Document ren6GE5jyNKGjX2wJEO78gzxq
Memorandum
July 5, 1985
OSHA HAZARD COMMUNICATION PROGRAM
EL PASO REFINERY
MR. C. R. PATAKY
This memorandum summarizes the status of your OSHA Hazard Communication Program subsequent to my two-day work session with you and your "team." As
expected, your refinery is in good shape for timely compliance. Many of the resources required are already in place. Furthermore, included in Attachment I is the "plan" we developed as a team for completing any remaining work. This status is largely the result of the prior development (by your facility) of effective
resources and the strong support you gave this program during my visit.
Especially impressive among your existing resources are Refinery Instructions 1118
and 1409. The former assures that proper MSDS's are provided your workers before
a chemical is used. The latter assures that both Operators and Maintenance workers
are protected from the hazards associated with non-routine tasks (in this case
shutdowns).
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Jff a y*
Thanks to all the input and support Jcf you and your team, we developed "a plan
custom-made for El Paso." Please revise this plan as necessary and by no means
rely solely on it.
Hopefully, you found some of the ideas and resources I brought useful. We (CUSA IH and I) will provide any additional on-site assistance you need to complete your program (a project schedule is attached). '
Finally, I thank 3im Keating, you and your team for your support and hospitality, both of which made my stay enjoyable. I have attached a personnel directory for your use, please call us anytime with your welcome comments and questions.
Attachments (3)
cc: Mr. D. L. Henderson Ms. B. Lazarus Mr, H. 3. McDermott Mr. A. 3. Maciey Mr. 3. C. Keating
ANTHONY MACIEY
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ATTACHMENT I 1 of 6
SUMMARIES
We completed the following work:
1. Made a presentation to Jim Keating and the Refinery Management regarding the requirements and compliance timing of the standard. At this presentation, Mr. Keating approved the implementation of the CUSA - Manufacturing Strategy (specifically, the "coordinated-team approach").
2. Conducted a tour of your facility (including a general drive-through, a walk through of the Crude Unit Control House/Plant Area, and a visit to your truck and tank car loading facilities) to identify those existing resources which already communicate the required information.
3. Conducted approximately seven (7) hours of "brainstorming" and training as a "team".
4. Held discussions with Jim Carson and Daryl Hagler regarding what labelling and paperwork is presently involved with truck or-tank car shipments out of the refinery.
Through "team" and various "one-on-one" discussions, we determined that:
A. Shipped Materials
1. Company MSDS's are not routinely sent to customers from here and customer requests for them are. rare. The refinery does not wish to take on any of this responsibility.
2. Container labelling (only bulk containers are filled here, although not all materials shipped are "products") is limited as follows:
DRUMS - products are not loaded into drums here, although catalysts and various wastes may at times go out in drums. Certain shipments of drummed materials will need to be addressed.
TRUCKS - many materials/products are shipped by truck (not including Marketing's operations) including fuel oil, asphalt, sulphur, spent acids and caustics, and MEA/DEA - typically, all trucks are placarded per D.O.T. requirements and are given a bill of lading of some kind.
TANK CARS - the same products that move by truck move by rail car with a few exceptions including sulphur and MEA/DEA. Rail cars are placarded with D.O.T. placards (only diesel shipments are labelled with an additional maniia card).
B. MSDS's (Intra-Refinery Distribution)
1. The Safety Group has developed an excellent system for providing the required MSDS's in the many work areas. Leroy Lehman administers this
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attachment I 2 of 6
program. Our review of the field books (the system includes one Master Book of approximately 2,500 Company and 900 Vendor MSDS's and 20 field books which are identical and which contain approximately 1100 MSDS's) found the books well maintained. Workers indicated they use and appreciate having the books.
2. The refinery has an outstanding written policy (RI-111S) that describes your MSDS distribution system. The instruction is most thorough and detailed. This instruction clearly designates the responsibilities and procedures involved and includes a Chemical Inventory Approval Sheet to assure that adequate information is obtained on hazardous chemicals before they are purchased.
