertical and 360 hori zontal thus making the hose very easy to handle. Facepiece is put on and tested in same manner as canister mask. Facepiece hose is then attached to demand regulator with knurled nut connection. This mask is equipped with a special feature re ferred to as a pressure demand regulator. When the button on the demand regulator is pushed to the up po sition, the mask is sup plied with a steady flow of air which causes a slight positive pressure inside the mask. This is an added safety feature to make it impossible for gas to enter the face piece. The equipment is in use and operating properly. This is indicated by the rise and fall of the regu lator pressure gauge needle. Contact the Safety Department for further in formation on the operation and use of this equip ment. A EXX-MOR-003316 1 How to Use The Scott Air-Pak The lull cylinder contains 1800 p .unds of air pressure which will last the average user ap proximately 15 minutes. Therefore, the rate of consumption will be roughly 100 pounds/minute. At any time the number of hundred pounds pressure in the cylinder indicates the number of minutes of air supply remaining. * This equipment is designed p arily for emer gency conditions and may be u in any atmos phere except that which irritates or poisons through the skin. It may be used under any con ditions of heat, cold, or mist in which a man can work. The cylinder, when full, carries 1800# of air pressure and will last the average user ap proximately 15 minutes. This is the most modem type of breathing equip ment and has these advantages: 1. Air supply cannot be contaminated. 2. Is independent of hose, therefore, allowing greater range of operation. 3. Can be put into operation in less time than a hose mask. k EXX-MOR-003317  Remove tank assembly from case. i Hook and adjust waist strap. Check demand regulator valves. Yellow valve --open. Red valve-- closed. Open cylinder valve. 105 EXX-MOR-003318 Check demand regulator gauge. (Should show the same pressure as cylin der gauge). Remove face piece from box--grasp head straps --lead with chin (follow same procedure as used for canister masks). Test face piece for tight ness--place thumb over end of breathing tube and attempt to inhale. If no leaks, connect breathing tube to de mand regulator--tighten thumb nut. If breathing is comfortable, wearer is ready to enter contami nated area. EXX-MOR-003319 Emergency In event wearer experi ences any difficulty in breathing or if pressure gets low, crack open the red by-pass demand regulator valve and leave the contaminated area immediately. To Change Air Cylinders I (Full replacement cylinders are available at Storehouse). A Remove empty cylinder from jacket. Replace with full cyl inder--line up gauge on cylinder with red mark on jacket. Tighten jacket clamp. 109 i EXX-MOR-003320 Place end of hose through harness loop. Connect hose and cylin der. 30-MINUTE SCOTT AIR-PAK This equipment is designed for jobs of less than 30 minutes duration. It operates in exactly the same way as the 15 minute Air-Pak with the exception that the harness is designed differently so that the larger air bottle can be comfortably carried. The harness is put on in much the same manner as a coat. It allows the air bottle to be carried vertically on the back with the valve down. DUST AND FUME RESPIRATORS (Mechanic 1 Jlter Type) Dust respirators must I used for all operations where is is an excessive amount of dust in the air. Such work as handling powdered chemicals, lime, soda ash, sulphur, lithalge, and handling filter clays, sand, etc., are examples of operations where dust respirators must be worn. The filters pro vided are approved for all dusts, both toxic dusts such as lead, cadmimum, arsenic, etc., as well as type A dusts such as silica, asbestos, coke, ce ment, etc. Special filters are used for protection against fumes given off by metals in a molten condition. Examples of such operations are: burning, weld ing or riveting steel coated with lead paint. EXX-MOR-003321 melting and pouring brass or bronze, soldering and babbiting operations, welding and cutting galvanized iron. Operation Y4 The facepiece should be inspected for any defects in the inhalation and ex halation valves and to assure that the head bands are in good con dition. B The filters should be changed as required to maintain ease of breath ing. Respirator must be ad justed so that it fits around the nose and mouth. Respirators with metal facepieces should be shaped by the user to fit his facial contours. Limitations And Cautions This equipment is only a dust filter. It will not protect against gases, fumes, vapors or smoke Do not wear a respirator which has been worn by someone else until it has been sterilized CHEMICAL CARTRIDGE RESPIRATORS Chemical cartridge respirators may be used for EXX-MOR-003322 'I all operations where annoying or irritating gases or fumes may be present in small quantities. Such operations as spray painting or where or ganic solvents are used when done in the open air are examples of situations where the use of this equipment