3. Purchasing assists in obtaining' vendor MSDS's. They will consider sending form letters to suppliers requesting that when data sheets are requested by the Ei Paso Refinery, the sheets (a) must meet OSHA's requirements and, (b) are to be mailed to the name and address listed on the form letter. Use of such letters should minimize the amount of time spent "finding" MSDS"s mailed to various addresses the supplier might have.
Chemical Inventory
1. The refinery has completed an initial inventory and has even been accessing the data base to generate various output reports (e.g. indexes). There is agreement here to review the inventory and update it so that it can serve as the required index of which chemicals are present in which work area(s).
2. Subsequent to my visit, Rich Hoien contacted me and explained that he is familiar with accessing and using the Chemical Inventory. Rich volunteered to provide any reports the team may need.
In-House Chemicals (mostly intermediates)
1. There are many resources in use which already effectively communicate the hazards of the various chemicals present in the work areas. These resources include: color-coded deck markings within which special protective clothing is required, signs warning of special hazards present, and safety policies and procedures. To a large extent, these resources satisfy the requirements that we provide "appropriate hazard warnings."
2. There is an existing practice for labelling samples sent to the QC Lab with "appropriate hazard warnings." It is not clear just how extensive and formal this program is, but it will at least provide a starting point for meeting the requirement that we communicate information to laboratory workers.
3. The suggested method of grouping (and then listing on paper) the many in-hou'e (mostly intermediates) streams appear to offer many
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ATTACHMENT I 3 of 6
advantages and simplifications here. Using this approach minimizes the amount of stenciiling of hazard information otherwise required on the many vessels, exchangers and tanks, etc. If many tanks are associated with a given work area, it may be easier to list the "appropriate hazard warnings" associated with each material (rather than with each tank) on the same list discussed above. Even though an MSDS may exist for a material in a tank (and therefore, the material would be listed in the Chemical Inventory) if appropriate, the tank must be. labelled with warning statements. Granted, if a hazard is significant and acute, it is appropriate that a warning statement be made on or about the tank. In these cases, it would be a surprise if some warning system was not already in effect. However, the suggested list or table of in-house chemicals' information may also be a good place to summarize certain chronic hazards/warnings associated with materials present in several tanks.
E. Training
1. Much of your on-going training, including that on RI-990G and on how to read a MSDS, will satisfy many of the requirements as well as provide an excellent starting point.
2. The development and current use of RI-1409 is excellent. This resource will satisfy most, if not all, of the requirements that we communicate the hazards associated with non-routine tasks (in this case shutdowns) to workers.
To briefly summarize this program, before any major shutdown, your Safety Group puts together a brochure containing RI-1409 and any related MSDS's. By following the instructions in the Refinery Instruction, and by completing the checklist it contains, management assures that ail workers are provided necessary hazard information on any (and all) chemicals present. The checklist then serves as documentation of responsibilities.
3. Your facility has the capability to utilize the many video tapes (existing and pending) which will meet many of the training requirements.
As a team, we developed the following plan, which will complete your program by the two effective dates (see schedule attached).
MANUFACTURER/SUPPLIER PROVISIONS (November 25, 1985)
A. Shipped Materials
1. I will see to it that other Company organizations (including Marketing, S&D and Product Engineering) provide revised Company MSDS's to your customers whenever those organizations arrange the transaction. Furthermore, it will be their responsibility to provide our customers with any additional label information, even if in the form of bills of lading or other paperwork. CHEV BB
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ATTACHMENT I 4 of 6
2, Marise and Leroy agreed to generate two lists for team review. One will be a list of those materials shipped (not necessarily products) from here that have no Company MIB/MSDS . The second list will be those shipped materials for which the refinery alone is involved with the shipment/transaction and therefore cannot depend on other organizations as in /fl above.
3. Based on the findings from //2 above, I will assist you in deveioping or locating required MSDS's (or equivalent) and in providing appropriate hazard warnings on the shipping containers.
MSDS Distribution (Intra-Refinery)
1. Purchasing will make you a recommendation for effective use of form letters to assist your Safety Group in obtaining required vendor MSDS's.