is advisable. It is recommended for use during long exposure to gases which are not oidinarily considered harmful or are not present in harmful concentrations. fumes may be present in high concentrations It must not be used in closed vessels. It must not be used as a substitute for a canister mask. i vDue to the nature of the work where this equip ment is used, time cards are not required. If any gases or fumes are smelled through the cartridge, it should be changed at once Operation The facepiece should be adjusted so as to fit snugly on the face. The head straps should be adjusted to maintain tension without discom fort. The correct cart ridge should be used for the service. The cart ridges are identified by the same color system as is used in the canisters. Maintenance and Inspection The facepiece should be inspected for any defects in the exhalation and inhalation valves, and to assure that the headbands are in good condition. The cartridge should be checked to see that it is the proper type and is tightly screwed into the holder. Keep the facepiece clean and dry. Limitations and Cautions This equipment must not be used where gases or Do not wear a respirator which has been worn by someone else until it has been sterilized Re turn it to the Storehouse for cleaning. Keep the cartridge dry. If it becomes saturated with moisture, it should not be used again. Section B FACE AND EYE PROTECTION To protect the eyes and face against injury from flying objects, splashing liquids and harmful rays that cannot always be controlled at the source, the following types of personal protective equip ment are provided: 1. Goggles (Safety glasses) 2. Face shields 3. Dust hoods and masks 4. Acid hoods 5. Welding hoods GOGGLES Nearly all eye injuries can be prevented by the 114 _______________i us EXX-MOR-003323 use of goggles. Eye injuries may be caused in so many different ways that it is impossible to say under what circumstances we may be safe with out goggles. ' There is hardly any job, wnether in a shop, on maintenance or construction work, on any oper ating unit, in a laboratory, or even in an office, where an eye injury has not occurred. From past experience of our own, as well as that of others, certain jobs and operations have been designated as requiring the use of goggles. See Safety Rule No. 85, Page 10-. Recommended Service It is obvious that no one device can provide pro tection against the wide variety of eye hazards presented in the many operations in the refinery. The following types of goggles are provided for the services indicated. Cup-type goggle HEAVY IMPACT-- Cup-type goggles pro vide protection against heavy impact from rela tively large flying ob jects while chipping, cutting rivets or bolts, riveting, calking, heavy grinding, striking opera tions, such as breaking concrete, etc. MODERATE IMPACT --Spectacle-type gog gles with side shields provide protection against impact from fly ing objects while doing moderately heavy or light work such as ma chining, scaling, etc., where the object may come from the front or side. They are provided 1 Plastic Frame Spectacle goggle with side shield :th plastic frames. MODERATE IMPACT --Spectacle-type gog gles without side shields provide protection against moderately heavy or light flying ob jects where there is rela tively little hazard ex cept from directly in spti owi. front ot the user. They are provided with plastic frames. EXX-MOR-003324 REFLECTED ELEC TRIC ARC WELDING RAYS -- A cap-type shielded goggle with special lens (Calobar) provide protection from reflected rays from elec tric arc welding. Where the impact hazard is light or moderate spec tacle-type goggles, with Shielded cup gpggl* or without side shields, may be fitted with special (Calobar) lens. These goggles will NOT protect against the direct rays from an electric arc. HEAT AND GLARE--Furnace and boiler ob servation presents an eye injury hazard from heat and glare. Goggles provided with special lens, such as cobalt blue or calobar, provide protection. LIQUID SPLASHES-- Rubber and Plastic type goggles a-e provided for protection against splashes of injurious liq uids, such as chemicals, oil, etc. They also pro- Rubber splash goggla 118 Plastic splash goggf* vide some protection against dust as well as moderate and light im pact hazards. DUST--A plastic frame goggle with a large sin gle plastic lens provides protection against dust. Plastic dust goggla Covarglas goggla SPECIAL SERVICE-- Goggles are provided for use where the user must wear corrective lens. They fit over the ordi nary glasses. They may be fitted with different lens to provide protec tion against reflected welding rays, glare, etc. Cowrglas bumors gogglo 119 EXX-MOR-003325 Operation For maximum protection and comfort goggles must be properly adjusted to fit the face. Goggles with elastic headbands can be easily adjusted by the user. The head band should be worn just tightly enough to hold the goggle firmly to the face. The headband should come just above the ears and then slope down on the lower part of the back of the head. Do not place the band over a cap or hat while using the goggles. The bridge may be adjusted by changing the length of the chain or leather bridge. Goggles with rigid bridges and adjustable nosepads must be fitted by a trained person. This adjustment will be made at the Safety Equip ment Repair Shop at the Central Shop Tool Room. Maintenance and Inspection When goggles are not in use, keep them in the case provided. Do not throw them in tool boxes, drawers, etc. They may be damaged or the ad justment thrown out of line. Keep your goggles and lens clean. Do not wear a pair of goggles which have been worn by someone else until they have been sterilized. Be sure the headbands are in good condition and elastic. Have defec tive bands replaced. The lens must be secu rely held in the frames Inspect them for pits or scratches which may cause eye strain. Have such lens replaced at once. If fogging of lens is experienced secure Anti-fog material at the Area Tool Rooms. Limitations and Cautions Do not make any repairs to goggles. Do not use defective goggles. Return them to the Area Tool Rooms. Be sure you use the correct goggles for the hazard involved. Do not use an impact type goggle for a liquid splash hazard or a calobar lens when exposed to direct electric arc rays. PRESCRIPTION GOGGLES When corrective lens are needed, prescription goggles will be provided as follows: EXX-MOR-003326 1. Maintenance, construction and miscellane ous employees whose work requires them to wear goggles a substantial part of their work ing time may be furnished prescription goggles of a suitable type, subject to the approval of the department foreman. 2. Operating and laboratory employees who must wear corrective lens may be furnished spectacle type prescription goggles subject to the approval of the department foreman and provided they agree to wear them during their working time. These spectacle goggles do not replace the need for other types of eye protec tion, where an employee is exposed to splash hazards. In such cases additional suitable eye protection must be secured and used. 3. In all cases the employee must furnish the prescription. 4. The procedure for obtaining prescription 'oggles is as follows: a. Obtain signed authorization form for pre scription goggles from your Zone Supervisor or Department Foreman. (Form R-1I43) Note: If Calobar lenses are requested, the approval of the Safety Supervisor is required on the authorization in addition to the fore man or supervisor. b. Take the completed form and your pre scription to Mr. John F. Reiter, Optician, at 123 East Texas Avenue in Baytown. He will complete the forms and order your goggles. c. When goggles have been received, you will be notified. 122 d. You will then pick up goggles from Mr. John Reiter. Certain operations present a hazard to the face as well as to the eyes. In such cases, one of the various types of face shields provides suitable protection. A transpar ent plastic shield in a suitable frame is recom mended for such jobs as metal sawing, working with chemicals at labo ratory benches, buffing, sanding, light grinding, wood-working opera tions, etc. tac* ShMd EXX-MOR-003327 Operation Tne headband is the only adjustable feature on the face shield. It should be adjusted so as to hold the shield in place. Maintenance and Inspection As the shield is plastic it is easily scratched. It should be replaced when these scratches cause interference with the vision. Limitations and Cautions These shields should not be used for heavy grind ing, chipping or other operations where resistance to severe impact is necessary'. DUST HOODS AND MASKS Dust hoods a, ' nasks are provided to furnish working comfoi - on all dusty jobs where nuisance or harmful dusts affect the eyes as well as the 1 |M 1 ||S 1 JIH * respiratory system. The hood type is particularly suited for use when nUB V ^ cleaning boilers, fur* naces, etc., or where irri- tating dusts are present. Duit Mask Operation The operation is similar to that of a dust respi rator. Maintenance and Inspection The maintenance and inspection is the same as for dust respirators. Limitations and Cautions This equipment is only a dust respirator It will not piotect against gases, fumes, vapors or smoke Do not use a mask or hood which has been worn by someone else until it has been sterilized Re turn i* to the Area Tool Room for cleaning ACID HOODS An acid hood should be used for protection of the head, eyes and face from chemical sprays and splashes. Opening chemical lines, repairing chemical pumps, emer gency repair work, etc. are types of work for which it is recom mended. Acid Hood--Rubbor Operation The headband should be adjusted to fit the wearer. The lens should be cleaned before use. 124 125 A EXX-MOR-003328 Maintenance and Inspection The lens shou^B be inspected to see that it is not broken. The hood should be checked for breaks or tears. Limitations and Cautions This equipment does not protect against fumes, vapors or gases. WELDING HOODS Welding hoods provide protection for the eyes and face under the severe