2. After this "plan" is further along (say, approximately September 1985) your Safety Group should review RI-11 IS and make any beneficial "finetunings" reflecting decisions and policies made for this program.
Chemical Inventory
1. We agreed to use the Chemical Inventory to provide indexes or lists of which chemicals are present in each work area. To do this, Leroy has agreed to "group" the 55 inventoried work locations (this number may
change once Leroy reviews the work location names) into one of the 20 MSDS field (or "partial") sets.
2. As noted previously, Rich Hoien has volunteered to generate these indexes. Leroy and Rich have agreed to work with Belle Lazarus (CTN 894-5949) of CUSA IH, to complete this grouping in the next couple of weeks. Once "grouped", Belle will reprogram your Chemical Inventory so that it groups the work locations into 20 groups. She will then provide an
output inventory best suited for your updating. The goal is to complete your final inventory and submit to Belie by approximately September 1, 1985.
EMPLOYER PROVISIONS (May 25, 1985)
In-House Chemicals
1. Marise has agreed to coordinate among Process Engineering,
Maintenance and Operations (especially) the development of "in-house
lists" for each work area. It is suggested that Marise choose two areas
and address them by approximately September 1, 1985. Then send this
information to me for review (once you have approved it). I will then
review it and return with my comments ready to assist in the final
groupings of your areas. It is important that we not go beyond the two-
area test case, since we want some consistency among the 12 refineries
and my direct input will be necessary.
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ATTACHMENT I 5 of 6
2. Based upon the groupings from #1,1 will work with your Safety Group to make a file search for related MSDS information. At this time, Marise will be asked to gather any useful composition data on the various streams and intermediates that fall into a given category. At present, we have not finalized recommendations as to how to best make this MSDS information (especially the composition data) "available in the work areas."
3. Also, based upon the chemical groups in each area, I will assist your Safety Group in deciding on the "appropriate hazard warnings" for label purposes. A tour of each area would then be needed to identify any instances where the warnings are not being adequately provided. Of course, in these cases, the missing warning statements must be stencilled on the containers or on nearby signs or somehow provided in standards, procedures, or on the in-house list. Recall that I have provided more detailed guidance on how to meet these requirements.
4. By March 1, 1986, I will supply any proposed generic Health Data Sheets applicable to your broad chemical groups.
Training
1. We discussed the requirements versus suggested resources as follows:
General
a. On the existence/requirements of the standard (CUSA IH will provide a video by November 1985).
b. On how to read an MSDS (a video on "MIB's" now exists which is being slightly modified, a video on "toxicology" will be available approximately November 1985, and a brochure on how to read/use an MSDS is expected 'to be ready by approximately September 1985).
c. On how we protect workers from the special hazards associated with unlabelled piping and non-routine tasks like shutdowns, etc. (many of your existing resources including training on RI-9900 and RI-1409 will apply).
d. On how we protect Maintenance workers, including contractors, from the hazards encountered in the refinery (again, many useful resources exist and should be applied here - especially RI-9900 and RI-1409).
Work Area Specific
e. On those chemicals present in each specific area (the Chemical Inventory can provide these lists - also refer to the "in-house lists").
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ATTACHMENT I 6 of 6
f. On the signs of exposure to those chemicals from e. (review of typical MSDS information and providing MSDS's or equivalent will be sufficient).
g. On how to use the information that the standard requires be available (site-specific safety meetings using the actual field information are the recommended method for accomplishing this training).
2. Your Safety Group, with input from the team and from any appropriate training experts, should develop a detailed training plan for approval by management. CUSA IH can provide additional guidance and resources upon request.
Written Program 1. By November 1985, I will provide a model outline showing the suggested
wording and format for the "Outline of Compliance." It is suggested that at least a consolidated version of this outline be inserted into the field books and included in the specific training programs. 2. The formal written program should include, at least: a. A master list of chemicals (i.e., Chemical Inventory plus the "in-
house" lists) b. Our hazard evaluation procedures (by CEHC) c. The "Outline of Compliance" (i.e., how this facility complies with
each provision of the standard).