conditions of arc weld ing. Persons assisting welders where they may be exposed to the direct art ould also use this eqt lent. Where a fall ing uoject hazard may be encountered the skull-gard welding hood should be used. Operation The headband should wilding Hood be adjusted to hold the hood in position. If a lift-front hood is not used, goggles with calobar lens must be worn under the hood or shield. Maintenance and Inspection The hood should be carefully inspected for light leakes around the lens frame and i .1 the body of the hood. Care must be taken to see that a lens of correct density is used. The cover lens should be replaced as frequently as is required by pitting of the lens. Section C HEAD PROTECTION Mtal Hat The protective or safety hat is a necessary item of personal protective equipment where the head is exposed to the impact of falling objects or severe bumps against overhead structures or objects. Since these haz ards are ever present in almost all parts of the plant, it follows that the sensible and practical course is to use a safety hat at all times when in the plant. Safety Rules require their use where a falling object hazard may exist. EXX-MOR-003329 Plastic Hat Safety Cap Operation The shell of a safety hat is supported by a cradle or hammock which keeps the shell awav from the head, cushions it against blows and -nits circulation of air around the head. The cradle should De so adjusted that there will be at least lj4" between the top of the head and the shell of the hat so that in the event of an impact the cradle will absorb a great portion of the shock and not allow the head to come in con tact with the shell of the hat. Maintenance and Inspection Cradle and sweatband should be replaced occa sionally because of deterioration due to perspi ration. The efficiency of your hat depends to a great measure on the cradle and, therefore, it must be in good condition. Limitations and Cautions Do not cut or drill any holes in your safety hat. You may weaken it and destroy its protection Electricians, linemen or others working around open electrical equipment must not use metal safety hats. Hats made from non-conducting materials are available for their use. Winter Bands Winter bands are avail able from the Area Tool Room. Hoods For further winter comfort hoods are also available to be worn under hats. J. 129 * EXX-MOR-003330 Eye Shields An eye shield of trans parent plastic can be attached to these hats. Tests Safety hats are made to withstand high impact. They will withstand impact of an 8 lb. ball dropped 5 ft. 81b. ball Safety hats are sub jected to standard drop tests. One test specified is the dropping of an 8- pound spherical weight from a height of 5 feet. The hat must withstand this impact without breaking or denting suf ficiently to touch the in ner side of the cradle or the hat block upon which it is placed. An other drop test is made with a 16-ounce carpen ter's plumb bob from a height of 10 feet to strike directly on the crown. The crown must not be dented or pierced more than 7/16 inch. Section D HAND PROTECTION CHEMICALS AND IRRITANTS The injurious effects of chemicals and many oils on the skin require the use of protective gloves. Protective gloves shall be used on any op eration where there is a definite contact or prob ability of contact with injurious chemicals, sol vents, aromatics, heavy catalytic cracked oils or hot oil. Where there is continuous contact with any type of oil, protec Gloves for Chemical Service tive gloves shall be used. Maintenance and Inspection The gloves should be carefully inspected for breaks before use. Chemicals or oil should be washed from the gloves after use, as it may weaken the glove if it remains on it for long periods. Do not wear a glove which has ben worn by someone else until it has been sterilized. Return it to the Area Tool Room. Keep the inside of the glove clean. If it becomes soiled or contaminated with chemicals or oil, return it to the Area Tool Room for cleaning. EXX-MOR-003331 HEAT When handling steam hose for long periods or when exposed to excessive heat during pre heating operations, a cloth protective glove is provided which will give protection. When melting and pour ing hot tar or asphalt the asbestos glove should be used. Inspect for breaks or tears. Keep glove dry. Heat Gloves Section E FOOT PROTECTION FALLING OBJECTS Foot guards are provided for use where objects are handled which present a falling object haz- ard and where a great deal of movement is not required. Handling header plugs at fur naces, removing brick furnace linings, and similar work are exam ples of jobs which may require foot guards. Foot Guard for use with Safety Shoes Operation Fasten guard securely to the shoe. Maintenance and Inspection Be sure the clamps and springs are in good con dition. HEAT When work must be performed on heated surfaces such as fur naces, wood-soled over shoes are provided for protection. Operation Fasten the protective sole or shoe in place with the straps provided. Wood sole shoes ( l JPPING When working where an extreme slipping hazard exists, such as tank cleaning, nonskid soles may be attached to the shoes or boots and aid in preventing falls. Operation Attach the sole to the shoe or boot with the straps provided. Nontkid cole EXX-MOR-003332 Section F BODY PROTECTION APRONS AND SUITS When opening or working on equipment in chemical, aromatic, or heavy catalytic cracked oil service, protection for the body may be obtained by the use of synthetic rubber or plas tic coated aprons. Where severe conditions exist, synthetic rubber or plas tic suits should be used. The suits may also be used for protection on extremely wet jobs such as in cooling towers, con denser boxes, etc. For special conditions, complete protection can Protective apron and gloves be obtained by the use of the acid suit which combines boots and gloves as an integral part of the suit. This should be used with an acid hood. Operation When using combinations of protective clothing, the upper garment should always overhang the lower to avoid dripping chemicals or oil into the lower. Trouser legs should be outside of boots. Where corrosive or harmful liquids are han dled the protective clothing should be washed with a water hose before it is re moved. Boots, coats, hats and aprons should be removed before gloves, and the hands should be washed before removing goggles or face shields. Limitations and Cautions When using this equip ment, it should be re membered that its^ use to eliminate one hazard may introduce another. Working with such equipment around re volving or reciprocating duce a hazard of loo conditions, be sure strings or parts. machinery may introends catching. Under such e are no loose or dangling When using this e<3 |ipment, be sure that the proper respiratory rotection, if needed, is se cured. If a hood is not used or required, use the proper goggle. COVERALLS Coveralls are provided and required as personal EXX-MOR-003333 protect- e equipment when performing opera tions. where a definite injury hazard exists, such as unloading lime, sulphur or other injurious dry chemicals, during cleaning operations in ' .aded gasoline tank and tank cars, etc. Maintenance and inspection Return coveralls for cleaning after use. Do not use defective coveralls for the service indicated above. Limitations and Cautions These coveralls do not provide adequate pro tection from liquid splashes of harmful chem icals or oils. Synthetic rubber or plastic coated aprons or suits should be used in such cases. Section G MISCELLANEOUS ITEMS LIFE BELTS Life belts are required whenever a fresh air hose mask is used. Their use is alsd required where work is per formed under an alti tude hazard. Operation The life belt should be fastened snugly but not tight. All buckles should be securely fastened. The life line, minimum size 34 inch manila rope, must be supported inde pendently of the scaf fold, carriage or plat form from which the |f work is being done. 136 The life line must be tied off as short as the nec essary movement of the worker will permit, m order to limit the length of any possible free fall. The longer the free fall, the greater the impact on the wearer and the belt. Maintenance and Inspection Life belts must be inspected very carefully before each use. Fabric belts must not be used if the outer plies are cut or worn through, or if there are any signs of chemical damage. All belt hardware must be inspected and replaced if it shows any signs of wear. If the belt is riveted, each rivet should be examined separately. The life line must be carefully inspected for any signs of damage or wear. If in doubt, replace the rope. Be sure that the life line is securely attached to the D-Ring of the belt. Be sj, e the tie-off point is of adequate strength. Limitations and Cautions If a life belt is exposed to or comes in contact with chemicals during use, clean it immediately. Report such cases when returning the belt. Keep the belt clean, dry and in good condition. Your life may depend on it. SWEAT PADS Sweat pads are provided to eliminate the dis comfort and possible hazard caused by perspi ration from the forehead running over the face and into the eyes. Its use is optional with any employee. 137 EXX-MOR-003334 Operation The pads should be dipped in cool water and squeezed dry before use. Sweat pad Maintenance and Inspection The pads should be washed out after each use. Keep it clean. EAR PROTECTION In boiler shops, on construction jobs, during the operation of pneumatic tools and cleaners, ex cessive noise may cause fatigue and distraction which might result in an accident and injury. For such jobs, ear plugs can reduce the sound level, and provide some relief. Ordinary conversation can be carried on while wearing them. Ear dfndrs Operation The correct size ear plug should be inserted in each ear before starting the job. Maintenance and Inspection The ear plug should be washed with soap and water and carefully dried after each use. When not in use they should be kept in the container provided. Limitations and Cautions Do not use an ear plug which has been used by