CHEV BB 003771
CUSA MANUFACTURING OSHA HAZARD COMMUNICATION STANDARD
PERSONNEL DIRECTORY
CUSA INDUSTRIAL HYGIENE (36TH FLOOR, 525 MARKET STREET, SAN FRANCISCO)
(Call for assistance in this order)
A. J. (Anthony) Maciey H. J. (Hank) McDermott E. M. (Eleanor) Lamperez B. F. (Belle) Lazarus A. M. (Andrina) Meier S. L. (Stan) Dryden
894-5973 894-3421 894-2966 894-5949 894-3144 894-6912
CUSA - Mfg. Coordinator Senior Industrial Hygienist Chemical Inventory Technician Analyst - Toxics Control Specialist - Occupational Health Manager - CUSA Industrial Hygiene
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CUSA-MFG SCHEDULE
OSHA HAZARD COMMUNICATION STANDARD COMPLIANCE
CHEV BB 003773
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In re sp o n se to th e upcom ing F e d e ra l C om m unication S ta n d a rd , ensure th a t
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CHEV BB 003784.
Attachment 2 (Excerpted from A.CGIH Industrial Ventilation, 17th edition)
5-55
-12 min
Duct velocity - 3000 fpm minimum Entry loss - i.78 slot VP + 0.25 duct VP Small lathe, etc., may be mounted in booth
un (on too/ post)
8 "min
Flex duct to allow
movement full length of work
"O Hood extends as tow as possible to U dear lathe rail. Hood may be
LOCAL HOOD connected to move with toot rest. ' Note: Local hood not satisfactory for spraying toxic metals.
0 = 200 cfm/sq ft face openings Duct velocity = 3500fpm minimum Entry loss = 0.25 VP
AMERICAN CONFERENCE OF
GOVERNMENTAL INDUSTRIAL HYGIENISTS
DATE
METAL SPRAYING
1-64
VS-4/5
CHEV BB
003785
SUMMARY OF RECOMMENDED AIR MONITORING ACTIVITIES
Attachment 3
Recommendations for future air monitoring appearing rn this report have been summarized below. All samples are to be collected within the breathing zone of individuals performing the specified activities at the frequencies shown. Initial and followup air monitoring requirements for asbestos, inorganic arsenic, and inorganic lead are specifically outlined in the cited Federal OSHA regulations. Full details of appropriate sampling methods and any necessary equipment loans can be obtained from Mr. R. J. Reinhart, Corporation Industrial Hygiene, at CTN 894-6930.
Activity to be Sampled
Contaminant
Freauencv
Any work which may release airborne asbestos fibers
Asbestos
Described in 29 CFR 1910.1001(f)
Any work which may generate airborne inorganic arsenic
Inorganic Arsenic
Described in 29 CFR 1910.1018(e)
Open-air dispensing of Betz C-30, DE-364, or maintenance (teardown) of injection system equipment handling same
Any work which may release airborne inorganic lead
Dimethylformamide
At least 3 separate occasions, to quantify exposure levels
Inorganic Lead
Described in 29 CFR 1910.25(d)
Rodding-out sulfur seals
S02
At least 3 separate occasions, to quantify exposure levels
Land farming work likely to generate airborne dusts
Total dusts and specific metals suspected to be present
Semi-annually
Drawing D5950 overhead reflux samples
h2s
Ac least 3 separate occasions, to quantify exposure levels
CHEV BB 003786
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CHEV BB
003787
QUARTER SUMMARY OF KOHITORIHG RESULTS EL PASO REFINERY
* Group re s u lts by co n ta m in a n t w ith in each lo c a tio n /o p e ra tio n . .** Comments s h o u ld a d d re ss c o n d itio n s , o r changes d u rin g an o p e ra tio n w h ic h w o u ld a f f e c t th e
exposure re s u lts e .g ., o p e ra tio n ended e a rly , a s p ill o c c u rre d , equipm ent m a lfu n c tio n e d , e tc .
In d ic a te the ty p e o f sam ple as fo llo w s : T = 8 hour tim e w e ig h te d a v e ra g e , S = s h o rt te rm sam ple