someone else until it has been sterilized. Never use paper, cotton or any other makeshift in the ear. PROTECTIVE CREAMS Protective creams are provided to protect the skin against the irritating effects of oil, certain chemicals, dusts and grime. Its use on the hands is suggested for operations where dirt, grime, paint, grease, etc., may clog the pores of the skin. It will also provide a certain amount of protec tion for tender parts of the body, while handling lime, sulphur, creosoted material, or while clea.i ing boilers, furnaces or towers where sulphl compounds may be encountered. i Operation The protective cream should be applied to the clean skin surface to be protected. The cream should be gently rubbed in and any excess re moved. The cream should be reapplied as often as necessary to provide protection, varying condi tions may require more or less frequent applica tions. Always remove the old coating by thor oughly washing with soap and water before reapplying another coat. 139 k EXX-MOR-003335 The cream should be removed befor. eating and at the completion of the job or shift. Limitations and Cautions Do not use protective creams as a substitute for gloves, aprons, suits, hoods, etc. They are in tended as a supplement to them only. Be sure you have the proper cream. A water soluble cream will not protect against water solu tions, a water repelling cream will not protect against oil solutions. KNEE PADS Operations which require the work to be done in a kneeling position may be made more comforta ble and less irritating by the use of knee pads. Such operations as hand sanding of floors, cement finishing, etc., are exam ples. Operation The knee pad should be strapped in place with the straps provided. kkm pad> 140 SAFETY SHOES There are few jobs, if any, where the protection of a safety shoe is not advisable. In order to make this protection available to every employee, a wide variety of safety shoes is stocked at the Main Storehouse. These shoes may be purchased, at cost, for cash or on payroll deduction. 141 EXX-MOR-003336 r Part Three SAFETY SUGGESTION PLAN Ideas for the elimination of hazards and the prevention of accidents come to all of us. But unless we do something about the idea--the accident may occur. In order to provide an incentive and to give recognition to such ideas a safety suggestion plan has been in effect for a number of years. The operation of this plan is governed by the following regulations: 1. Ideas should be definite suggestions for pre vention of accidents and personal injuries and the elimination of hazards. Items covering main tenance and repairs are not eligible for an award under this plan. 2. Ideas are to be submitted on Safety Sugges tion blanks, in triplicate, to the Safety Depart ment. These blanks are available at the various departmental offices, or Safety Department Office. 3. All employees, except Superintendents, As sistant Superintendents, members of the Central Safety Committee and members of the Safety Department are eligible for awards under this plan. Department Heads and Foremen, Chief Operators and Supervisors will not be eligible to receive awards for suggestions pertaining to their own department. 4. In order to be eligible for an award the sug- EXX-MOR-003337 gestion must be submitted within one year of the date of its use. 5. When a suggestion is rejected, except for those rejected due to prior submission by an other employee, the original suggestor's right to an award is protected for a period of two years from date of the original letter of rejection, in the event use is made of the suggestion within this two-year period, regardless of the number of similar suggestions submitted since the re ceipt of the first suggestion. Notification of such use is the responsibility of the suggestor. At the end of the two-year period, an additional two years may be added provided the original sug gestor resubmits his idea. Such resubmission is the suggestor's responsibility. 6. Ideas developed during the course of an ac cident investigation will not be eligible for an award. 7. Safety Suggestions will be reviewed and in vestigated by the Safety Department with the Department concerned. 8. The Safety Award Committee will review the suggestions which have been handled to com pletion. Initial awards of $5.00 will be made on those suggestions which meet the requirements given above. The Committee will submit one or more of these suggestions each month to the Central Safety Committee for consideration for the monthly capital award of $5.00, which is in addition to the initial award. 9. Capital Awards of $25.00 each will be made to the six best suggestions submitted each year. The Award Plan Year starts on August 1. An award of $50.00 will be made to the best idea of the six given the capital awards. 10. The Capital Awards will be made by Com mittees selected by the Management. The six ideas will then be reviewed by a committee ap pointed by the Plant Manager for the selection of the best idea of the plan year. 145 EXX-MOR-003338 EXX-MOR-003339 f EXX-MOR-003340